jtm0n3y's tranny rebuild thread/how-to - Page 3 - Dodge SRT Forum
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post #31 of 241 (permalink) Old 03-29-2010, 03:32 PM Thread Starter
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ALL PARTS FINALLY HERE!

Got the input shaft together on saturday along with 49 high quality pics!
Complete how-to coming soon!!!

Pics of the PWerks 3/4 shift fork and 3rd gear shift extender added to post #2.
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post #32 of 241 (permalink) Old 03-29-2010, 05:10 PM
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I gotta feeling this how-to is going to persuade more people to tackle their own tranny jobs rather than outsource the work.

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post #33 of 241 (permalink) Old 03-29-2010, 05:55 PM Thread Starter
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Vendors are going to hate me
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post #34 of 241 (permalink) Old 04-02-2010, 04:18 PM Thread Starter
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everything will be done this weekend guys

here's a little preview...

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post #35 of 241 (permalink) Old 04-03-2010, 12:15 AM
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How much did it cost for all the parts minus the PC? I am thinking about rebuilding, but have a limited budget.

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post #36 of 241 (permalink) Old 04-03-2010, 07:05 AM Thread Starter
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I have quite a bit into it...i did the PC myself. roughly 2300
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post #37 of 241 (permalink) Old 04-03-2010, 08:36 AM
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Subscribed. I have a feeling I might need to rebuild here soon...
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post #38 of 241 (permalink) Old 04-11-2010, 06:22 PM
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bump for an update on progress...how's it goin?

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post #39 of 241 (permalink) Old 04-11-2010, 09:11 PM Thread Starter
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Been super busy with work. Everything is pretty much done all the pictures are taken i just have a little more typing to do. I'm really happy with how everything came out and I hope this helps all of you!
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post #40 of 241 (permalink) Old 04-11-2010, 09:15 PM
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Quote:
Originally Posted by jtm0n3y View Post
Been super busy with work. Everything is pretty much done all the pictures are taken i just have a little more typing to do. I'm really happy with how everything came out and I hope this helps all of you!
the pc looks badass dude.
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post #41 of 241 (permalink) Old 04-11-2010, 09:59 PM Thread Starter
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Thanks dude! It was well worth all the time i put into it!!
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post #42 of 241 (permalink) Old 04-13-2010, 09:04 PM
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this is going good i cant wait for the end turn out. its going to be sweet
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post #43 of 241 (permalink) Old 04-28-2010, 08:00 PM Thread Starter
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Input shaft assembly

First I'm going to explain how to get the 5th gear nut off. People seem to have problems with this step and not a lot of people have a spare junk clutch hub lying around they can use. This method is very easy and totally safe.

Before you can take the nut off you need to grind the pinch points off that lock it into place on the gear. I used a dremel (9901 Tungsten Carbide Cutter) to do this. Don't be worried if you knick the gear when you're grinding back on the nut. Any knicks will be covered by the new nut.



Find access to a vise the has the V-Clamp setup (circled) like the one pictured below.



Place the shaft into the V-Clamp so that both "V's" are going to be applying pressure to only the splined part on the end of the shaft. Apply enough force that the shaft stays straight out and doesn't spin back and forth. As you're tightening the vise turn the shaft in a circular motion so that the teeth on the V's lock into the grooves of the splines on the end of the input shaft. Don't be afraid to apply a moderate amount of force when tightening...you're not going to damage anything or gouge the splines. The following couple of pics are self explanatory for visual reference.





Next get an adjustable wrench and place it on the nut. Use a long piece of scrap wood or a baseball bat and hit the handle of
the wrench hard and fast to break the nut loose QUICKLY. You can then thread the nut the rest of the way off with ease.



Now onto assembly of the input shaft

The first thing that gets installed onto the shaft is the thrust washer.



Slide the washer down the shaft and take a pair of vise clamps and work your way around the washer until it's seated all the way around tight against the gear. To get the washer to initially go over it's place on the shaft you may have to clamp down on one side of the washer and gear and use a punch to tap the other side of the washer over the shaft. You can then proceed to work your way around to seat the washer.





Once installed correctly this is what it will look like.



Next is the third gear needle bearing. Just slip it over the shaft until it sits on the thrust washer as pictured.



Onto third gear. Slip in onto the input shaft oriented as shown and slide it over the needle bearing you just installed.



When installed it will look like the pictures below. I took them from different angles so you can be sure you have everything right.







The third (or fourth...they're the same/reversible) gear blocker ring comes next which is part of your synchronizer assembly. It only goes on one way really...teeth facing down towards third gear so that it fits over the taper of the gear.



When installed it will look like this. Disregard the circle for now.



Onto the 3/4 synchro itself. Look at the picture below and take note of the two valleys that the arrows are pointing to where there are no splines. These two areas line up and go over the oiling holes on the input shaft that are circled in the picture above. It is CRUCIAL that you line these two grooves up with the holes or you'll burn your new synchro up real fast.



Slide the synchro down over the splines on the input shaft being sure everything lines up then you can install the 3/4 synchro snap ring. To install the snap ring (easily anyways...) you're going to need to tool below.





Use this tool to pry open the snap ring and slide it down the input shaft. Snap the ring into place.



When installed everything will look as pictured below.



Next is the fourth gear blocker ring. This gets installed teeth facing up so that when you install fourth gear it fits over the taper.



Take note of the pictures below because they apply to third gear as well as now. The blocker rings need to line up with the grooves in the synchro itself. This is also crucial further along in this tutorial when you press 5th gear on the shaft.





Next slide the fourth gear needle bearing onto the shaft until it hits the 3/4 synchro snap ring.



It will look like this when done.



Fourth gear comes next. Slide it on and down over the needle bearing that you just installed.



When installed it will look like this.





Input shaft assembly continued on next page

Last edited by jtm0n3y; 04-29-2010 at 02:19 PM.
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post #44 of 241 (permalink) Old 04-28-2010, 09:07 PM
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If you dont mind me asking, how much did all this run you?
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post #45 of 241 (permalink) Old 04-28-2010, 09:20 PM Thread Starter
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Little over 2,300 dollars for everything.
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