Checking Fully Assembled Length of Gearbox Shafts and Selector Drum. How?
 

After searching, I found that not many have rebuilt their transmissions. If they did, their posts did not mention how they checked the assembled lengths of their gearbox shafts and selector drum (see pages 23.17 - 19 in the repair manual).

There are references to the following tools:

Reference Washer 23 4 764
Reference Washer 23 4 765
Reference Washer 23 4 766
Adapter Disc 23 4 767.

I cannot find these tools for sale or the dimensions to have them made.

For those who have done this job, how did you do it?

Thank you,
Jeff

Jeff, check your email. tjs

If the new ones are anything like the Airheads, you need a dummy rear cover to check for the appropriate amount of shims.

Hope that helps.

Cheers

Notes from when I replaced all 6 Transmission Bearings. I did'nt take any measurements and 22k miles later it's shifting better than ever using Silkolene BOA 80W-90 High performance Hypoid gear oil.

29MAR2011 – @70,043 Miles disassembling the Transmission revealed that the Cush Drive components appear to be undamaged. On the other hand, the 6 Bearings on the ends of the 3 Shafts are slightly loose and one of the Intermediate Shaft Bearings makes a slight dragging metallic sound.

04MAY2011 – I bought 6 replacement Single Row Deep Groove Ball Bearings made by NTN (Taiwan) from Peoria Bearing (1515 NE Adams St., Peoria, IL 61603-3401, Tel. (309) 673-8171) for a total of $73.75 including Tax (8.3% Peoria Co.). I saved a total of $238.20 including Tax (9.75% Cook Co.).
Bearing Part No. Description Qty Static Load (LBF/N) Dynamic Load (LBF/N) Price
6003LLBC3/L627 17x35x10 Sealed Bearing 1 775/3350 1530/6800 $12.67
6204LLBC3/L627 20x47x14 Sealed Bearing 1 1500/6650 2890/12800 $7.85
6205LLBC3/L627 25x52x15 Sealed Bearing 4 1770/7850 3150/14000 $11.90

11MAY2011 – I bought two 500ml bottles of Silkolene BOA 80W-90 High performance Hypoid gear oil from Southard Cycle for $19.38 including tax. BOA 80W-90 High quality, high performance, mineral based hypoid gear oil. Provides outstanding protection for gearboxes and final drives over a wide range of operating temperatures. Specifications: SAE 80W, SAE 90 and SAE 85W-90, API GL-4 or API GL-5, MIL-L-2105B.

12MAY2011 - I installed the 6 new Bearings on the 3 Transmission Shafts. I then wrapped the Shafts separately in Saran and put them into the Freezer. I cleaned the Transmission Case (front half) and removed the old Input shaft Seal.

15MAY2011 - I laid the Transmission Case (front half) into the Kitchen Sink with the outside part facing up. I then poured Boiling Water onto it once and after a few minutes I did it again. I then removed the 3 Transmission Shafts from the Freezer, unwrapped the Saran off them, and then installed the 3 Transmission Shafts w/Intermediate Shaft Shifting Fork into the Transmission Case (front half).

18MAY2011 – I installed the new Crankshaft Rear Main Seals (2) and the new Flywheel/Clutch components. I used Honda Moly 60 Paste to lube the contact surfaces between the Clutch’s Diaphragm Spring, Flywheel, and Pressure Plate. I left the Pressure Plate mounting Bolts (6) loose so that they can be tightened post Transmission install. This will allow the Clutch Disc to center itself on the Transmission Input Shaft during Transmission installation.

I also installed the Output Shaft Shifting Forks (2) with Slider Shaft, Intermediate Shaft Shifting Fork Slider Shaft, Shifter Barrel Cam Shaft w/Spacers and Shifter Mechanism w/Spacer into the Transmission Case (front half). The Transmission was in 6th Gear after assembly. I rotated the Shifter Mechanism using the Shift Lever through 5th, then 4th, then 3rd, then 2nd, and finally to Neutral position while spinning the Output Shaft by hand.

Thanks, R111S! I have been distracted by a medical issue and the holidays, but ready to get back on this job. Your notes will come in handy.

-Jeff