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tranny rebuild woes (longish)
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Posted by Jeff S2 (more from Jeff S2) on Wed, 22 Aug 2001 15:49:29 Share Post by Email
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So I'm putting my '85 900 5sp tranny back together, and I've got up to
putting the primary case on. I used LocTite 518 (cherry flavor) for
the seal. There's a spacer (about 42 mm long) that goes on the output
shaft just prior to the 5th gear synchro; the spacer is giving me some
problems.

If I include the spacer, the 5th synchro is a bit too far forwards
(towards front of car, screw convention). When I install the Input
bearing assy, it binds against the 5th gear synchro and turns the
output shaft whether I put it in 5th or not. If I go back and remove
the problematic spacer, the 5th synchro sits somewhat farther towards
the rear. Then when I install the input bearing assy and pinion and
try out the gears, they all work beautifully. All except for 5th,
which doesn't quite engage.

So it seems that I need the spacer to be just a bit shorter in order
to get 5th gear to work.

Q1) Is it legit to mill the spacer just a bit shorter ?

Q2) What causes this problem ? One idea I have is the LocTite. If
there were a (slightly thicker) gasket, it would move the input assy
forward a bit and leave the 5th syncho as is. I can't remember if
there *was* a gasket. FWIW, gears 1-4 line up perfectly w/ their
partners on the layshaft.


TIA,
Jeff


posted by 205.170....

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