Rebuilt gearbox

[kevin p]

View attachment 61561

I've been saying for years that I wanted to rebuild a gearbox for my 97 EX.
And hear it is.
Armed with a ATSG service manual it comes apart remarkably easy.
I couldn't afford to change any hard parts, just seals and gaskets.
All the brake bands and clutch plates were in excellent condition. No burning or scoring. If I could have afforded to change them I would. False economy if you have the funds, but I didn't.
Armed with circlip pliers and somewhere clean to lay the parts in the order they came out, off I went.
Instead of the special tools that should have been used, I managed with a large F clamp and the inside of a masking tape roll!!
In the seal and gasket set was a small bag with updated seals.
The clutch packs should be tested with 20psi, and MUST activate, according to the manual.
Neither donor box clutches would work [ one a 35000 miler and the other 80000 plus miles] with the Ford type brass sealing rings that were fitted as standard. So armed with the F clamp and cardboard tube, I dismantled all the clutches and put the revised teflon sealing rings in. They activated with just a wiff of air!!
I had the torque convertor reconditioned and now just need to keep my fingers crossed after I install it.
I also welded a drain bolt in the pan to aid further transmission oil changes.
Can anybody advise whether its best to just raise the front of the Ex or get all four corners on axle stands so its level to remove the box?
Kev.

 

[blueka]

It's easier if you have all 4 wheels off the floor Kev... I tried to remove the girlfriend's Dad's tranny back at the beginning of the year, and it would've been impossible if the back was down... it's a big job and if the exhaust bolts don't come undone, then it's a total ballache... we ended up just swapping the solenoids in the box with it in the truck and went from there.


Si

 

[kevin p]

Ay up Si, hope you are well.
Thanks for that info. I think i've decided to try and get it as high as I can so I can waxoyl the whole underneath as well. Going to take the fuel tank off and do a real good job. I'm also doing seals in all the brake calipers. Gonna sandblast the calipers and paint them. Also making a jig to hold the transmission onto my trolley jack so it will align with the engine.
Hows your projects going?
Kev.

 

[JonC]

Kev, awesome job on the gearbox! The sort of thing we'd all like to take on but run out of balls when it comes to actually doing it.

That said, have you seen these guys; http://www.youtube.com/watch?v=HaHIK-dwhbA&feature=mfu_in_order&list=UL

I saw this and then read what you'd done and it really changed my attitude about what's worth tackling. Of course many things are easier when you've got a nice, warm workshop, lights, lift, sponsorship.......

Cheers!

 

[blueka]

slowly but surely, the guy I was supposed to be getting my donor vehicle off decided he wants to break the deal we made and sell it in parts instead of my buying the whole thing off him. So I'm a bit fed up right now.... but it'll get there!

Hope you get yours sorted out, sounds like you've got a big job coming up!!


Si

 

[kevin p]

Ay up JonC and si.
Hopefully gonna get it done before Xmas. Just had my benefits stopped thanks to a foreign doctor who couldn't understand english!!!!!! I havn't been able to work for 14 years and now have no money whatsoever. Merry Christmas DWP!!!!
Sorry, anyway, I can't afford the tranny fluid at the moment. Fingers crossed it works when I get it done.

Kev.

 

[blueka]

I know Wetdog was selling some tranny fluid a while back, might be worth giving him a nod to see if he's still got it and would let it go cheap, he's only up in Leigh, not too far a drive...

Hope you get your benefits sorted out...


Si

 

[kevin p]

Cheers for that Si.

 

[blueka]

incidentally, do you still those brackets that raise the ladder/sensors up for the air ride?


Si

 

[kevin p]

I do. Its only a flat piece of steel with four holes. Takes about 30 mins to make. Then paint.

Kev

 

[blueka]

I might have to get one, my Dad drove my truck the other day and he didn't know what the light came on for. He doesn't want to drive it now.


Si

 

[kevin p]

I'll try and make one when I'm physically able. Health is abit dodgy at mo.
Kev.

 

[blueka]

Just get better mate... It's not like I need it any time soon... If I go back to England, I'll give you some notice...

Take it easy


Si

 

[janolsson]

Ay up kev
If you are in a position to do the tranny swap in the week of 9th january on, i could come over and help for ***** and giggles.

 

[kevin p]

Ay up Jan.
Thats a very generous offer mate. Finances are really bad at the moment. Looks like I've got to wait 6 months for a DWP tribuneral !!!! I've got to get a load of hay in a horsebox for my daughter in the next week. Then I'm getting the Ex in my garage. Gonna drain the fluid and sieve it through some tights and judge wether its clean enough to reuse.
Thanks anyway Jan and i'll keep you posted.
Kev.

 

[janolsson]

Ay up Jan.
Gonna drain the fluid and sieve it through some tights and judge wether its clean enough to reuse.
Thanks anyway Jan and i'll keep you posted.
Kev.

Would coffee filter work better, might take a while but would certainly get more particles and time is one thing you have!

 

[kevin p]

Good idea. And i can carry on wearing the tights.

 

[kevin p]

Gearbox is out at last!!!!! What a pain. Ford definately put bolts in places for the production line and not for the poor sods who have to repair them. Thanks Rich, it does come out with the drivers side exhaust in situ.
Lots of cleaning underneath and some underseal now theres a big gap.

Kev.

 

[rich uk]

yey ... watching you progress ( ;

best of luck with it

 

[kevin p]

Thanks Rich.
Just bolted the new one in.
Its been along day. Plenty of cussing, ggrrrrrring and the occasional rant. lol.