There sure are a lot of parts in a 901 box, Now I'm going to try to put them back in Options

[DNHunt]

Lots and lots of parts that are hard to keep track of. And lots of cleaning.

[DNHunt]

What have I done?

[DNHunt]

This started as a grind in 1st and 2nd. I used Bondo's and Red Beards info to get it apart. One thing I would advise is take it apart before you order parts cause it may be worse than you think and surprises are expensive. I invested in some syncros, dogteeth, gaskets and such before I found this. The price tag just went up.

[DNHunt]

So here I go. The race for the new big bearing on the pinion shaft needed to be installed in the case. It is positioned by a couple of snap rings. The reason I went ahead with this tranny was because this race is still a press fit into this case. I used piston ring pliers to expand this snap ring and istall it on the race. I haven't reistalled the ring gear and diff yet cause I wanted to be able to verify if the race was seated.

[DNHunt]

One snap ring on

[DNHunt]

Seating the race. I used a piece of PVC pipe about the same diameter to drive the race in. I tapped very lightly, slow going. The case wouldn't fit in the oven and the wife was on a terror last night so I couldn't heat it. (IMG:http://www.914world.com/bbs2/html/emoticons/mad.gif)

[DNHunt]

Here is the race seated and the second snap ring installed. The 1st ring contrats against the bearing race. The second ring expands against the case. These 2 rings on the race trap the bearing race in position. Pretty cool.

[DNHunt]

New seals. I sure love PVC pipe

[Bleyseng]

Ran it low on oil huh, Dave.

Watch how you install the gears back onto the shafts, they should be prefectly aligned with each other. They have a shoulder on them so they face only one way (look in the book or do you have the workshop manual?).
Aligning the shift rods is tricky so follow the books carefully.

Looks good!

[DNHunt]

Time to install this after a few squirts of gear lube and a little lube in the bearings

[DNHunt]

Installed

[DNHunt]

I installed a new O ring with a little gear lube and torqued down the cover

[DNHunt]

Onto the gear stack. I needed to replace dogteeth on 2nd gear. I put the gear in a vice and tap off the dogteeth with a mallet amd chisel. It ruins the chisel but, the gear is fine.

[Verruckt]

QUOTE (DNHunt @ Nov 5 2005, 08:31 AM)

What have I done?

What manual is that, and where did you get it? I'm looking for one of those. I have a few that I'm going to be digging into over the winter months.

[DNHunt]

Here's the new dogteeth installed on the gear. 2nd gets a new syncro, new dogteeth and the 4th - 5th slider. 3rd gets a new syncro.

[DNHunt]

I put the brake band stops (I can't remember if they are called stops or blocks) on the dogteeth of 2nd gear.

[DNHunt]

Brake bands installed. There are 2 on 2nd through 5 th. 1 on 1st.

[DNHunt]

This picture shows the new syncro installed and it's relationship with the brake band blocks. Nice sharp new dogteeth (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)

[DNHunt]

I installed the snap ring (a bitch) to finsh the assembly of 2nd gear.

[DNHunt]

I had a hell of a time with the snap rings slipping off of my pliers so I cut off some 6lb finishing nails and filed the heads down until they fit in the holes in the rings. The heads kepth the rings from shooting off.