Month: September 2010

      Bolt the extension case back into place and don’t forget the reverse shift rim bolt that we pointed out earlier. Then we concentrate on the shift tower. The shifter locating bolt is a commonly replaced item, as it is very prone to wear. There are two different sizes based on the model […]

      The needle bearings should slide easily with no obstructions. And don’t forget the circlips as you go. Remember the input shaft we set aside earlier? You will need to replace the bearing on the end of the input shaft. Use a bearing puller for removal and then press the new bearing into […]

       Your rebuild kit should include all of the main bearings as well as the needle bearings, so remember to swap in the new components as you go. As you (carefully) pull the main shaft assembly apart, you will notice three (3) ball bearings in the mix. Don’t lose these. Also, don’t try […]

           When you first look at the main shaft, it may appear very daunting. But as long as you have a large workbench where you can lay everything out in order (and you have your Factory Service Manual handy) it’s not really tough. This is actually two shafts. The main shaft […]

      The factory service manual says to press out the countershaft using a hydraulic press. I accomplished the same thing using a brass drift and a small sledge hammer. Do not use the hammer by itself, you WILL damage the countershaft and you run the risk of cracking the case if you miss… You […]

           Back at the lower case, you can easily remove the reverse gear shaft and idler gear. Set it aside. Next we turn our attention to the countershaft. Using a bearing puller, remove the countershaft rear bearing. This is the first of three bearings you will replace on the countershaft. Being […]

       Next we go to the front of the transmission and remove the clutch release bearing. Now you can see the 8 bolts that hold the input shaft bearing retainer in place. You will also note that even when the bolts have been removed, it is very difficult to remove the retainer. There […]

       The o-rings are the most critical part of the air seal. When installed, they create an air chamber that ‘floats’ on the bearing journal. The air comes in through the seal housing and is plumbed through the journal wall into the interior of the carrier. Give the o-rings a good coating of oil […]

  Teflon tape should be a staple in a toolbox. Seal the threads well and install the fitting in the new tapped location. This seal isn’t for air, the system never pressurizes the axle housing. This is more to keep all the lubricant in the housing if you get a little radical on the trails.  […]