Can't Shift Into First

[rcecale]

Matt, the article I mentioned above from Marcesq shows detailed instructions on how to do just that. Thanks for the advice for putting it back together!

Randy

[ischmitz]

Randy,

actually, it is a 41mm socket. A 1-11/16in. (41.275mm) should be close enough. See here at Sears http://www.sears.com/sr/javasr/product.do?BV_UseBVCookie=Yes&vertical=TOOL&pid=00947784000

[john walker's workshop]

actually it's a 1-7/16" socket.

[rcecale]

I'll pick up one of each...I can always return the one I don't use. Thanks!!!

Randy

[rcecale]

Okay, now what?

Could it be that my air hose is too long? Got 100 psi on the 27 gal. compressor hooked up to the impact wrench with a 50 ft. hose. The impact wrench is set to "full power" and the nuts are not going anywhere. Actually, I can hold the socket in my hand and squeeze the trigger with the other and I am able to keep the socket from spinning. It impacts the heck out of the socket, but there is no power behind it. The gun is rated at 275 ftlbs of torque and I know I'm not getting anywhere near that. Could it be the hose?

All I am achieving is one beat to heck nut....

Randy

edit: Compressor is 5 HP, 7.3 CFM @ 90 psi...should be strong enough to drive the wrench, isn't it?

[rcecale]

Guess I just needed to be a bit more patient. Went back out and tried some more and it actually worked! WOO-HOOO! Now to get to removing the rest of the parts between me and first gear!

Randy

[UTKarmann_Ghia]

You go Randy! This is where it starts getting rewarding. Remember too that you can't impact those nuts back on, you HAVE to torque them (I'm sure you already know that)

Have you already decided how to remove the input shaft nut? You'll need like a 12" 1 & 7/8" deep well socket to do that (I think that was the size) and some ALUMINUM vice jaws to hold the shaft. If you 'd like, I can mail you mine if you promise to return it. It worked great, just let me know. You'll need that thing VERY soon and it's VERY difficult to remove the nut without it.

If you want it fast, I can overnight it to you for shipping cost and you can snail-mail it back to me.

Let me know.

[ischmitz]

Originally posted by john walker's workshop
actually it's a 1-7/16" socket.

So the nut is 36mm, right? The one on the input shaft were you need an ultradeep socket is an 41.

Ingo

[rcecale]

The castellated nut on the main shaft was a 27mm. The nut on 5th Gear I was able to get with a 1 7/16. It felt a little sloppy on the nut, but it definitely did the trick!




This is where I sit right now...(I've also pulled that bushing off of 5th gear as well.


Just trying to work off the intermediate cover, now. I believe this is where the deep-well socket will come into play, if I read correctly. Wayne calls for a 30mm deep-well

I know I'm not supposed to pry on the mating surfaces, and I have no intention to...but are there any tricks to removing the housing. Tried using a piece if wood as a chisel, and tried banging on it but I'm not sure how hard I can safely hit it. The last thing I wanna do is mess it up. Any ideas?

Randy

[rcecale]

There were 10 nuts...not 9!!!

Anyway, more progress pics...







Randy

[rcecale]

Call it a hunch, but my guess is that these aren't supposed to look like this...

The first two:


And the third...



Randy

[john walker's workshop]

yeah, looks like the hub is broken too. next, remove the two 17mm wrench size bolts that are next to each other in the side of the differential housing, and fish out the springs and detents under them. (magnet). remove all the nuts and lockwashers that hold the bearing retainer plates to the diff housing. shift the mainshaft into 3rd gear, (that's up, toward the end of the shaft). be sure the pinion shaft is in neutral when you do that. leave the forks and shift shafts alone. wrap your hands around both shafts and forks with the trans bellhousing down on a table or the floor, and wiggle the whole works out.

[rcecale]

John, that advice was right on time. Came in to confirm my next step and you already had it sitting here. THANKS!

With that said, both shafts are out.

You can see in this pic that about half the dog teeth are missing.


How do I get this thing apart so I can replace them? Also, what else should I look for that may need replacing?

Thanks!!!

Randy

[rcecale]

Originally posted by UTKarmann_Ghia
You go Randy! This is where it starts getting rewarding. Remember too that you can't impact those nuts back on, you HAVE to torque them (I'm sure you already know that)

Have you already decided how to remove the input shaft nut? You'll need like a 12" 1 & 7/8" deep well socket to do that (I think that was the size) and some ALUMINUM vice jaws to hold the shaft. If you 'd like, I can mail you mine if you promise to return it. It worked great, just let me know. You'll need that thing VERY soon and it's VERY difficult to remove the nut without it.

If you want it fast, I can overnight it to you for shipping cost and you can snail-mail it back to me.

Let me know.

Hey, Matt!

I appreciate the offer. Marines really do take care of their own! I believe the socket you're talking about is the 30mm that Wayne calls for in the 101 Projects book. I have that...the thing I don't have would be the Aluminum vice jaws. If I find I need them, I'll just see about picking them up. I'm figuring the money I'm saving by doing this myself is money to be spent on tools. this way, I'm prepared if I need to do it again...or even better yet...if any Pelicans need help!

Randy

[Beethoven]

This has got to be one of the more riveting threads in memory. Can't wait for the next stage.
Btw, when you say half the dog teeth are missing--where exactly? Could you point it out on the photo?
Thanks, and good luck!

[UTKarmann_Ghia]

The one I'm talking about is a 1 5/8" deep socket, not sure what mm that is. The input shaft has a nut which is that size. See thread below. You may be able to remove the nut without the socket, using a big-a$$ wrench, but it has to be torqued on assembly and a wrench just wont do it. Offer still stands if you need to borrow the tool. You'll know what I mean when you take apart the input shaft to replace synchros and such. PM me if you need it.

edit: it's a 41mm nut, not a 30mm.

The best tools are home-made (915 nut socket)

[john walker's workshop]

fold a couple of shop rags for padding and lay them on the floor. preferably a concrete floor. grab the pinion shaft and firmly pound it against the rags a few times. inertia will remove the stack of gears from the shaft. (pinion gear up, open end of the shaft down). don't freak out with this method, everyone does it. i use a soft steel plate from my press instead of rags. the shaft is harder than the plate, so no damage is done. keep the pieces in order as they come off. the mainshaft is done the same way, after the nut is removed. a nut removal tool can be made by cutting the proper size socket in half, and welding a length of pipe between them, as long as the ID is large enough to allow the tool to fit over the end of the shaft. or clamp an old clutch disc in a vise to hold the shaft, and use a large pipe or crescent wrench.
the exception to this is with early pinion shafts that have a speedo drive gear on the end. do not pound these. instead, use a press.

[rcecale]

Originally posted by Beethoven
Btw, when you say half the dog teeth are missing--where exactly? Could you point it out on the photo?

Hey, Beethoven! Thanks for the interest!

In the pic I posted above, all of the dog teeth have been broken off. The good teeth are on the other side. The area circled in yellow shows how flush they are. The dog tooth circled in red (on the right side of the pic) is actually there...it's the last of the good ones on the other side.


Here is a picture of 5th gear showing how the dogs are supposed to look.


And, even though this gear is bad, it shows how the dog teeth should stick out.


Randy

[UTKarmann_Ghia]

Man, that's some serious damage...good thing you didnt drive the car any further.

[rcecale]

Definitely a case where the dog's "bark" was worse than it's bite!

Randy