56 replies to this topic

[kev]

You may have to clean up the threads a little of the nut being reused especially around the crimps…get it nice and clean and burr free



But a little lube on the threads and spin it down…it went this far by hand!



Now the tricky part…torqueing this sucker to 181-195 ft-lbs per the manual.   I guess you can go different routes with this.  What I did was buy a crows foot – 1-9/16” was the closest I could find.  You kind of have to drive it down on the nut a little.  But what happens when torqueing is the crows foot expanded and slipped.   Rather than trying to find/construct another tool, I simply tack welded a bar across the crows foot while it was over the nut.





Now torque her up!   I had to even reinforce my support bar for this!   I took her to the max torque.





We can crimp now or go back to the last two shift arms.  I’m just going to show the crimping now even though I did the arms first…doesn’t matter.

Crimp your nuts in two places for both the countershaft and main shaft

[kev]

Ok, back to the shift arms.   Put in the other lubricated spacer now



Now lubricate and slide in the last fork



Lube 3rth/4^th shift rod…and the holes it travels thru in the housing.



Install it…needs to pass thru the holes in all three forks



Next go for the 5^th/reverse…again lubricating the shaft and holes



We’ll come back to the roll pins.  Lets put on the last bearing

Install the c-clip





And the bearing



Using a pole, I drove it down carefully

[kev]

Don’t forget the 2^nd c clip



Ok, all we need to do is to pin the shift rods to the forks and we are done with the gear train!

I bought a set of high strength M5x22mm roll pins

What you want to do is to drive them in the forks/rods in the orientation as shown.  This is very critical!  If you drive them in 90 degrees out, the C shape of the roll pin will flex and cause deflection when shifting!



Oh make sure the holes align in the forks/shafts…slide the shift collars back to neutral if the tranny is still in the locked state from torqueing.
Use a drift punch and drive the pins in

[kev]

Last but not least….the ball bearings, etc for the shift rods…

Coat the ball bearings in oil and install them in the three holes in the outside of the housing







Now the springs…tapered side in first…I was very critical to put all of these items in the same location that they came out from…remember the marked bin earlier?





Now, put a little gasket maker on the threads of the set screws and install them





Set them to the exact same position that you removed them from.  You can double check the values from the manual to see if they are in the approximate range if you’d like…mine were a little off but I liked how it shifted prior so I set them right back to where they were.



Now fill the holes with RTV

[kev]

Little gasket maker on the flange and the gasket





Ok…set her aside while we focus on the extension housing

Extension Housing Assembly

Starting point…all cleaned really good (and in my case painted)



Here is how clean it should be on the inside



Inspect that shift arm good!









Now clean up the flanges…Note that I covered the areas to minimize debris

[kev]

Recleaned again and ready to move on

Oil the shifter rod good!









Flip over and install the rear seal.  I added a little RTV to the outside.









Cleaned up

[kev]

Oil the inside good



Oil the holes for the shift rods



Ok taking a break, switch over to this sucker.   I don’t think I showed removing this little lever thing earlier, but if you did remove yours…here is how to reinstall



Flanges again:

[kev]

Take a dab of RTV on the bolts













Cleaned up

[kev]

Speedo Assembly

I had to buy both seals for the speedo…I just went thru Mitsu.  And some more roll pins..high strength M3 x 16mm



Make sure your parts are all nice and clean



Oil your inner seal



And put it in





Oil your rod slightly and install







Install the roll pin in the housing

[kev]

Slide on the gear and install the last roll pin



Lube the outer o-ring and install



FINAL ASSEMBLY

OK, just about done



Take your shifter rod and go to the right and back…just like during disassembly





And slide the extension housing into position while holding the rod



Now engage the rod into the forks of the shifter arms…you’ll feel it



Install your bolts and tighten then to spec..11-15 ft-lbs



Don’t forget the tabs for the reverse light switch wire..I almost did

[kev]

Lube these suckers and install…make sure you are putting them in the correct sides





The spring





Other side







You’ll see them contact that flange on the rod

RTV on the bolts



Install and torque to spec..22-30 ft-lbs

[kev]

Now is a good time to check your operation!   Could even shift to all gears if you like



Don’t forget about this last steel ball and spring







Now lube up that o-ring and gear on the speedo and install





So the speedo gear housing is actually a cam..you need to rotate it to engage the splines.  You’ll feel it couple.  Or just orient it with the notch on the outside in the position I show





Line up your slots and install the retainer.  

[kev]

Last gasket





And final housing







Couple of final items to install.

New gasket for the fill plug







Clutch fork…you know how to do this...I'm going to skip a few pics here...

[kev]

Added some RTV to the flange and installed the steel protector





Last but not least; the pan with new o-ring (lubed) and new gasket for the drain plug







There you have it!



Everything is installed except the reverse light switch…if you look closely you can see that I have a temporary rubber cap in its place.   I didn’t put that in until the tranny was in the car.  Don’t forget the ball bearing that goes in front of the switch!

[kev]

CONCLUSION

In all, I hope this helps.  I tried to be very detailed and shared my screw ups/failures in hopes that you too can see/learn from them without having to go thru the same path.  In all, this was a fun rebuild.   It was an expensive rebuild due to the parts needed and the rarity of parts available for our vehicles…but heck we are used to that!

The cumbersome part of it was the time it took…mostly waiting for parts and fabricating my puller tool.   I really wish I wouldn’t have lost that one group of photos but I hope my explanation and use of assembly photos was sufficient.   For anyone performing this task, please help us out by snapping a few pics in the area that I missed…mainly in the removal of the input shaft/bearing and removal of the center bearing.  
Again if you are performing this rebuild, study this thread and the manuals first prior to initiating.  Don’t rely on only my pics.  Who knows I may have missed an important photo…not to mention that I’m writing up this process after it being a full year or so since I actually did it.   Be thinking and understanding of what you are doing, not just following the procedure I outlined.   Also, I only showed focus on the worm or degraded items that I found upon inspection on my rebuild.  Study every component looking for wear or flaws and make the determination if you need to replace more parts…or possibly even abort from the rebuild and find a replacement unit.

As always please feel free to send me PMs about ways you did things differently from me, more efficiently, etc.   Also, if you something that I did that was downright wrong…please let me know!   I would not be offended in the least way and don’t want to convey the wrong process to other members.  

kev

[importwarrior]

Any comments or process questions PM Kev or post here.

http://www.starquest...howtopic=148679

Great post Kev!

[kev]

Please see the note at the beginning of the first post in this thread, the photos have all been relinked!