Transmission and Transfercase RESTORE STAGE - *in Progress* Started 4/14/06.
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3/14/2006 The last major hurdle for dismantle and checking parts was the Transmission and Transfer case. When I purchased the vehicle there was a grinding sound in 4WD. But Axels, have been cleaned up so there is only one place left it could be... transfer case.
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3/14/2006 I debated for a couple months whether or not to take this apart myself. Since John Barton posted some great details on dismantling your transmission on G503. I tried cleaning it up here, and started removing bolts but then stopped. Read some more about the details, an thought I should take it to a pro.
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4/12/2006 I took it to a place in Van Nuys CA, called Transmission Super Shop, they dismantled the transmission and transfer case, and we inspected all of the parts.
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4/12/2006 The front and rear Yolk shafts were not smooth, therefore with the wear on these pieces we would expect some leakeage. The seal will ride on this shaft, so they need to be smooth
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4/12/2006
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4/14/2006 All of the gears looked good, very little wear, but we wanted to replace the output shaft and the 2nd gear, because there was some play (wiggle) on these pieces, and some wear at the end of the shaft
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4/14/2006 When the new parts came, you can see the difference. Here the front yolk shaft is clean, and the seal will sit on it well.
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4/14/2006 New rear yolk shaft
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4/14/2006 Now that all the parts are in, we need to paint the housing and prepare for remantling.
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4/29/2006 Here everything is rebuilt, painted and put back together.
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5/6/2006 Now its time to work on the clutch and get ready for the install to the engine. Here you see the new clutch pads have the marking for flywheel side.
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6/10/2006 I replaced the throughout bearings, you can see the one on the right is worn compared to the newly installed one.
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6/30/2006 Replaced the spring and installing the throughout bearings and fork prior to hoisting and installing.
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6/30/2006 After the engine rebuild I installed it on engine mounts. I used a jack to have the Engine at an angle, so I can hoist the tranny and install to engine.
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6/30/2006 To line up the bellhousing, I lined up the tranny by using long bolts around the bellhousing.
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6/30/2006 The challenging part is getting the tranny core shaft into the crankshaft. After a little while of trying it finally went in.
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6/30/2006 Bellhousing bolts are tightened to 35lbs, and the bolts on the crossmembers installed.
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6/30/2006 This bolt (2 required) are a little hard to find. They go in the mid section of the bellhousing. I one had one, went to Brent Mullins for the other.
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6/30/2006 Another note, I had my skid plate installed before this phase. I removed it to make it easier to install.
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