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S40 gears won't spin after taking housing apart

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Old 12-06-2023, 07:24 AM
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Default S40 gears won't spin after taking housing apart

I've tried to search and I'm sure someone on here will tell me I didn't search hard enough, but I couldn't find anything that could help me. S40 trans would spin in every gear seemingly fine, input shaft was fine, now after opening it up for some reason it's all stuck. I cant get anything to spin but reverse if I lift it slightly, I have another s40 I just opened up and it still spins fine after being open. Can anyone help me figure this out?

Backstory:


​​​​​This is my first time working on a transmission and the only reason I opened it up was to inspect the condition given the seller left holes open on it and in the yard.
I'm doing an auto to manual swap and have acquired an s40 with a Japanese vin and '95' stamped on it so I assume it was from an eg. The input shaft seemed to have no play and every gear seemed to go in and spin just fine. However due to visible debris and sitting in someone's yard I opened it up to clean any junk out and inspect if there was any damage. The magnet was very clean as was the rest of everywhere. I have only split it open and have not messed with any internals at all. I have acquired yet another s40 for a great deal with more attachments on it that I still needed anyway (Canada vin with '97' stamped).
Upon opening up the second one it was much dirtier inside and much build up on the magnet. Both trans' are open and for some reason the 1st one will not spin any more. It's like it's locked up but was completely fine when it was sealed together. The 2nd trans is also open but will spin in every gear just fine.
Old 12-06-2023, 08:19 AM
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Default Re: S40 gears won't spin after taking housing apart

That's pretty normal. The shafts are no longer supported and are easy to bind.

Also the shift forks are no longer supported so it's possible you have shift collars sitting on synchros also stopping the shafts from turning.
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Old 12-06-2023, 12:11 PM
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Default Re: S40 gears won't spin after taking housing apart

Originally Posted by Ryanthegreat1
Also the shift forks are no longer supported so it's possible you have shift collars sitting on synchros also stopping the shafts from turning.
This is my guess. Make sure all of your shift sleeves are centered and not engaging with any synchros. Also - when taking apart the D-series, you have to remove the interlock bolt inside the bellhousing. It's relatively easy to have more than one gear engaged accidentally with the interlock bolt removed.
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Old 12-09-2023, 04:02 PM
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Default Re: S40 gears won't spin after taking housing apart

Thank goodness. Thank you guys for the response. So can I assume then upon re seating of the housing this will go back to normal?
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