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fmichaels
Jedi Knight
Offline
i started my tranny rebuild last night. this morning, my finger tips on at least 7 fingers are hurt'n bad. it's all due to the double plunger lockwasher that secures second gear. now let me say that i didn't really have to remove this gear, but it was the last thing on the shaft and it contains needle bearings, so i wanted to make sure there was no damage or dirt.
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getting the lockwasher out wasn't too bad, but reinstalling it was impossible. i spent two-hours and used every profanity i had trying to get the d-plunger back in. if you've never seen this arrangement, the mainshaft uses a series of spring loaded plungers and washers to lock the gears onto the shaft. for the d-plunger, its a single hole through the shaft with plungers on either side sharing a common spring. the trick is too compress both plungers and drop and rotate the lockwasher onto the shaft. easier said than done. (oh and BTW, the washer sits down inside a lip from the cone of the gear so it's not a simple matter of pushing the plungers in)
.
after 2 hours i knew i wasn't going to get this washer in. i had read all of my reference books and didn't see anything that helped. haynes just said to push the plunger (note singular) in and rotate the washer (yeah right!). then i read a small picture caption in my practice classics book in an article by joss joselyn. i had to read the caption a couple times but it referenced a hardy engineering trick for getting this washer in. What hardy did was to cut a small notch (they called it a nick) in the underside of the washer to allow more room to get, in my case, a dental pick on the plunger.
.
well i read it many times and hesitated since i don't like adding notches to things that didn't come with a notch to begin with. i eventually got out the dremel and cut the small notch just as the book said. well, with the notch and a dental pick, it worked like a charm with no ill effects. if only i would have read this 2 hours earlier.
.
not to belabor my story i also tackled the balls and springs on the 1st/2nd syncro hub. i bought a 2" PVC street elbow from home depot and cut off about 1/2" of the female flange. this gave me a 1/2" thick ring. i then cut the ring once such that the ring could be expanded. i marked the ring at the areas where the balls were located and took my dremel and put a notch (detent) on the inside of the ring for the balls to sit in. i slipped the ring over the syncro and carefully pushed the spring and balls in one at a time. after that, it was a simple matter of sliding the 1st gear over the hub and pressing it down capturing the balls. and i thought that was going to be my hardest task.
.
anyway, the mainshaft is done and after my fingers heal a bit, i will begin the first motion shaft.
.
getting the lockwasher out wasn't too bad, but reinstalling it was impossible. i spent two-hours and used every profanity i had trying to get the d-plunger back in. if you've never seen this arrangement, the mainshaft uses a series of spring loaded plungers and washers to lock the gears onto the shaft. for the d-plunger, its a single hole through the shaft with plungers on either side sharing a common spring. the trick is too compress both plungers and drop and rotate the lockwasher onto the shaft. easier said than done. (oh and BTW, the washer sits down inside a lip from the cone of the gear so it's not a simple matter of pushing the plungers in)
.
after 2 hours i knew i wasn't going to get this washer in. i had read all of my reference books and didn't see anything that helped. haynes just said to push the plunger (note singular) in and rotate the washer (yeah right!). then i read a small picture caption in my practice classics book in an article by joss joselyn. i had to read the caption a couple times but it referenced a hardy engineering trick for getting this washer in. What hardy did was to cut a small notch (they called it a nick) in the underside of the washer to allow more room to get, in my case, a dental pick on the plunger.
.
well i read it many times and hesitated since i don't like adding notches to things that didn't come with a notch to begin with. i eventually got out the dremel and cut the small notch just as the book said. well, with the notch and a dental pick, it worked like a charm with no ill effects. if only i would have read this 2 hours earlier.
.
not to belabor my story i also tackled the balls and springs on the 1st/2nd syncro hub. i bought a 2" PVC street elbow from home depot and cut off about 1/2" of the female flange. this gave me a 1/2" thick ring. i then cut the ring once such that the ring could be expanded. i marked the ring at the areas where the balls were located and took my dremel and put a notch (detent) on the inside of the ring for the balls to sit in. i slipped the ring over the syncro and carefully pushed the spring and balls in one at a time. after that, it was a simple matter of sliding the 1st gear over the hub and pressing it down capturing the balls. and i thought that was going to be my hardest task.
.
anyway, the mainshaft is done and after my fingers heal a bit, i will begin the first motion shaft.
