metal chunks in my transmission

[DGG]

Thanks. I did read that post. I am up for the challenge. Like you said, I'll tear it apart and go from there.

[cedryck]

Atf ugh!!!

[DGG]

Got the gearbox and transfer case out, and am in the process of taking it apart. Was wondering if I should replace the clutch plate or anything on that end while I have great access.

[mearstrae]

Give everything a good check, and change anything that even looks marginal, no sense in taking things back apart again in a year or two to set something right.

'99 Disco II
'95 R.R.C. Lwb (Gone...)
'76 Series III Hybrid 109
'70 Rover 3500S

[DGG]

some preliminary shots. Anything look unusual so far?

[DGG]

another

[slowmo]

I wouldn't put that back on. New clutch/pressure plate, (can't tell about throw-out bearing) and that starter ring gear doesn't look too great either.

So to answer your question, nothing unusual!

[DGG]

It's still on the engine. You're saying replace with new?

[slowmo]

I would. It would be quite a pain to put it all together and two weeks later the clutch goes out. The ring gear might be ok, but again why risk it. I learned my lesson on a '61 MG Midget when I was a poor student. Clutch went out about a week or so after an engine rebuild. I - was - not - happy.

[DGG]

Yes. I figure I should replace all questionable parts while I have such good access to everything.

[DGG]

I'm currently dismantling the entire transmission. Everything is going well. The synchromesh was completely destroyed, but so far that seems like the only damage. All the other stuff looks pretty good.

My plans are to replace all the bearings and seals. Breaking down the individual systems is going pretty smoothly except for one thing so far.

Removing the output shaft is proving difficult. My workshop manual says "To remove the output shaft, first remove the circlip retaining the front bearing in the transfer box casing" I did that without any problem.

Next, "using a soft faced mallet, drive the output shaft rearwards to free the rear bearing outer race from the casing". This is where I am having trouble. The output shaft doesn't seem to want to move. Maybe I'm not hitting it hard enough, or there is some trick to it. I was thinking about taking it to my local mechanic and have him press it out, but I would like to do it myself. Any suggestions? Thanks.

[SafeAirOne]

My workshop manual says "To remove the output shaft, first remove the circlip retaining the front bearing in the transfer box casing" I did that without any problem.

Next, "using a soft faced mallet, drive the output shaft rearwards to free the rear bearing outer race from the casing". This is where I am having trouble. The output shaft doesn't seem to want to move. Maybe I'm not hitting it hard enough, or there is some trick to it. I was thinking about taking it to my local mechanic and have him press it out, but I would like to do it myself. Any suggestions? Thanks.

Not that it matters, but the circlip removal is step 8 in my SIII WSM. Removal of the rear bearing race is steps 4 & 5. I had no problems using the following procedures when I did mine. Hit it harder...or maybe a bigger hammer is in order? I think I used a large ball peen hammer with a wooden block as a buffer.

[DGG]

I think you're right, a bigger hammer. I'll try again tomorrow. Thanks. Just don't want to damage the shaft.

[DGG]

A big hammer and a block of wood, and tha races came out. Now to cleaning all the parts and housings.