And so it begins. I'd planned on doing this yesterday, the first day I was off when my kids were in school, but I was in the mood to veg, so I played video games instead.
You may recall the Bearing from Hell that I had to remove during the tear down, eventually resorting to a grinder with a cutoff wheel. What a mess. Well, this is its replacement, which I tapped into place using that little hammer and the brass drift, hitting somewhere around 300 times to ease it in place. I could have taken it to a machine shop to have t pressed on, but I didn't want to bother. Unfortunately, the picture below is also proof of my only really serious mistake in the rebuild. I left a washer off that goes between this bearing and the gear beneath it. Needless to say, I got good at taking the T90 apart and putting it back together. It was, for the most part, a fun exercise.
See that large gap between the bearing and the gear? That's where the washer goes, or was supposed to go.
Lots of tapping later, and it's on.
This was the more intriguing job. Those are needle bearings, and I needed to install 88 of them in four groups of 22, each separate by a thick washer. That wood dowel keeps them from falling away from the edge during installation of the cluster gear (which is what the entire gear unit is called). Once a set of 22 is installed, I slide them down using some 1" electrical conduit tubing. There are two sets of 22 pushed in from each end of the cluster gear.
Two thrust washers installed.
The cluster gear dropped into the bottom of the case. It'll sit there for a while.
The first install of the main drive gear. It'll happen many times more. :-)
This is where all the complexity of the transmission rests. It's the main shaft which will hold several gears, the shift actuator pawls, synchro gears, and more. It's complicated.
My original 2nd gear is on the left, the new one on the right. A few noticeable differences: the interior brass has different stampings, and the small synchro teeth are less worn on the new one (which is why I ordered this one from Rugged Ridge), which will prevent it from popping out of gear on deceleration.
I bought this original Jeep Service Manual for CJ's off of eBay, and it is quite cool. This page helped me understand a bit more about how to install the small synchro tabs and their springs.
Front view of the main shaft with some of the synchros installed.
The main shaft test fit #1.
The front bearing plate installed. Again, the first of many times. I used just a bit of RTV on the gasket.
At about this point, I lost my will to take photos. I didn't really feel like documenting the removal of that bearing off the input shaft just to add the washer in there. And all the farting around I did to get the shift pawl to work with the synchros didn't really need pictures.
The wire below is holding the main shaft in the case. It is ultimately held in by the Dana 18 transfer case, which I'll be rebuilding tomorrow.
The three tabs on the left are from the original, and the three on the right came with the Crown T90 rebuild kit. During my installation and test of the shifting pawl, two of the tabs on the right got bent up something awful. I used the originals and got it to work better. I'll know for sure after the Dana 18 is attached.
All buttoned up for now. Seems to work okay, but I honestly won't know for sure until it's running and shifting.
No comments:
Post a Comment