Ingo...thanks for the explanation. Believe it or not, I actually figured that something like that was the reason (Optimizing First Gear).

Grady...I'll take a look at Fifth and will flip the synchro as well. Third and Fourth, I've taken a very close look at and will do so once again before I put it back in, now that I have more of an idea what I'm looking at.
I haven't broken it apart like I did First-Second for a couple of reasons. Mainly because it really does look to be in good condition...nice sharp dogteeth, etc. Thanks!

John, as always, thanks for the advice. I was re-reading the article I refered to earlier in this thread and ran across the quote of you explaining how to smack First-Second onto a metal plate for disassembly. It's amazing how much more this all makes sense after having done it.

Randy

Comparing the New Slider (Top) and the Old Slider (Bottom)
http://forums.pelicanparts.com/uploa...1084585375.jpg

This thing is going to be TIGHT!!! :D :D :D :D :D

Randy

The First-Second Stack-Up.
http://forums.pelicanparts.com/uploa...1084589104.jpg
http://forums.pelicanparts.com/uploa...1084589123.jpg
http://forums.pelicanparts.com/uploa...1084589139.jpg

Tried to take a few pics so the whole setup could be seen. How does it look. Put it together piece by piece using the PET drawing Grady sent me.

Still gonna pop open the differential case to get a look before putting it all back together. Will do that tomorrow in the light of day.

Randy

Looks great Randy, she's really coming along. Isnt it funny how AFTER you've done it that it all starts to make sense? :D

It really IS funny, Matt. Last night I went to the beginning of this thread and started to re-read it. I just can't believe how much I have learned in the last couple of weeks. Had to laugh at some of the questions and statements I made at the beginning. I really had NO idea what I was doing and now, I think I could really be helpful to somebody else that was trying to do their own.
I still have a ways to go to be finished, but if it continues to go like it has, this is gonna be sweet! Looking foward to the feel of my new gears.
Hey, speaking of feeling the new gears, is there a way to test this thing out before putting the whole enchalada back into the car. I mean, a way to shift through all the gears to make sure they engage properly, and not slip into two gears at once. John made a statement earlier that if one of the detents was installed incorrectly, it would allow the tranny to slip into 2 gears at once. If I can prevent anything like this, or catch it before re-installing it, that would be great!

Randy

Been meaning to ask about this. I found this underneath the car and don't recall seeing where it came from. Does this look familiar?
http://forums.pelicanparts.com/uploa...1084595745.jpg

Randy

Oh my god, that 'stack up' photo of first gear is just georgeous!!

(Ok., I better stop now, as I sound like a gear queen...)

Looks like a bushing from the accelerator linkage bell crank on the driver's side of the transmission but it also could be from the accelerator linkage bell crank on the top of the engine. Jim

Randy, you can go through the gears once the nose piece is on, but it's a bit tough depending upon how tight the new gears are. As far as the dentents are concerned, they are simple yet sometimes overlooked. All you have to ensure is that they are in the correct position when you assemble. The Bently shows you these so it's a no-brainer...unless you forget :D

Randy,

My reason for suggesting disassembling the syncros on 3 & 4 is to insure that some metal didn’t find its way in there and that all the parts (dogs, bands, stops) are in good condition. It’s not uncommon to find a stop chipped.

I would put the best syncro on 3rd and the next best on 4th. I would turn all three.

Another thing to inspect is the inner surface of the dog ring for any signs of a lip that touches the syncro ring. The dogs can look OK and still have a little lip that leaves a scratch ring around the syncro. Post some photos of the 3-4-5 rings.

Best,
Grady

Grady, against your better advice, I've decided to leave 3-4 alone. I understand I'm taking a chance, but at this point, that's the way I've decided to go. Except for removing it along with 1-2, and looking at it very closely, I haven't done anything with 3-4.

With that being said, here's my next question. Went to replace the shift shaft seal and that thing just does not want to come out. Am I doing something wrong? Don't want to tear anything up more than I already have.

http://forums.pelicanparts.com/uploa...1084641267.jpg

Randy

Also, this pin that works the Reverse Switch, it fell out while I was cleaning the nose cap. I had noticed it prior to when I began cleaning, but not it's orientation where it goes into the hole. Does the smaller end go in the hole? It seems to move more freely that way.
http://forums.pelicanparts.com/uploa...1084642256.jpg

Randy

the seal has a metal outer shell that doesn't want to come out sometimes, as you found out. pretty mush have to work on it carefully until it does. try working the shell inward with a small pointed center punch or pocket screwdriver and a hammer by catching the upper edge.
the small end of the pin goes toward the switch.

Thanks, John! When I go to put the new shift haft seal in, will I need to use a socket or something to seat it correctly?

Randy

Randy,

This image is of your 1st gear syncro stop.
Your 3-4-5 stops are smaller and slight differences otherwise.

It is not uncommon for a corner of this hardened part to break off (arrow)
and the syncro system still work perfectly.
The problem occurs when more breaks off.
The parts jam and it tends to stick in that gear.
It usually is an intermittent problem for a while.

I know it is a pain to get the circlips off but you have
the gear in your hand just now.
Considering the devastation in 1st gear,
I wouldn’t chance it.

I’ll zip it now.

http://forums.pelicanparts.com/uploa...1084645069.jpg

Best,
Grady

well, the 3/4/5 stops are actually larger than the 1 and 2 units, and i've never seen one chip like the small 1 and 2 stops do.
the seal just taps in with a smooth faced hammer.

Just a few shots before I put the Intermediate Housing back on.
http://forums.pelicanparts.com/uploa...1084652947.jpg
http://forums.pelicanparts.com/uploa...1084652991.jpg
http://forums.pelicanparts.com/uploa...1084653044.jpg
http://forums.pelicanparts.com/uploa...1084653079.jpg
http://forums.pelicanparts.com/uploa...1084653113.jpg
http://forums.pelicanparts.com/uploa...1084654258.jpg

Randy

looking good. you can't install the housing until the shift sleeves are centered properly. don't assume the last guy did it right. install the pinion shaft thrust washers, 5th gear, the 5/rev hub and snug the big nut. then eyeball center on both sleeves. i'm sure you got the detent positioned in the diff housing. remember, there's another one in the intermediate housing.

Well, it went back together a lot faster than it came apart. :) The real trick is gonna be whether or not it works. It all feels good when I move it around. I can somewhat work the shift shaft and make it engage the different gears.

I think I may have gone a bit heavy with the 874, but I have to say, the orange beads look pretty cool. :)

Gonna try to hang it on the engine tomorrow and after that, back in the car it all goes. Getting anxious, for sure.

http://forums.pelicanparts.com/uploa...1084669472.jpg
http://forums.pelicanparts.com/uploa...1084669486.jpg

John, I did remember the detent between the two shifters, in the diff housing. Moved it betwwen the two holes this morning with a magnet. Also, the two in the Intermediate housing were positioned correctly, according to the article by Marcesq I mentioned earlier in this thread.

Randy

Okay, is there a trick to hanging the transmission? Lining up the splines? I can get it started but it only goes on as far as to leave about a 3/4" to 1" space...like the splines on the input shaft are a little off. Is it just as simple as spinning the shaft and trying again? This tranny isn't too heavy...yet...but I'm thinking it'll get pretty heavy after trying this several times. :)

Randy