Transmission Rebuild

Well I finally got around to rebuilding the trans and transfercase.  I had a hard time removing the shifter from the top
of the transmission, it was really rusted in place.  I had to resort to heating the screw-on cap with a torch and using
a large pipe wrench, but it finally freed up.   I therefore wasn't too surprised to find more water than gear lube in the
transmission.  I don't know if it was from all those years outside of from the pressure washing that I did.

Here's the T84 three speed transmission. I separated the transmission and transfer case and decided to attack the transmission first.
I had some experience with the T90 transmission on my CJ-2A which I rebuilt twice.  The first time I actually used two transmissions to
make one, but I should have done it right the first time and bought some new parts.  I don't plan on making the same mistake here.
The input shaft was a little loose so I was expecting the front bearing to be shot along with the needle rollers on the main input gear.

Well when I opened it up and found I'll have to replace a little more.  I guess that water seeping in along the shifter did a number on the
shifter rails and the shift forks.  I'll have to replace these rusty pieces.  If I try and clean them up I'll only be doing this again later.

I had to go look in the book to find out how to remove the shifter rails.  There was so much rust and crud that I could even tell that there
were set screws that locked the forks to the rails. Once they were removed I was able to drive out the shift rails.

There's a cluster gear underneath the main shaft gear cluster that you see here.  Once I drove out the shaft that the cluster gear rides
on it allowed the cluster gear to drop to the bottom of the case so that I had room to remove the input shaft/gear.  It turns out that the
guts aren't as bad as they look.  There's a nice coating of old, thick gear lube on the parts that actually washed off nicely.   Once the
case was empty of parts I washed it out and then cleaned it up in the sandblast cabinet.

I took an assessment of the parts that I'll need to buy.  I had already purchased the gasket kit, front and rear bearings, syncro rings and small parts kits.
I'll need shift rails, shift rail alignment pin, cluster gear shaft, cluster gear bushings and shifter forks.  I'm now waiting for the parts to show up from
Turner 4WD.

Once the case was empty of parts I washed it out and then cleaned it up in the sandblast cabinet.

Here's all the parts cleaned up and ready for reassembly.

I had new bushings pressed into the cluster gear (left) and then had them reamed for the correct clearance.   I had a friend's machine shop, MAVCO Engineering in Littleton MA ream the bushings for me.

The three small shafts are the shift rails and the shift fork alignment pin.  The originals were just too corroded to use.  I also replaced both shift forks since they had some noticeable wear.

Once everything was set it didn't take long to put it all back together.

No real problems on the assembly though I did have to tap the new
shift rails into place.  I also replaced the steel balls and springs
that engage the indents in the shift rods.

The pivot pin that goes through the shifter was really worn away.  By first applying a little heat I was able to drive
the old pin out of the shaft. You can see by the picture that the ends were no longer round.  I had to locate a piece
of number 3 (.213") drill rod in order to make a replacement pin.  There was no sense replacing all the shift rails in
the trans and not fixing this.

Here's the finished product, all buttoned up.  Resist the temptation
to shift it through the gears at this stage. Without the transfer case
holding the rear bearing in place you can separate the mainshaft from
the input gear and have to open it back up again.