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
Joined: Sep 2007
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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: 75,008 U.S.S.A.
JohnRR
I Win
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I Win
Joined: Jan 2003
Posts: 75,008
U.S.S.A.
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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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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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Pickup Man
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Pickup Man
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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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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 TN
'84 D150 Shorty
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Pickup Man
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Pickup Man
Joined: Sep 2007
Posts: 738
TN
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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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