JW,

I thought that is what might have happened. So, if I pry off the plug, I should see the detent itself stuck in the bore?

Also, what is happening with the pin that keeps popping out from the right side of that hole? It does not seem that it could fit by the roll pin, but it is getting by somehow, even though the roll pin is fully seated.

Does anyone have a picture of what this part should look like exactly before reassembly?

Thanks,

Olivier

the detent is not stuck there. it just slips into the bore when you're not looking, and you forget to position it properly before installing the case. referring back a few posts to the picture that shows the detent in the shift rod hole, you will notice the end of a roll pin to the right of the hole (in that depression with the toothy notches). there is another roll pin farther to the right again. the roll pins hold a spring captive, and another detent at the far right of the spring. down the inside of the spring lives a pin. the pin is not held captive by the roll pins, and is free to slide out. the detent goes in on top of the pin, keeping it inside the spring. when the far right detent is pushed by the 5th/rev shift rod moving, it pushes the pin against the left detent, moving it into a notch in the shift shaft and keeping it from moving until the 5th/rev shift shaft is returned to the neutral position.
so yes, the detent is over to the far left of the bore, where it doesn't belong, otherwise the pin wouldn't be exposing itself. pry off the end cap and push it back into place.

Can I get to it with the tranny in the car . . . . . http://www.pelicanparts.com/support/...oilet_claw.gif http://www.pelicanparts.com/support/smileys/splat.gif http://www.pelicanparts.com/support/smileys/paddel.gif

O . . . . picture coming . . . the pin can get by the roll pin as the roll pin holds the sleeve that goes down into the bore.

with the trans in the car, you can probably tap the cap off and look in the bore with a mirror and strong flashlight. look for the rounded end of the detent. if you see the rounded side of a shaft, you're safe. or measure the depth of the bore. 45mm, you're ok, 23mm, you're screwed. the detent is 22mm long.

OK, I think I get it now, my detent crossed over to the other side of the hole were the shaft goes, so I should move it to the right side of the hole (in the picture)

I thought it was supposed to be on the left side of the hole and had just become stuck there.

Thanks, I will try to sort it out tonight.

Olivier

Only got 22mm . . . . . . I'm screwed

WHEN I PULLED THE CASE THE PIN (GREEN ARROW PUSHED THE UPPER DETENTE UP INTO THE BORE ABOVE THE 3RD/4TH SHIFT SHAFT (BLUE PILL). THIS IS BAD. ESPECIALLY WHEN YOU FIND OUT ABOUT IT AFTER THE ENGINE AND TRANNY ARE BACK IN THE CAR.

THE PILL MUST BE PUSHED DOWN TO WHERE THE RED PILL IS BEFORE INSTALLING THE CASE. JUST POP THE CAP (TO LEFT OF BLUE PILL) OFF AND USE A SMALL ALLEN WRENCH TO PUSH THE
PILL DOWN WHILE INSTALLING THE CASE.



http://forums.pelicanparts.com/uploa...1077158235.jpg

Sorry, Marc. I am working up the courage to button everything up here, too, and I am worried I missed something.

Olivier

Thanks, Marc. I finally got it together right. I missed your picture before going out there, that would have helped!

I had also messed with that roll pin, so I had to sort it out and get the sleeve back where it belongs. Inside the bore, from left to right, there is the pin visible in the photo, a metal sleeve that retains the spring but allows the pin to slide by the roll pin. The spring is on the right of the sleeve. I had the visible pin propped behind the roll pin, but it is right now. I confirmed the action of the detents. The one you are dealing with sits on the right side of the hole now (where it belongs), but there is no tension pushing it against that rod until the other "pill" is pushed by the 5th/reverse rod.

JW, is that the right amount of tension, or did I upset the pin and spring placement somehow?

The paper gasket between the housing got wet with trans oil during all of this, do you think that will compromise the gasket? I have anerobic sealant that I could use instead. It worked great for 2 years on the shift guide plate.

Pictures to follow...

Olivier

Pictures
 

Here are some pictures. JW, Marc, or anyone else, do these clearances look about right?

http://forums.pelicanparts.com/uploa...1077165005.jpg

http://forums.pelicanparts.com/uploa...1077165041.jpg

http://forums.pelicanparts.com/uploa...1077165068.jpg

Olivier

O:

Use the copper head gasket spray on the paper gaskets . . . . John suggusted this, and my case was dry . . . . . guess I'll have to do it again

Marc,

What exactly is the copper head gasket spray you mention?

I would like to use a fresh gasket, but waiting for another part at this point...

Olivier

K&W coppercoat.

Should I get a fresh, dry gasket?

Yes . . . . unless you want to do what I have to do ;)

Do any local places stock something like that? I am just trying to avoid waiting for another delivery.

Olivier

Pelican only has the gasket set, which I already have, but I need only the gasket between the diff and middle housings. Does anyone have a part number for just that gasket?

Thanks,

Olivier

i can mail you one if you want. or get one at a local dealer.