Project 2a (brakes lines, M/C, RPV) (Tranny rebuild)

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[Posimoto]

I’ve been patiently waiting for you to post your “2a lift install thread”.   

Note: when I removed the main drive gear nut I simply removed the cotter pin and turned the nut off by hand this is not typical. A ½” ratchet or even an air gun will do the job. You will also need to lock the gear so it doesn’t spin freely (if it isn’t locked it will turn the engine over and you won’t be able to remove the nut). What I do to stop the nut from spinning is put the tranny into first and third gear. I also looped wire around the low gear and the top cover bolts to hold the main shaft in place while removing the t-case. If you don’t use wire to secure the shaft the synco unit parts will drop to the bottom of the case.

    

[jerry k]

hey chuck, glad to see you got the tranny out. are you going to re-build it  or use the other one you dug up in the gararge ?
-jerry

[Posimoto]

I removed the t-case, but I’m sure that’s what you meant. I did however pull the tranny last night. The tranny/t-case combo I dug up in the depths of my shop was missing a front bearing retainer that’s not a big deal because I have a spare but I wouldn’t feel comfortable installing it without rebuilding so I just as soon rebuild the one in the flattie.

As soon as I removed the tranny I found the problem….take a look

[Posimoto]

That’s right the bearing retainer bolt fell out and a second one was half way to dropping.

[Posimoto]

The first thing that came to mind.……where’s the bolt? I grabbed my extension magnet to fish the bottom of the b-housing and pulled out a retainer clip that goes to the clutch pressure plate. Ok, that wasn’t what I was looking for so I used my inspection mirror and found the bolt wedged between the flywheel and b-housing.



 





Anyways, I pulled the b-housing, pressure plate, disc, and flywheel. I plan to resurface the flywheel, hopefully repair the pressure plate, and buy a new disc.

I finished the initial cleaning and removed what felt like 30 pounds of grim.

[Axle]

That looks better!

[jerry k]

nice work chuck, thanks for the update. looks good all cleaned up... i recognize the light colored sand stuck to all that grime 

-jerry

[Posimoto]

I thought you may recognize it.   

After inspecting the flywheel and clutch disc further I feel their good to go I’ll sand down the flywheel to remove any burs and repair the pressure plate.

I did some research turns out the PO installed the flywheel incorrectly. The placement of the flywheel is important in a 2a because it carries the timing marks yes, back in the day they used a peep hole in the block to check the timing marks on the flywheel.

Anyways, it’s not a big deal I have the flywheel out and will find TDC and position the flywheel the correct way. The PO didn’t know but he could have used the number 3 cylinder to time the engine with it being 180 out.

It is always good practice to replace the pilot bushing whenever you’re pulling the tranny. Below to the left is a new bushing, on the right is a fairly new bushing gone bad resulting from a loose front tranny shaft.



I started on the t-case and found one of the tabs broke off the housing. I have an extra housing in my shop I will replace it with.

[Posimoto]

I replaced the front housing with a spare I had from a 60s case. I also used the front shaft although I had to replace the fine thread castle nut with a course lock nut. When I removed the front flange from the case I was surprised to see an oil seal instead of the proper felt seal. The e-brake backing plate was mangled so I repaired it as best I could with a 2 pound hammer. Both shift rod poppet springs were broke which causes the levers to pop out of gear were replaced as well.

I installed all new seals and gaskets with loctite on all fasteners.



The flywheel was installed incorrectly by the PO and was 180 degrees off so I check TDC and marked the flywheel for proper installation.

 

A special thanks to Jeff at Crown for setting me up with all the parts He has a 2nd gear on order for me that should be in today.

[Twisty]

Are you going to make it on Sunday?

[Posimoto]

If the gear comes in today and I get the list below completed I’ll take the flattie. If not, I’d still like to go, maybe grab an empty seat.

Tranny rebuild
install tranny/t-case/b-housing/pressure plate, disc
set timing
install new points and set
oil change
weld d-rings on rear bumper
trouble shoot wiring on trailer (light not working)
install brake controller in tow vehicle (rotate tires)

[Axle]

If anyone can get that list done, its You. 

[Posimoto]

The flattie won't be going tomorrow the tranny gear I needed for the rebuild wasn't available for pickup yesterday.

Last night I repaired the pressure plate and installed it along with the pilot bushing, disc, points, condenser, and disassemble the tranny.

[Twisty]

Chuck, do you have a manual when you disassemble the transmissions and transfercases?  Or have you done it enough that you can remember how they go together?

Sorry to hear about this weekend.  You sure tried though!

[Posimoto]

Chuck, do you have a manual when you disassemble the transmissions and transfercases?  Or have you done it enough that you can remember how they go together?

I prefer to read or review any tranny or t-case rebuild whether it’s the first time or multiple times. I write notes as I go along, like if a particular washer has a lip and which way it faces. I’ll group the bolts separately and note the ones that are different lengths and sizes. I also take pics if need be.

I try to obtain the parts needed before the build but once you disassemble the unit you may find it needs some additional parts. For that reason the unit may sit for awhile until the parts comes in this is when it’s nice to have the notes and pics to fall back on if needed. By using the above process I feel confident its done right.