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A guy at a transmission shop was supposed to figure out why my reverse went out. The only thing he said was wore out in the trans was the shift fork. I believe my pushrod bushing on my clutch is the real culprit. Anyhow, he had it since February and I'm just getting it back a few weeks ago unfinished because he kept saying he had other stuff to do. Got new seals everywhere. I'm currently trying to get the transfer case pushed on the gears but the rails that go through the shift fork are uneven when I set them on the synchronizer sleeve. The 2 grouped up are even but the one that sits by itself is longer for some reason?? Because its longer, it will bottom out faster in the holes of the transfer case. Are they supposed to even bottom out in the hole.
Please help. I've got a week to get it back in my truck so I can take final exams. I can't afford how much they charge to take them online at home.
More than likely your reverse synchros went out, super common on this transmission.
Reverse on these trans were poorly designed. It has a slider, a synchro, and the gear itself, all of which are prone to wear. All three should be replaced. The reverse gear is really hard to find. But it happens to be the same as the fifth gear.
What's up with these rails? I pushed the single one as far back as possible and pushed the 2 grouped together as far forward as possible. One of the gears on the shaft is shaking a little bit, but I don't know if it's suppose to be doing that.
there is 4 shift rails and it is best to build it up from the Back case.
Why won't the rails line up? The hardest part on the manual was after putting the *****, keys, and springs in. It said while pushing the synchro ring down, pull up the synchro sleeve at the same time. I just reversed that part to make the rails get a little closer
I haven`t taken one of these apart, but there is forum member (cadunkle) that has been through his several times.
Haven`t seen him on the forum the past 6mo, but here is a thread he did rebuilding his and some problems he had.
Maybe this will help.
Got the problem fixed with the rails. Shift fork was on the rail in the wrong direction. Does anyone know which direction the ridge in the oil baffle in the 2nd pic is supposed to be pointed? It goes on top of the shim that goes on top of the throwout bearing retainer tube. Should the ridge be pointed to the retainer or away from it?
Got the problem fixed with the rails. Shift fork was on the rail in the wrong direction. Does anyone know which direction the ridge in the oil baffle in the 2nd pic is supposed to be pointed? It goes on top of the shim that goes on top of the throwout bearing retainer tube. Should the ridge be pointed to the retainer or away from it?
Look in the manual that lonewolf posted.
Its been a long while since I had mine apart, but I followed the manual and got it all back together. Getting everything lined up and plopped into the rear case (might be what you call the transfer case?) is a bit of a pain without the fancy fixture that the manual shows.
@tecgod13@lonewolf_ I got the Rails back on right now, turns out I had the fork on the rail the wrong way. I've been looking at the manual and saw a spacer with item number 76, part number 7072, but I can't figure out if it's referring to the race in rear case or a real deal spacer that I can't find with my transmission.
it's a Regular spacer that slips on to the main shaft, it is not a race or bushing. it's required on the 2 wheel drive version as the yoke basically seats on it.
Now I can't say for sure if it is required on the 4X4 Version as I haven't messed with a ZF on a 4X4
