transmission reassembly question

[BroncoCarl]

Had a good day of progress on the old 3-speed tranny... two steps forward, one step back sort of stuff.

I'm actually getting very close to getting it back together, just need to put the countershaft back in. However, I did have a few questions that would be great to get some clarification (peace of mind) on:

1.) Is the amount of space as indicated by this screwdriver between the large snap ring and the tranny case normal?

http://www.guessasketch.com/73eb/DX3500_0611.JPG

I'm sure the bearing is in the correct spot on the shaft as the small snap ring is installed correctly... but I don't recall there being any space between the large snap ring and the case way back when I started. It's almost as if the output shaft isn't mated completely with the input shaft. I'm sure there aren't any roller bearings out of place between the shafts because it wouldn't have gone together so easily, and I think the gap would be larger if that was the case. Any info on this would be appreciated.

2.) I noticed a bit of play (about 1/16 to 1/8", see pics) at the end of the input shaft after the bearing was in place. It seems the play is in the roller bearings themselves. Is this too much play? Am I asking for trouble putting this back together without replacing them?

http://www.guessasketch.com/73eb/DX3500_0619.JPG
http://www.guessasketch.com/73eb/DX3500_0618.JPG

Thanks for your help!
Carl

[BroncoCarl]

Update:

I dug through my *before* pictures and found this one:
http://www.guessasketch.com/73eb/Picture327.jpg

So it seems that the large snap ring should sit flush on the tranny housing... which means something is preventing it. I was rather careful in the assembly process to make sure the in and output shafts didn't slip apart to allow any bearing to fall out... and the two shafts turn each other nicely and the shifters appear to move the shift forks... so any ideas on what could be preventing the output shaft from going all the way in?

I only smacked the output shaft bearing long enough to get it past the small snap ring groove, it didn't seem to want to go further, and it didn't make any sense to try and make it go further. I didn't smack the output shaft itself, I didn't think there was a need... unless the output shaft pilot is a press fit into the input shaft?

Any feedback would be appreciated. I'm sort of stuck here.

Thanks,
carl

[RCrawler]

As far as the play in the input shaft, that seems to be pretty normal, even after the bearing retainer/ nose cone is bolted in place.

Once you get the input bearing retainer bolted on, the output shaft wants to slide out of the case because there is nothing to hold the bearing in place until you install the transfer case adaptor. You can take a flat piece of steel with a hole drilled in it that will bolt up in one of the adaptor holes and push the bearing back in the case where it is supposed to go. This will allow you to shift the transmission without the shafts trying move out of the case to verify that everything is working. You'll also want to install the upper detent pill and spring and apply finger pressure as you shift it.

HTH,
Jason

[BroncoCarl]

Another Update:

Gave the output shaft some spins, gently shifted through some gears and generally talked nice to it, and the output shaft eased into place, putting the large snap ring flush with the case. I rigged up a little thing to hold it in place (as you suggested, thanks)... and am ready to put the countershaft in.

Any words of advice before I attempt that? I sure would hate to spill some needle bearings into the bottom of the case and have to tear it apart again ;(

Thanks for the help!
carl

[DeenHylton]

Needle bearings in general: On a non-caged needle bearing it's much easier to keep everything in place by NOT pre-lubing with oil. Make sure the shaft is clean and dry and then use a HEAVY GREASE to hold the needles in place until the transmission or transfer case is assembled...

that has always worked for me.

Deen