output shaft swap (in car)

[wingnut]

well, I searched for a thread here, and on the other site but found nothing with pics anymore. Just happen to have a tranny laying here collecting dust before I grab a local blue 91 RT/TT to do this in car next weekend. feel free to correct me either in terminology, techniqe or tools. credit goes to Larry (realmccoy) for answering my silly questions all the dam time, and here we go...

first up, a side view of a typical 18 spline tranny, albeit laying a bit on its side...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/sideview_zpsc39caf3a.jpg?t=1363668873

and the approximate location of the 12 bolts needing to be removed to seperate the end case...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/ee2c6a9f-db23-4d40-8f2a-cba47d1d22ef_zpsd043e201.jpg?t=1363672135

on the side is the small cover plate holding three each springs and balls in place...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/springcover_zps2c4520f1.jpg?t=1363668873

[wingnut]

once you pull the two bolts, hold the plate down, cause the springs are a bit ...springy...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/removecover_zps4d9eec4c.jpg?t=1363668873

springs exposed...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/springs_zps84fe2a98.jpg?t=1363668873

three steel balls in their home...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/balls_zps41284ae5.jpg?t=1363585595

[wingnut]

stick a big magnet to the side of a screwdriver and they come right out...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/magnetballs_zps54f72225.jpg?t=1363668873

once you pull the 12 case bolts, theres one oddball bolt for the idler gear...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/idlerbolt_zps803c6075.jpg

and all the bolts laid out in basic format with the steel balls off to the side...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/bolts_zpsf73a3081.jpg?t=1363584028

[wingnut]

last bolt keeping the end case on is under this litle black plug...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/plug_zps74ba27da.jpg?t=1363668873

thar she be...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/removeplug_zpsfdc3ae44.jpg?t=1363668873

it seemed to take a 7mm allen head to break it loose...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/7mmallen_zpsebfc8800.jpg

...note to the wise, do this while clutch is still in so you can wedge it from spinning on you!

[wingnut]

once that allen head is loose, we can carefully back the end case off ...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/splitcase_zps81a87334.jpg

but, had to go back, using deadblow on the allen head to force the shaft out of the case...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/removecase_zpscb3787c3.jpg?t=1363668873

end case finally off...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/exposed_zps1fd95780.jpg?t=1363668873

[wingnut]

this is where we notice there not enough room or flex to pull the entire unit out...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/5cc94ddc-d1cb-41e3-b9d1-ac41b9a20697_zpsb95fe5ba.jpg?t=1363671476

so, we punch the roll pins in to seperate it...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/rollpins_zps9f53aa60.jpg?t=1363668873

give em a whack they cant go in too far...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/punchpinsin_zps78525f68.jpg?t=1363668873

[wingnut]

then, it practically falls right out...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/seperateVCU_zps7250a435.jpg?t=1363668873

slide it off the output shaft...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/removeVCUcover_zps6e05a35d.jpg?t=1363668873

and pull/tap the shaft outa there...
http://i130.photobucket.com/albums/p243/Muddmann27/tranny/removeshaft_zps735a0164.jpg?t=1363668873

[wingnut]

ill get some pics of doing it in the car soon, but the process is the same...

...depending on how fast ninja ships his shaft/spool combo :D

[HLxDrummer]

This is awesome, thank you! Makes me feel much more comfortable about putting my 300M shaft in my new trans.

This is the method you would use if the trans is in the car, too, correct?

How did you reseal the case?

[CoreyB]

​Nice write up, thanks for sharing.

[Jimvr4]

Great job Wingnut!

[Chris@Rvengeperformance]

good, but you don't need to loosen that idler gear bolt. I found a huge cheapo 2 jaw pulley off ebay that makes pulling the end case off easier and safer.

[Uniuno]

How do you get that black plastic cap off the end without destroying it?

[Chris@Rvengeperformance]

How do you get that black plastic cap off the end without destroying it?

carefully with a small screwdriver.

[wingnut]

good, but you don't need to loosen that idler gear bolt. I found a huge cheapo 2 jaw pulley off ebay that makes pulling the end case off easier and safer.

you know, i seem to recall reading somewhere that it was required but after cracking this one open i was seriously wondering why...

http://i130.photobucket.com/albums/p243/Muddmann27/tranny/idlerbolthome_zpsfa535e4a.jpg?t=1363619061

...for those that dont kow what were talking about :D


How do you get that black plastic cap off the end without destroying it?

as mentioned, tiny screwdriver, or i used a small pick to get under the edge of it.

[Uniuno]

Good to know, thanks! I was worried that I'd have to get a new one and be unable to find it. I ended up taking the trans apart from the other end to avoid it..

[importrunner]

I'm so envious that you got those super long bolts out both of mine snapped right at the end case. Very nice write up!

Sent from a wannabe ipad

[J. Fast]

A few things worth mentioning as I've done this on a couple occasions,

1. Before you pull the shaft, tape the threads on the bell housing side (I use electrical tape) so you don't score the seal.

2. Once you remove the shaft, insert a dental mirror in the shaft hole on the bell housing side and make sure the pressure spring is still in place on the seal. If by chance you knock the pressure spring loose and it drops into the transmission (and you don't fish it out) you'll likely trash your transmission.

3. Make sure you tape the threads on the new shaft when reinstalling.

4. Irrigate the bolt holes on the center case before reinstalling when the shaft replacement is complete. If you don't clear the old excess material out and you try to torque the bolts through it you'll pop the thread seats on the transmission covers.

Use red Permatex to reseat the freeze plug on the end cover, and the same, or Honda bond, to seal the case interfaces.

You can prep the mating surfaces with gasket stripper using a 1/4" brush kit, and then wipe them down with an industrial degreaser on a rag.

The transfer case should be pulled when utilizing this method.

[Chris@Rvengeperformance]

all good points.

[wingnut]

The transfer case should be pulled when utilizing this method.

agreed...but then i woulda had to mention pulling the downpipe, and i was hoping they were both painfully obvious :D

[fullracegt]

this is a pretty sweet thread!

[wingnut]

http://i558.photobucket.com/albums/ss26/CSBDan/Smilies/bth_upssmiley1.gif finally got around to opening the UPS package from Ninja...

http://i130.photobucket.com/albums/p243/Muddmann27/tranny/spool_zps3f63ea39.jpg

...should have the in car portion done saturday, with a good camera this time :D

[Ninja Performance]

Sweet thread! Pics of the procedure in car would add the finishing touches!

-Chris

[HellBringer]

Great write up! I did this about 10 years ago in the dark with no AC (post Hurricane Charley) and it sucked..! LOL! Better than dropping the trans, though. If I remember correctly, you skipped a step -- before opening the VCU you need to pull the reverse gear off. I remember getting it off wasn't bad, but pounding it back on was a real bitch. I think I had to use a steel pipe with a bigger OD than the shaft the gear rides on, and it took a loooooong time to get it back on because there's not much room to swing a BFH. Also spent at least an hour trying to find the damn balls because I didn't remove them when I took the cover off and somewhere along the way the made their way out of the trans and onto the floor. And lastly, and I'm fairly certain the springs are different lengths, so be sure to mark which is which -- that caused me some more rework once I thought I had it all back together.

[Ninja Performance]

This is done without pulling off the reverse gear.

-Chris

[HellBringer]

^How? It looks like its also removed in the pictures following punching in the roll pins? I definitely wouldn't have removed that SOB if I didn't have to, but my memory is fuzzy on this...

[Ninja Performance]

You can remove it, but does not need to be. And removing the reverse gear leaves the possibility to accidentally popping out the slider balls/springs.

Here is a pic from the same subject on 3si

http://user.mc.net/~strvnart/VR4/IMG_0630sm.JPG

[wingnut]

Thanks guys, looking forward to getting this fiji blue stealth moving under her own power this weekend :leghump:

And yes, I pulled the gear just to see what the process entailed. But soon realized there is enough play between them, that its not a necessity, so I did not include it as a step.

If it gets too tight in-car, I used a big 3 jaw puller to pull it off...will let ya know :Banana:

[hated]

Thanks guys. I need to do this myself, so appreciate the info and pics. Ninja: You got mail.

[reses]

Nice, the other site pics/links are broken, I'm really interested on sending my spool to Ninjaperformance and get the new output shaft and spool pressed, I got the transmission out of the car right now, the splines and spool are worn but I have the 25 spline (5 speed), its the same procedure?