H55F on a 1984 FJ60

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Im making slow progress on this. But im making progress. Ill look into what he wrote when i get home from work
 
this is how i got that gear off, with a torch to aid. it was super sketchy and i dont plan on doing it like this again XD

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I don't know if you've already found @roma042987 's write-up on swapping input shafts, but he did a good job of streamlining the procedure. There's a lot of extra stuff in the FSM.

h55 h55f transmission input shaft swap

I tried his technique on getting the input shaft off and its been working! its over halfway off. but as i dont really have a transmission stand i have to pickup and turn over the transmission alot.. so im going to finish it tomorrow so i dont kill my back, also do i need a hydraulic press to reassemble this or can i use a good ol' hammer?
 
ok pics include, how i took off one of the things. and the rest is part of what we're trading. bad news though the input shaft has a small chip in it i took a picture to show you where it is. i dont think it will be an issue with the transmission though. the part that chipped was one of like 100 little walls that stop the fork in 1st gear, (i think that's right)
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I will clean these as best i can before shipping. i cant say it will be a good clean, just to where you shouldn't get your hands too dirty.
 
It's been so long since my last transmission rebuild, I can't remember if I used a shop press or not for reassembly. Pretty sure I pressed on the input shaft bearing that way. I don't recall using it elsewhere in the reassembly process. I have a cheap shop press from Harbor Freight. I try not to use a hammer for installing/removing if It's possible. In some cases, that's just my preference. In other situations, I believe it reduces the possibility of damaging parts.

Nice! I like how you made a long-jaw puller. That's a trick I'll need to keep in mind. No worries on how clean the parts are... I'll be blasting the bell housing anyway. I see the chip on the input synchro, should be fine. Did you drop the counter shaft before pulling the input?

Did you pick up a rebuild kit yet? I believe they run about $300 or so. @cruiseroutfit can set you up. There's a few vendors on mud and their worth supporting.

I should be able to ship your parts to you by Thursday or Friday. I'm sending you a PM to coordinate shipping/contact information.
 
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i ended up having to drop the counter shaft (i think), i got cocky and strayed from the manual but i found out quick enough that i needed to.
 
The main shaft and counter shaft have the gears meshed together. It looks deceptive because it appears as though parts (gears, synchro, etc) can just slide out. Removing the parts without dropping the counter shaft will end up damaging something. At least that's been the case with the manual transmissions I've rebuilt.

Now that you have the input removed, the rest of your rebuild should be pretty easy in comparison.
 
I just have one more bearing to pull then I'll post up pictures of the parts I'm swapping with you.
 
ok this is what i have to send, i assume we can just keep the bolts.
Bell housing,
Throw out bearing arm with rubber boot,
input shaft
bearing retainer

im getting the box to ship them in today, i dont know 100% when im shipping. im going to wipe off some of the grease to ease the filth.
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I found my puller that I modified for the pickup transmissions. They worked fine for the front counter shaft bearing. I need to finish the long arm puller I'm grinding down for the rear bearing. I'm shooting for dropping off the package this Monday.

This $10 dolly from Harbor Frieght was pretty helpful. Might be worth the $$$. It was convenient to sit on a stool and go to town on the 5-speed.

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All done! Sending this out Monday afternoon via USPS Priority Flat Rate Shipping:

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Just now getting around to unpacking the parts you sent me... excellent job by the way; here are the markings I found:

On the outer race:
35TM03NX It might be 35TMO3NX

On the seal:
40TM05U1 It might be 4OTMO5U1

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My 5th gear wont fully engage. Im trying to troubleshoot. Some people say to replace the sleeve but we'll see...
 
Even with a brand new transmission, I had some issues getting the shift forks just right. Do a search & you'll see it's a common problem. Keep fiddling...
 
Hopefully its ok to file this back down. A vise is not a suitable subsitite for a press... this was pressed onto 5th gear, i decided to take it off during my troubleshooting of why 5th gear wont fully engage. -.-

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My memory is a bit fuzzy. I recall checking to make sure things we're freely rotating throughout to check if the parts were meshing properly. These are the steps where I used the shop press:

Using a plastic hammer, I got the components started on the back half of the counter shaft. I did this so I could place the transmission on the press without having these parts fall off. It was a pain getting the transmission balanced on the plates of the press; but once there was enough pressure, my hands were free to slightly rotate the input shaft. The piston of the press was on the front end of the counter shaft. The back half sat on metal plates. By doing this, I could make sure things were sliding into place without chewing teeth up.

Before it was all snug, I remove the transmission from the press so I could use a set of feeler gauges to make sure the back side of the counter shaft was assembled with the right clearance. Once I had everything back on the press, I snugged everything down. I then set the transmission on the bench and used a puller to removed the feeler gauges. I tightened the puller in degree increments until I could remove the feeler gauges. Then I rechecked the clearances to make sure I was within the recommended tolerances.
 
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All my thrust clerances are within spec. Im trying to avoid taking the trans back and forth from my buddy's place to use his press so the first bearing was installed with a plastic mallet. The 1st gear sync (the straight toothed gear) has some play back and forth but i couldent find the cause of it. And light reaserch tells me this is ok? I am using a press to install the input shaft bearing though.

What does the manual mean by mp grease? Is it multi purpose grease? And what kind do i get it
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