I got around today to beginning the rebuild process of my H42 transmission. I have a gear set to build the case into an H41 transmission.
Following the numbered steps in the FSM, I got all the snap rings off and am at the step where it says; "drive out the input shaft assembly." The only problem is, there is no way to get a drift or punch on the edge of the bearing without damaging the input gear. Anyone else ever done this job?
Pulling off the transfer case was familiar territory, but the transmission does not come apart as easily. It looks like once it's disassembled, re-assembly will be pretty straight forward.
I got this done. Here is the scoop for any future searcher.
You must pull the counter shaft bearings first, and drop the counter shaft into the bottom of the case. Mudrack helped me out with his puller tools.
Then you pull the main shaft bearingat the rear. They come pretty easily.
Then you use a brass drift to drift out the input shaft and it's associated gear, being carful not to mangle the syncro. The counter shaft must be lying in the bottom of the case or the input shaft and bearing will not come out.
Then, you hold all the main shaft gears together, tilt the assembly up and pull it out of the case.
Then you go back and pull the counter shaft out of the case.
The rebuild means disassembly of the main shaft, and installing new needle bearings on the main shaft. I tried very hard to keep them in order, then matched them up in order with the H41 gears I had, and install the H41 gears on the shaft.
You press the input bearing on the input shaft, and you're ready to reassemble.
1-Counter gear in the bottom of the case, small end faces the rear.
2-Main shaft goes in the case, being careful not to let the syncros and shift collars slide off.
3-Install the needle bearings inside the input shaft. There are 17 of them.
4-Drive the input bearing into the recess in the case-I used a drift, while holding the shafts together so none of the parts slip out.
5-Drive the mainshaft bearing into place with a drift. Then the entire main shaft and input are supported by the bearings on both ends.
6-Lift the counter gear into place and begin to drive in the bearings on each end. There is some trickery involving the snap rings-the rear counter shaft new bearing has a snap ring that must be removed to install.
(This caused me considerable pain, untill I looked at the original bearing, and realized it had no ring. Once the ring was off, it went together perfectly.)
7-Install all the snap rings that retain the shafts and bearings in the case.
8-Install the front bearing cap with new input shft seal.
9-Spin and shift through the gears, making sure it is in neutral before you put on the top cover.
Lessons learned--There are no work arounds for the counter shaft bearing removal. You must have the pullers or don't even try. With Mudrak and the right tools, the bearings were all pulled in about 15 minutes.
The rear counter shaft bearing in the standard rebuild kit has a large retaining ring that must be removed to drive it far enough into the case. I confirmed this looking at the factory bearing-no retaining ring. The input and output shafts (mainshaft) also have these large locating clips and they are retained.
Rebuilding a transmission is surprisingly easy. Once the bearings were pulled out, I had it back together in about 30 minutes. Like I said, I was surprised.
Most important lesson, though. It is INDEED possible to put H41 gears into an H42 case. The only gear common to the two cases is the reverse gear, otherwise they all change.
Huge thanks to Gary for helping me with with a valuable lesson.
