overhaulin' transmission

[Sniady]

I'm in the process of rebuilding my gtv's transmission, and I need your advice.

I have the shafts out of the case, ready to be dismantled. All gears look to be intact. Not worn, or chewed up. What should I replace? The syncros, and sliders, are a must, but what about all the cage bearings, bushings, and layshaft bearings? The bearings don't have any resistance, and don't feel notchy, or making any noise. Should I replace the bearings while i'm in there? Any problems ever experienced with these bearings?

While removing the shift fork shaft, I noticed two square round bearings dropped on my bench (not a round bearing ball), where the heck did they come from? Is there just two these guys?

What's recommend to seal the case back up besides the bolts, and nuts (gasket sealer, rtv silicone?)?

What else can you recommend I replace? What should I be aware of, and look out for? Any tricks, or tools I need to remove any parts?

willing to spend up to a 1,000 bucks, on my rebuild.

p.s. will post images soon.

[jgates]

Are the bearings jelly bean shaped? If so, they fit in the rear of the case between the shift shafts and are actuated by going in and out of detents in the shaft to (theoretically) prevent shifting into 2 gears at once. No springs.

I really like Permatex Anerobic Gasket Maker part number 51813 for the transmission, Permatex Right Stuff pn 765-2427 would be better perhaps, more difficult to dissassemble.

Might want to get a new set of lock tabs for the bolts that secure the shift forks to the shift shafts. If you don't, use the Anerobic Gasket Maker.

Have fun.

John Gates
Enumclaw, WA
'65 Spider Arrugginito

[Sniady]

Thanks jgates.

Yes, they are jelly bean shaped.
So do they sit in the center shift shaft in both grooves?

[jgates]

In the rear of the case, where the shift shafts go thru, there are holes between the shafts. One jelly bean goes in each of these holes in the case. Take a look, if it doesn't become apparent let me know, I'll take a picture or 2.

JG

[velocedoc]

There is 3 of those jelly beans. One goes between the two forks and the other two go inside the shift forks. When you select a shift rod, the jelly beans slide one way or the other to lock the other two from moving.
I use Permatex Aviation gasket glue to seal the cases, cleans up really easy and seals well.
Replace the synchro's and sliders, 5th gear caged roller bearing and the small caged roller bearing between the 3/4 gears. Check the wear on the shift forks especially 5th grear. If they appear to have excessive wear (thin at the end) then I would consider spending the money to replace them.
Replace both seals at the end of the gearbox.
New inner and outer boots, and rubber coupler are advised to replace.
Rear transmission bushing while you have the chance to do this on the bench is highly recommended.

[jgates]

Quite right, there are 3. Sniady found 2; all should be accounted for. Nothing worse than finding one on the floor after installing the transmission.

JG

[Sniady]

Veloce doc, thanks for the great info.

While tearing the tranny apart, I heard something fall on the floor into a box. The search will begin for the jellybean.

[Little Italian]

We've always called these peanuts. The two cage bearings are cheap. Change those. IAP has them. The three bearings that have an embossment hub on them are rare and really expensive. IAP has them too but at a big price. The other two ball bearings are standard bearing but FAGs are perfered. Again IAP or Centerline. Replace all the syncro and at least the 1-2 syncro sleeve. If you can get them, replace the big syncro retainer circlips. These are very hard to remove. I may make a tool to fit in the vice to spred them apart. The fifth gear syncro sleeve can just be turned over. The reverse side never sees service. Of course add new oil seals. Polish your shift rods and dress the surfaced of the brass shift forks. Easy.
Debur the edges of the hubs. Inspect the teeth on each gear - the syncro teeth. Well covered other places on this site. These are not replaceable yet. I'm working on these. The're interference fit to the gears and can get damaged speedshifting. Second is usually the worst. Need a shaper and Bridgeport mill to make them first. Also, check this site about adding a second limiting strap to first gear. Would allow a eazy downshift into first at stoplights. Would reduce wear from syncronizing first off the second gear syncro. If you have a donor gearbox, you can rob the good sycro gear tooth hubs to replace 1 and 2 if you need.

Clean everthing so you can eat with the parts. Just good house cleaning. Get a new rubber shift boot too. Good luck.
I understand the guys in Europe have trouble with there Selespeeds. We do too. We don't have any.

[Sprintn]

WHile we are talking taking the tranny apart... When removing my rev counter gear, the threads on the outer part of the assembly were very brittle and squeezed & cracked while gripping them to remove the assembly. Do I need to replace this whole thing... and where can I get it? I started a thread regarding this but I was not getting a response. Sorry... don't mean to hi-jack Sniady's thread. I'm taking my tranny apart as well so will be watching this thread closely.

THanks
Sprintn

[andrewg]

Inspect the dogrings on all the gears. They can be pressed off and "used good ones" pressed on in their place. Replacing synchros andshift sleeves are worthless unless you also have good dogrings.

[Sprintn]

Daaannnngg!!! These things are dificult to remove!!! I have a very nice retainer ring tool and it still slips out of the holes!!!! How do you get these things off without having them get buggered-up!!!

Thanks
Quentin

[Craig]

Quentin, don't worry about damaging the 'C' clips they're tough.

Open it slightly with the pliers and slip something under the clip so that it can't drop back in the groove. Do this in a few places and pry it up with a screw driver if needed.

[Sprintn]

will it "kink"?
I don't want to bugger-up the top edge of the retainer ring slot either.?.?

[Craig]

Not a chance!

[Sprintn]

Alright Craig... I'll give it another go.
If I munk things up I know the general area of where to find you! LOL!!!

Cheers
Quentin