Transmission rebuild

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green40

green40

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Joined
Apr 16, 2003
Threads
224
Messages
3,475
Location
Swanzey NH
We'll be rebuilding an SM42o and possibly a 3 speed T-case Sunday
May 3, 9:30 ish, at my place in Swanzey. If you are interested in learning
how it's done, please join us.

Lane
 
I would love to help with this, but I will be up at the Vermonster all weekend.
Lane are you going to take pics of you rebuilding it? maybe a little how to write up ;)
 
See you then Dave, Bette is going to whip up some awesome burgers
and a nice salad for us. I've been trying to get the 40 moving again
so we have some room, not going as planned tho!
 
MMMmmm, burgers, beer, buddies and a pile of bearings and gears, I can't think of a better way to spend a sunday afternoon.

Lane, can you email me your address or phone #. I'm 99% sure how to get to your place, but just in case.

Jr.
 
Camera is ready!
Junior, emailed the addy to ya, see you tomorrow!
 
A big thanks to Junior and Dave for coming down and doing some serious rebuilding!
We started at 9:30 and Junior hit the road at almost 8 pm.
What we got done was a complete rebuild of a 3 speed Toyota transfer case, new bearings,
seals and gaskets. None of us had ever taken one apart but Junior spent a few minutes with
the FSM and figured it out. A press would of been nice but we made due with hammers and drifts.
The SM420 is about 80% done, we got to a point where we needed to install 2 wire springs, unfortunately
one was broken so I need to source that out before we can finish.
We did have to fabricate a special tool to take apart the input shaft so we could replace the bearing.
Got a piece of steel from the pile and Junior donated a punch that was the right size and we welded
it up. Worked great!
Bette made us a nice lunch which we washed down with a nice cold beer that Dave brought.
Got alot done and had a good day with friends!
Thanks guys!!!
t1.webp
t2.webp
t3.webp
 
A rare sight, someone actually reading the directions!
t4.webp
 
To be fair, I did pretty much nothing. :) That said, it was a FASCINATING process. For someone who's never seen these "big chunks" pulled apart it was very educational, Dave really knows his stuff and answered all of my stupid questions. :) Very cool.
 
green40 said:
A big thanks to Junior and Dave for coming down and doing some serious rebuilding!
We started at 9:30 and Junior hit the road at almost 8 pm.
What we got done was a complete rebuild of a 3 speed Toyota transfer case, new bearings,
seals and gaskets. None of us had ever taken one apart but Junior spent a few minutes with
the FSM and figured it out. A press would of been nice but we made due with hammers and drifts.
The SM420 is about 80% done, we got to a point where we needed to install 2 wire springs, unfortunately
one was broken so I need to source that out before we can finish.
We did have to fabricate a special tool to take apart the input shaft so we could replace the bearing.
Got a piece of steel from the pile and Junior donated a punch that was the right size and we welded
it up. Worked great!
Bette made us a nice lunch which we washed down with a nice cold beer that Dave brought.
Got alot done and had a good day with friends!
Thanks guys!!!
Click to expand...


It was definitly a day of "custom" tools. A front inner axle shaft is perfect for driving out bearing races :hhmm:

1"x1/8" flat stock added to a puller can remove stuck bearings in China :hillbilly:

The input gear on a three speed case is the perfect spacer for setting the bearing on the rear output shaft :eek:

A drill press can and will double as a bearing press, having a freezer in your shop to shrink inner bearings is a must too :idea:

Dremels are a magical tool :clap:

Next time I'll have you come to my shop where I'm better equipt tool wise, then again there shouldn't be a next time :rolleyes:

We'll finish up the 420 after the spring meeting, hopefully you'll have the retainer spring by then. Foiled by a two dollar part!

Thanks for the lunch Lane and Bette, those burgers were real tasty.

Thanks Dave for the fruity beer:cheers:

Had a great time,

Jr.
 
vtcruiser60 said:
Wow...those syncro rings look incredibly worn!!!!!

Do you know which spring is missing or broken in there? You think it will be hard to source?
Click to expand...

The spring wasn't missing, it was evenly distributed around the internals of the tranny. It was one of two detent retaining springs for the third and fourth clutch hub. That was the syncro for third gear. In the pic Lane posted you can see on the new syncro the three slots that the detents ride in, this helps keep the syncro lined up with the gear. On the old one you can see how it was forced into third so much that it completely stripped the crown off. IT WAS NOT GOING INTO THIRD, PLEASE STOP FORCING IT. Nit Wits!!!

Should be easy to get from Novak Ind. excellent company to deal with!

Jr.
 
Junior, have your emery cloth roll here.
I'll bring the tranny and T-case over to your place when I get the parts and we can
put it all together.
I was looking at the Novak site and I think I'll do the modification on the
input shaft that you were talking about.



Lane
 
Lane....I picked up a spare rubber boot for a stock tcase...the dust boot cover that is on the nose cone.....do you need it for the three speed? I can toss it in the box with the aisin hub faces.
 
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