Staked coutnerahsft bearing in the case and put in a shorter 4th gear. Went into all gears fine after assembling case. Went into gears fine once I put it in the car. Put fluid in it and set the car down. Won't go into any gears. Car is hard to push and makes a rubberish squeaking noise as it is pushed. Not going to fire it up since I don't know whats wrong.

 

Are we talking D-series here, or what?

 

yeah

 

shift linkage ok? Thats the only rubber squeak noise i can think of.

 

linkage is fine. i think it is the clutch/mainshaft. going to pull it off and put it back on

 

i had a phantom issue like this that has never been resolved, it occured when turning a 4 speed D into a 5spd and simultaneously altering 5th gear. i believe a sycro ring got mismatched... the car would never go into 5th once it came off of my workbench but would be fine until then.

 

I jacked it up and looked at the linkage just incase. Nothing changed. Only gear it will go into is R. goes half way into 3rd.

Pulled the starter and the pressure plate looks close but doesn't appear as if its off. Pulled the FW cover and the FW looks straight. Took a break to check this thread, going to pull the trans off, double check to make sure it shifts ok, check the pressure plate and splines, then put it back on.

 

Would the input shaft turn by hand when the case was reassembled?

 

Didn't try to turn it.

Pull the case off the engine, put it back on. Went on easier this time. Started it up. Had all gears this time. If I let off clutch in neutral it stalls. Trying to back out of my garage reverse makes a clunking noise and is jerky. Going in 1st it makes a rapid clunking noise. Put it back in the garage. Going to pull the trans and slipt it open tomorrow.

 

could be too much tranny fluid. u should fill it with the car level on the ground. too much will cause it to not go into gear with the car on.
happened to me. how much fluid did it take?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Aquafina &raquo;</TD></TR><TR><TD CLASS="quote">Didn't try to turn it.

Pull the case off the engine, put it back on. Went on easier this time. Started it up. Had all gears this time. If I let off clutch in neutral it stalls. Trying to back out of my garage reverse makes a clunking noise and is jerky. Going in 1st it makes a rapid clunking noise. Put it back in the garage. Going to pull the trans and slipt it open tomorrow.</TD></TR></TABLE>

or could be something else...

 

2.0 quarts as called for by Helms for an overhaul.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Aquafina &raquo;</TD></TR><TR><TD CLASS="quote">Staked coutnerahsft bearing in the case and put in a shorter 4th gear. Went into all gears fine after assembling case. Went into gears fine once I put it in the car. Put fluid in it and set the car down. Won't go into any gears. Car is hard to push and makes a rubberish squeaking noise as it is pushed. Not going to fire it up since I don't know whats wrong. </TD></TR></TABLE>
OK, a couple of things come to mind...

First, when you changed the 4th gear, did you replace BOTH the mainshaft and countershaft gears? They must be replaced as a pair in order to work correctly.

Second, did you make sure to orient the 3/4 synchronizer hub and sleeve correctly? If you put them in 'upside-down', it's possible for the synchronzer/gear to bind up.

Finally, did you remember to put the internal linkage guide pin back in the clutch housing side of the transmission?

 

This is only the 30,000,05030,0350350th time I've reassembled a trans lol, so yes.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Aquafina &raquo;</TD></TR><TR><TD CLASS="quote">This is only the 30,000,05030,0350350th time I've reassembled a trans lol, so yes.</TD></TR></TABLE>

Doesnt matter, we all make mistakes time to time. Double check everything...

 

I know. The gears are correctly matched. The interlock guide bolt is in correctly. Only thing I'm worried about is the synrcho assembly as it sounds (if you visualize the sound) like that is causing the noise.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Aquafina &raquo;</TD></TR><TR><TD CLASS="quote">I know. The gears are correctly matched. The interlock guide bolt is in correctly. Only thing I'm worried about is the synrcho assembly as it sounds (if you visualize the sound) like that is causing the noise.</TD></TR></TABLE>

Were any of the synchro assemblies dry when you assembled them?

 

No.

 

Figured out the problem.

Mainshaft 2nd gear is hitting the bottom corner of countershaft 3rd gear.

How the hell do I shim it? Thats the only clearance issue with any gears.

 

That tells me that the countershaft is too 'high' in the case, or the mainshaft is too 'low'. Here are a few things that can cause that...

Did you remember to install both washers under the mainshaft?

Was the overall height of the 4th gears that you used the same as the ones you replaced?

Is the input bearing in good shape?

Was there excessive wear between the 2nd gear distance collar and 1/2 synchronizer hub/countershaft 3rd gear?

Did you use too much shim on the mainshaft?

Hope that helps...

 

Stock and 1.066 gears both have 30 tooth countershaft gears. The one I have on is big diameter. The one I need is small. Swapping them out in the morning when I have someone to hold the shaft as it is spinning itself out of the table vise.

 

Well the gear I had on it was correct.

If I take the mainshaft washers out, the clearances are fine. What will happen if I run without the washers?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Aquafina &raquo;</TD></TR><TR><TD CLASS="quote">If I take the mainshaft washers out, the clearances are fine. What will happen if I run without the washers?</TD></TR></TABLE>
Some very bad things. Keep in mind that once the case is put together, the countershaft will be 'lifted' and held in place by the snap ring in the end of the case. Did you remember to set the ring in the bearing groove?

 

^mark is the tranny king

 

Yeah, snap ring is set.

Drove around for about 4 hours last night. Input shaft bearing is bad.

Going to pull it again to replace that and see if I can work out the spacing issue.

I put my stock 3rd in for 4th and that thing is short. 3rd tops at 73, 4th at 82. Going to put ZC 5th in and that will be about perfect gearing for Gingerman next month.