Tranny rebuild troubles - advice please

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May 27, 2011
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I took on the questionable task of rebuilding my '69 Cruiser's 3-speed tranny and transfer case. I don't have a large budget for the car right now, so I thought that would be the best way to go at the time. This was very time consuming, but I got it done. Everything shifts and rolls well. This weekend I put the tranny and transfercase back together and once I did that, something starts binding up and I cannot turn the input shaft by hand anymore. If I back out the mounting bolts just a tiny bit, everything turns and shifts nicely. I have triple checked that I didn't miss a spacer or something.

I am now at a point where I would like to minimize my future time and money expenditure and just get this thing fixed. So, do I go to a professional for help with the current 3 speed setup? If so, do I go to a normal transmission shop, or a cruiser specialist. I get the feeling that cruiser shops around here (Denver, CO) farm out tranny work, anyway. Any advice is welcome.

Thanks,

Colinmgoo
 
It is not clear what mounting bolts your are talking about, but I assume they are the ones that mount the transfer case to the tranny. If that cause binding between the tranny input shaft and output shaft, chances are that one of the needle bearings fell out of the input gear and is wedged against the nose of the output shaft. Take it apart and try again.
 
bind

Good call Pin_Head; was thinking exactly the same thing.

Thanks jb
 
Thanks, Pin_head. Yes, I am talking about the mounting bolts that mount the t-case and the tranny. I took the tranny apart and checked for loose needle bearings. They are all still in place.
 
My lesson for the week: Order of Operations is important. I had been trying to install the tranny and output shaft onto the transfercase with the rear bearing already installed in the back side of the t-case. The output shaft was not getting all the way through the bearing, so when I would tighten the mounting bolts, the output shaft would push back into the transmission and bind up on the input shaft. I was able to fix this by removing the rear bearing, installing the tranny onto the t-case, and then install the rear bearing. It was difficult, as balancing the tranny and t-case on my press was very heavy.

Thanks for the suggestions.
 
Good information. I can't find an answer to my question anywhere so I am hoping someone here can help me out. I bought the Terrain Tamer kits for tranny and transfer cases. I bought new synchronizer rings from Toyota, although the misleading information netted me two different sizes when indeed I need two of the smaller ones. Here is the issue, the old rings have three notches in them that do not pass all the way across the ring, leaving a land about 1 mm thick. The new ring has the same three notches, however, they pass all the way through. Is this a fabrication change of no import or does that land have to be on there? I see no wear on the land face at all, just dirty. I can't imagine that something that thin was designed to locate the ring, but then again, I don't know. Thanks, Lenny.
 
Synchronizer ring question

Here is a copy of the ring from FJparts. You can see adjacent to the three notches the thin band of material around the outside. The new rings from Toyota have the notch cut all the way through to the outside. I cannot see where this is an issue as there is no wear on this land on the old rings, the teeth are more than 50% worn, but nothing on the land. Please advise, thanks, Lenny.
synchronizer ring with land.gif
 
Gracias Pin Head. For our other listeners he said, "I believe there is no problem." But you all knew that anyway, right?
 
Update on the synchronizer ring. Toyota sent the wrong one twice but I finally received the second one, correct one, on 5FEB14. Took the parts for the transfer case and transmission to the mechanic on Monday this week. I determined that the special tools and hydraulic press required were not items I needed to buy for a one time use and so took it back to the shop. This morning the mechanic calls and wants me to bring the old synchronizer rings over. I am convinced that the mechanic (not the owner) is hung up on the slight appearance difference. Regardless, he claims they will not work although I watched him install them in the hub and move the assembly back and forth. It is just that small amount of light he can see through the flange, which is not cut all the way through on the old ones, that hangs him up. Regardless, when discussing technical issues in two languages I am at a disadvantage. I think the owner understood what I was saying but it wasn't worth offending his mechanic over. So it will be reassembled with the old rings and I'm out quite a bit of money as I have a pile of synchronizer rings, plus shipping, plus waiting time, that will not be used. I get the impression the mechanic feels he needs to display that he knows more than me. And with regards to Land Cruisers he is correct, he does. However, when discussing particular applications of components I am long in the tooth regarding hot rods, bikes, etc. and can tell the difference between bulls*** and problems. Such is life in a foreign country.
 
Hahahaha! There is a concept that is rapidly becoming extinct! It is possible that he feels that since I am a retired gringo that I am filthy wealthy and everything I have done to the vehicle should be done by him. I don't know, a little aggravating. On the transmission shaft one nut threads on over a keyway cut into the shaft. He showed me the old nut which was a pretty crudely made item, that had been center punch staked into position once torqued. So he is describing to me that a custom nut has to be made which has a keyway cut into it!?! How on earth would you ever know where to cut a keyway into a nut which must be torqued? I was looking at the exploded view and clearly a tang washer is employed that would key into the shaft and then be bent over the nut once it is in place. Oh well. We read stories about Cuban mechanics keeping 60-70 year old vehicles on the road. It isn't limited to Cuba, I'm sure BJ40Green has similar experiences in Costa Rica. I know that Coen & Karin of Landcruising Adventures told me a few stories about their experiences on their ten year journey and that while they return to the Netherlands once a year they find they are bringing more parts back with them each trip as they tire of the crude repairs that just don't last. One of their calendars shows pictures of the six month overhaul they had done in Bolivia. They left my house and headed for Quito. There current information shows they are working on the rig in Quito.
 
Creo tu necessicitas una nueva mechanica. Con sufficiente dinero, todo es possible.
 
Ah yes, the rich gringo. I do have another mechanic that my landlord introduced me to when I bought his Nissan X-Trail nearly two years ago. Marlon would not have been able to tolerate having The Beast sitting in his shop for six months as was the case a year ago. However, in the future I will use him for routine maintenance, probably for fitting up my new MAF header and arranging for new exhaust connection and the like. It is a learning curve for certain.
 
Tranny rebuild

Walked the dogs over to the shop today to see how things were going. I tell you these telephones down here are slightly above smoke signals. The transmission/transfer case assembly were sitting on the bench ready to go. The mechanic had tried calling on Friday several times, it showed on his phone, not on my wife's phone. So we walked back home and called the tow truck. Of course there was a problem. The new speedometer gear (driven) that I bought that matches number wise, looks exactly like the old one except has fresh teeth, fits but won't turn so would I please bring the old one back. Six months, numerous parts sent, returned, and then not used including synchronizer rings (no good reason for not using) and the problem with the speedo gear. I had also brought back in October a good set of used front hubs and had ordered all new washers, nuts, etc. Of course the nuts were too large at the thread even though they checked the 50mm hex. Aaarrggh. Anyway, it comes back home on Wednesday and I will install the gas tank, carpet, seats, etc. and fire it up! Only 15 months and $18K invested! Groan.
 

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