Project Rookie: A833 OD rebuild (Pics)

Project Rookie: A833 OD rebuild (Pics) - 10/17/12 02:46 PM

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.

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 02:53 PM

Shifter assembly and rod/levers removed..they are oriented how they mount on the side cover

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 02:58 PM

Close up of levers...some number stampings are visible

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 03:01 PM

Shift rods and small parts

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 03:05 PM

Scrubbed, cleaned, and repainted:
Levers

Rods

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 03:09 PM

Here is one I thought could be super useful..side cover bolts in position where they go. Should be able to see in the pic the one bolt with the taller shoulder, and the two thinner longer bolts at the bottom

Posted By: scratchnfotraction

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 03:12 PM

Posted By: bonefish

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 03:24 PM

well,what happened?i was lookin forward to this.ya didnt get scared once ya got that cover off ,did ya

Posted By: JohnRR

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 04:20 PM

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.

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 04:37 PM

Thank you! (This is why i love this board!) Clarification here: levers when installed should look something like this:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 04:44 PM

OK, once I got the transmission on the bench, I took the side cover off. For reference:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 05:11 PM

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):

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 05:13 PM

P.S. you pros out there...if I'm doing something incorrect, for the love of God please stop me and say "Hey stupid! Your doin it wrong!" Lol

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 05:52 PM

Next, I simply removed the bolt from the tail housing, rotated it back down, and with a few taps with a rubber mallet, worked it back and out.
Tada:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 06:04 PM

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):

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 06:22 PM

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

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 06:39 PM

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:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 07:00 PM

Alright...tailshaft...first, remove the speedo pinion. Then, if look in the pic, you can see the tangs of a snap ring between the tailshaft housing and that last gear (1st speed gear I believe). This varies on some transmissions, but on this one, the snap ring has to be EXPANDED to release the main shaft assembly. Doing this by myself was tricky..in one hand, pliers to expand the snap ring, in the other my trusty rubber mallet to tap the shaft forward. Once I got past the snap ring groove it was gravy.

Mainshaft assembly out (those pros with a keen eye may observe that the 3rd/OD syncro assembly is removed...I'll return to that later)

Posted By: JohnRR

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 07:01 PM

Looks good so far, post up a picture of the cluster gear pin .

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 07:12 PM

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:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 07:17 PM

And not to be forgotten, the main case all prettyfied:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 07:19 PM

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

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 09:10 PM

Tonight when I get home I will take more pics of stuff...in the mean time, this is the 3rd/OD syncro assembly and the second speed gear removed from the main shaft assembly. To remove, I simply removed the snap ring and slid everything off the shaft.
As shown in the manual:

The parts (note:The clutch gear and shift struts and springs are still located in the clutch sleeve)

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 09:24 PM

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?

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 09:26 PM

Additional pics:
Shifter mount plate cleaned and painted:

And shifter stick redone:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/17/12 11:01 PM

Great big shout out to Wayne at Brewers Performance..got parts on the way..rebuild kit, bellhousing, inspection cover, and clutch fork. Brewers is awesome

Posted By: JohnRR

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 01:13 AM

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 ?

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:00 AM

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..

Here is the pile of rollers lol, and the spacer rings, and thrust washers:

And this is the spacer:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:02 AM

Reverse gear shaft:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:05 AM

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

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:27 AM

Here are my speedo pinion parts cleaned up..mine is a 36 tooth

Inner seal removed awaiting its replacement:

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:28 AM

Side cover cleaned up and painted

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:41 AM

Bearing retainer cleaned and painted

OK...dummy rookie mistake, but I nicked the seal bore on the retainer..will that causes sealing problems?

Posted By: JohnRR

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:46 AM

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.

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 03:58 AM

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!

Posted By: jbc426

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 08:30 AM

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.

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 01:00 PM

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

Posted By: JohnRR

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 01:38 PM

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 .

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 04:23 PM

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?

Posted By: JohnRR

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 05:02 PM

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

Posted By: '84 D150 Shorty

Re: Project Rookie: A833 OD rebuild (Pics) - 10/18/12 10:09 PM

OK, pros, I need some advice on removing the main bearings...I don't have a press so how can I get these things off?