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Project Rookie: A833 OD rebuild (Pics)
#1321729
10/17/12 10:46 AM
10/17/12 10:46 AM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
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Pickup Man
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Pickup Man
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OK, so I've never rebuilt a transmission before, so I'm rebuilding mine..and I thought it might be cool to take lots of pics and share cuz it might be helpful! I know there are a few threads out there on this already bit thought it may still be useful to get a rookies perspective and I have lots of reference pics to may help someone (including me lol) remember where stuff goes! So....here we go!
EDIT: side note: the transmission being rebuilt is a aluminum case OD in a truck.
Last edited by '84 D150 Shorty; 10/17/12 10:55 AM.
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321737
10/17/12 12:20 PM
10/17/12 12:20 PM
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Joined: Jan 2003
Posts: 74,976
U.S.S.A.
JohnRR
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I Win
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Quote:
Shifter assembly and rod/levers removed..they are oriented how they mount on the side cover
Something is not right here , the 1-2 lever, right top, should be the opposite orientation from the 3-4, left top.
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321740
10/17/12 01:11 PM
10/17/12 01:11 PM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
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Pickup Man
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OK..the countershaft. First thing I did was remove the 6 bolts for the tailshaft. You then can rotate the tail shaft and use one of the bolt to hold it in place and you now have access for the other counter shaft bore. Apparently aluminum OD cases are "blessed" with a loose fit counter shaft, and a plug that seals the opening...what I did was drill a hole in the plug, and used a brass drift to gently push the shaft through the other side. A woodruff key will fall out. With the shaft out, let the countershaft gear cluster sit at the bottom of the case. From the manual, rotating the tailhousing:  The plug (with hole drilled):  The bore the plug was installed in:  The opposing bore (note the notch where woodruff key sits): 
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321743
10/17/12 02:04 PM
10/17/12 02:04 PM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
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Pickup Man
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Pickup Man
Joined: Sep 2007
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Next I removed the four bearing retainer bolt from the front of the case, slid the retainer off, and with my trusty rubber mallet gave a couple love taps and the main drive pinion and bearing come out the front of the case Retainer removed:  And out she comes:  And here you can see the rollers (I'm quite amazed they didn't fall out lol): 
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321744
10/17/12 02:22 PM
10/17/12 02:22 PM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
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With the main shaft and drive pinion out of the way, now its time for the countershaft gear cluster..I simply worked through the rear of the case....with it came rollers (I counted 76), 4 spacers rings, two thrust washers, and a spacer shaft Gear cluster out:  Exploded manual view: 52, 49- rollers 53, 48- spacer rings 54, 47- thrust washers 50- spacer shaft 51- gear cluster 46- countershaft 45- woodruff key 
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321745
10/17/12 02:39 PM
10/17/12 02:39 PM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
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Pickup Man
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Next item on the menu is the reverse idler gear...I removed the reverse switch..oh, and I almost forgot; when you pull, the side cover, there is a spring and ball which serves to position the reverse lever..don't lose that! I will get a pic of that tonight and where/how it is located. Anyways, so the manual shows a nice fancy tool to remove the reverse gear shaft...I made my own ghetto version lol. I didn't waste time making it pretty, I just wanted the shaft out! So using my ghetto tool I pressed, the shaft out the back of the case The manual:  My ghetto variation of the tool:  And shaft and gear out of the case: 
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321748
10/17/12 03:12 PM
10/17/12 03:12 PM
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Joined: Sep 2007
Posts: 738
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'84 D150 Shorty
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Pickup Man
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To further disassemble the tailshaft for cleaning and prep it for the rebuild, I removed the rear oil seal and mainshaft yoke bushing...I just used a punched and hammered thebushing in till it fell out...not sure if there is a "right" way to do that? Bushing after forceful removal:  Tailshaft minus seal and bushing:  Tailshaft cleaned:  And tailshaft all pretty and painted: 
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: JohnRR]
#1321750
10/17/12 03:19 PM
10/17/12 03:19 PM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
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Pickup Man
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Quote:
Looks good so far, post up a picture of the cluster gear pin .
Will do, and a pic of the reverse gear shaft is coming as well 
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321755
10/17/12 09:13 PM
10/17/12 09:13 PM
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Joined: Jan 2003
Posts: 74,976
U.S.S.A.
JohnRR
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I Win
Joined: Jan 2003
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Quote:
OK now here is question for the experts: The clutch gear (I think some call it the syncro inner drum?) Show signs of wear on one side and one face of the teeth (see pic). There is a slight step at the end of the wear point...can I use a file and deburr it, or is it a no-go?
you could stone that down , that's in the OD position and what you can expect to find from running the factory fluid fill , where's that picture of your cluster gear pin , I hope you got a new one ?
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321758
10/17/12 11:05 PM
10/17/12 11:05 PM
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Joined: Sep 2007
Posts: 738
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'84 D150 Shorty
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Here is the reverse spring and ball I mentioned earlier:  The ball goes in here followed by the spring:  The spring sticks out and then seat in this hole on the side cover 
Last edited by '84 D150 Shorty; 10/18/12 09:49 AM.
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321762
10/17/12 11:46 PM
10/17/12 11:46 PM
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Joined: Jan 2003
Posts: 74,976
U.S.S.A.
JohnRR
I Win
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I Win
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Quote:
So here is the countershaft...which looks to me to be in greatshape. One thing I've observed is that I've not seen the damage to the countershaft bores that I've heard about happening to aluminum main cases....which surprises me because I am NOT gentle on the throttle..
I can't really tell but I wouldn't call that great shape since you can clearly see the wear pattern of the rollers in it , the shaft isn't that expensive , do yourself a favor and change it now while it's apart. ATF does not have the viscosity of gear oil which you can see by the condition of the 3/4 syncro hub.
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: JohnRR]
#1321763
10/17/12 11:58 PM
10/17/12 11:58 PM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
OP
Pickup Man
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OP
Pickup Man
Joined: Sep 2007
Posts: 738
TN
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Quote:
Quote:
So here is the countershaft...which looks to me to be in greatshape. One thing I've observed is that I've not seen the damage to the countershaft bores that I've heard about happening to aluminum main cases....which surprises me because I am NOT gentle on the throttle..
I can't really tell but I wouldn't call that great shape since you can clearly see the wear pattern of the rollers in it , the shaft isn't that expensive , do yourself a favor and change it now while it's apart. ATF does not have the viscosity of gear oil which you can see by the condition of the 3/4 syncro hub.
Okie doke, I will order one in the morning!
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321764
10/18/12 04:30 AM
10/18/12 04:30 AM
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Joined: Mar 2007
Posts: 3,277
West Coast, USA
jbc426
master
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master
Joined: Mar 2007
Posts: 3,277
West Coast, USA
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Quote:
Quote:
Quote:
So here is the countershaft...which looks to me to be in greatshape. One thing I've observed is that I've not seen the damage to the countershaft bores that I've heard about happening to aluminum main cases....which surprises me because I am NOT gentle on the throttle..
I can't really tell but I wouldn't call that great shape since you can clearly see the wear pattern of the rollers in it , the shaft isn't that expensive , do yourself a favor and change it now while it's apart. ATF does not have the viscosity of gear oil which you can see by the condition of the 3/4 syncro hub.
Okie doke, I will order one in the morning!
Order new roll pins too since your changing out the shaft.
1970 Plymouth 'Cuda #'s 440-6(block in storage)currently 493" 6 pack, Shaker, 5 speed Passon, 4.10's
1968 Plymouth Barracuda Convertible 408 Magnum EFI with 4 speed automatic overdrive, 3800 stall lock-up converter and 4.30's (closest thing to an automatic 5 speed going)
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: jbc426]
#1321765
10/18/12 09:00 AM
10/18/12 09:00 AM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
OP
Pickup Man
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OP
Pickup Man
Joined: Sep 2007
Posts: 738
TN
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Quote:
Quote:
Quote:
Quote:
So here is the countershaft...which looks to me to be in greatshape. One thing I've observed is that I've not seen the damage to the countershaft bores that I've heard about happening to aluminum main cases....which surprises me because I am NOT gentle on the throttle..
I can't really tell but I wouldn't call that great shape since you can clearly see the wear pattern of the rollers in it , the shaft isn't that expensive , do yourself a favor and change it now while it's apart. ATF does not have the viscosity of gear oil which you can see by the condition of the 3/4 syncro hub.
Okie doke, I will order one in the morning!
Order new roll pins too since your changing out the shaft.
The kit I ordered includes the rollers, all the gaskets, thrust washers, spacer rings, input seal, output seal, yoke bushing, speedo pinion seals, and both main bearings 
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: JohnRR]
#1321767
10/18/12 12:23 PM
10/18/12 12:23 PM
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Joined: Sep 2007
Posts: 738
TN
'84 D150 Shorty
OP
Pickup Man
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OP
Pickup Man
Joined: Sep 2007
Posts: 738
TN
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Quote:
Make sure there are no burrs on the shift levers in the side cover before pulling them all the way out to change the o-rings on the shift levers .
Noted. I assume that is so the bores don't get scratched and cause a leak with the new seals?
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Re: Project Rookie: A833 OD rebuild (Pics)
[Re: '84 D150 Shorty]
#1321768
10/18/12 01:02 PM
10/18/12 01:02 PM
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Joined: Jan 2003
Posts: 74,976
U.S.S.A.
JohnRR
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I Win
Joined: Jan 2003
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U.S.S.A.
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Quote:
Quote:
Make sure there are no burrs on the shift levers in the side cover before pulling them all the way out to change the o-rings on the shift levers .
Noted. I assume that is so the bores don't get scratched and cause a leak with the new seals?
correct
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