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Leaking 5-speed drain plug

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Update: Transfer Idler Gear was installed backwards and was not making full contact between main shaft and lay shaft. Pics to follow in am. I think we’ve found source of whirring noise, gear was only making 1/2 contact connecting to layshaft. Now rear seal leak to fix.
 
Bugsy Tranny Autopsy 1 100_3743_LI.jpgBugsy Tranny Autopsy 2 100_3744.jpgHere are the pics as promised of Bugsy's Tranny Autopsy. Comments from the Shop Owner on tranny .

So far I have actually discovered the transfer idler gear was on backwards, and was not aligned with the mainshaft and layshaft gears. Assuming this gear had run for its whole life by turning (and seating in) in one direction and was then asked to push the other way, it could certainly explain a noise. It is all I have found so far, but it certainly is an assembly mistake by the last guy. Since it not something that is done wrong with any frequency, it would be hard to say 100% that this would cause a noise.



Here is the only problem I have found so far. You can see the offset of gear teeth outlined in yellow on 3743. On the other photo, 3744, I have turned the gear around and now there is good alignment.
 
Back to the original problem of a crack around the drain plug. I once repaired on of these by jb welding an adapter/reducer into the drain fitting. Now the oil takes longer to drain but it seems it was a good in situ repair.
 
Interesting fix Trevor. Driveshaft gets dropped off tomorrow for check on rear seal. Hope this fixes my noise. Drew on the other hand this may be a fix for you.
 
Thanks for the tips. My plan now is to swap my spare trans in and see what can be done with my broken one. Worse case is it becomes a donor for internals.
 
I spoke too soon, Drew. Sorry, but the rear extension that I will need has the drain plug in it. The transmission I have slated for overhaul in my white Midget has a very worn rear output sleeve. Gears on the layshaft have been chewing some aluminum in this one as well. I imagine it can be shimmed.

Kurt
 
No worries, Kurt, thanks for looking. I'll dust off my spare and get it prepped to go in the car.
 
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