Transmission Re-Build Up-date

[bighly]

Transmission Re-Build Update

Well. Many work items have been done and a great time was had by all. As long as the tranny was out I:

- Installed a rear cranckshaft seal (round version).
- New brake lines everywhere(in conjunction with the front end rebuild)
- New fuel line
- New accumulator O-ring in OD / cleaned
- Bill Bolton lightened flywheel (couldn't help myself)

The culprit on the tranny was the abscence of the little rubber buffer pads on the OD adapter plate and Bellhousing (yes the 1$ part) This caused the 3rd gear syncro to be partially engaged whilst in 4th. Perhaps aggravated by my tendency to use the lever as a hand rest while driving. Once 3rd gear syncro was worn down enough the three springs and detent balls associated with 3rd/4th gear popped out. This caused it to be even more difficult to shift and was probably when I parked her late last year. At least the little parts did not get into the gears and really grind things up. This is detailed in other emails and archives elsewhere. I keep getting the idea reinforced that when the engineers put a part in it was for a reason, to leave it out may work but could cause some bigger problem later.

I will be reassembling over the next few days with new syncros, bearings, thrust washers, seals, clutch, throw out bearing, shift fork bushes, springs, roller bearings for the 1st motion shaft etc etc.....

I am reusing the gears and layshaft.

I still need to research the archives for the wooden dowel on reassembly trick I have heard in Healey lore and legend.........

OH yes did I mention the one off size roller bearing? 15 correct one smaller on the 1st motion shaft where it mates the mainshaft. Still haunted by the PO. Missing locktabs on the flywheel...... I need to go real slow on reassembly to be sure its all there. Perhaps I will be able to get some photos and post em on the website........

I'll keep ya all posted on how the puzzle goes back together.
Wow that got long

 

[Dave Russell]

Re: Transmission Re-Build Update

Sounds like you have things covered. Thanks for the good info, appreciated by all.

The "broom handle" is called a dummy shaft. It could be wood, metal, plastic, or?. The concept is a temporary shaft to hold the rollers & washers in place while inserting the gear into the case & getting the real shaft into place.

The dummy should be just long enough to hold the bearings & washers in place & short enough to allow the gear to slip into the case. It'd diameter should be just enough smaller than the regular shaft to allow it to easily slide through the gearcase holes.

Grease the rollers & washers, insert the shaft & place the rollers around it. Slide the gear into the case, partially insert the real shaft, get things lined up, & push the shaft through. Let it push the dummy shaft out the opposite end as it goes in. Be careful to hold a little end pressure on the dummy shaft as you go to prevent it from prematurely falling out of the gear.
D

 

[aeronca65t]

Re: Transmission Re-Build Update

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by bighly:
....I keep getting the idea reinforced that when the engineers put a part in it was for a reason, to leave it out may work but could cause some bigger problem later...<hr></blockquote>

Thanks for sharing...keep up the good work!

Your comment about the problems created by resting your hand on the shifter is a good one....I killed a Sprite trans that way when I was 19. It kept popping out of gear after a while and at one point, I drove it from NJ to Florida while holding it in gear the entire way!
I "repaired" it by taking another blown trans and putting the two together. In the process, I got the idea that I could "improve" it by machining off part of the syncro-rings and make it a "crash-box" (so I could shift without the clutch). It was a dismal failure because, as you said above, the engineers made things a certain way for a reason. Ah well, at least it was a good lesson for me (it *must* have been...I still remember it 35 years later).

Sounds like you're doing things properly....G'luck!

[ 04-16-2004: Message edited by: aeronca65t ]</p>

 

[John Loftus]

Re: Transmission Re-Build Update

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by jeep4x4srule:
why bother with all that hassle..just get a rebuilt transmission and put it in.

<hr></blockquote>


better yet ... just take it in to AAMCO!

John

 

[Dave Russell]

Re: Transmission Re-Build Update

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by jeep4x4srule:
why bother with all that hassle..just get a rebuilt transmission and put it in.

<hr></blockquote>
Back so soon?

 

[Michael Oritt]

Re: Transmission Re-Build Update

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by John Loftus:



better yet ... just take it in to AAMCO!


John<hr></blockquote>

John--

But you must make an exception for Fred Crowley, notable Texas AH racer and AAMCO'ist extraordinaire!

 

[bighly]

Re: Transmission Re-Build Update

Glad I did this myself. Got yas to look for upon reassembly

Keep track of all the detent springs and balls

Line up the rear mainshft bearing carrier pin with the OD adapter plate

Line up the layshaft cutout with the flat on the bellhousing

Be sure to get the OD pump cam atop the pump plunger

I would do this job again. It was pretty fun actually. Looks like I will do a shakedown drive about mid week. On the bench everything seems fine as I run it through gears. All the new detent springs made a huge difference in the feel of the detent in gears and neutral.

Thanks for all the advice especially Brian N and Bill Bolton who I spoke to on the phone Friday.

 

[Brian N.]

Re: Transmission Re-Build Update

Tracy

If we get past this rain this week, I'll try and swing up your way, maybe do a little test drive with you. Let me know how your schedule goes.

Brian

 

[bighly]

Re: Transmission Re-Build Update

Its back together and I went out for a spin, adjusted the OD. I am readjusting the valves and reinstalling the interior.