Figured I'd just start a new thread on this one...

I tore into one of my old junk gearboxes... to practice. After a real quick readup in the factory service manual, it only took about 45 minutes to have the output shaft out. Pretty easy stuff there.

And, I have no doubt that with the rear part of the main shaft out, I could definitely get at the reverse gear. Lay shaft and input shaft can stay in. Question now is... regarding re-assembly.

When separating the back shaft from the input shaft, some bits fell out. Specifically, 3 little brass rectangular doodads, 1 clip, and 1 syncro? ring. I don't know exactly how those all go together, nor do I know if its possible to put that part of the shaft back in the way it came out...? More roller bearings in there too..

Second big question....is it worth it? I've got all these extra parts now...front main bearing, 3 sets of needle bearing assemblies, and...I've also retrieved the proper bearings for the cluster gear/layshaft to take to teh shop for matching up. So, should I just do the whole thing...and have it done right at this point. OR do as little as possible and be done with it...? Like I said though, this gearbox was quite and working well when I parted the car out... Also, short of the reverse gear puller, I could well have this thing back together by the end of the weekend...or perhaps end of the day. And save the rest of the parts for later if it all goes south quickly.

Maybe I'll tear into that rear main shaft and see what sort of damage I can do in there....

And...for the record, this most recent box I've torn apart had the most chewed up (or lack of) teeth I've ever seen...so no damage done in that regard....

-Matt

Brass doodads? steel surely? Find someone to flog you a magnet.

The 3 rectangular doodahs are the detents for the syncro cones. If you look at the cone there are 3 little cutouts they sit in. You fit the 3 detents back in place. You'll see the spring that remains in place has a little hook on one side, it hooks inside one of the detents (Volvo call the detents locating keys). You then hold them in place with one hand and slip the selector sleeve in place. The selector sleeve is handed, the detents might be I can't remember of the top of my head but is obvious when you look at them. You then refit the other spring, its hook fits into another detent from the one the first spring is hooked into, and the spring is fitted the other way round. ie one spring is fitted clockwise from the hook the other anti clock wise. You then glue the syncro cone in place with vaseline/petroleum jelly, making sure its keyways match up with the detents. Stick the rollers into place inside the input shaft with vaseline, and re assemble.

As I have told you before once you've re-assembled make sure the mainshaft doesn't slip back. Its that front syncro cone that comes loose from the detents. The box will not work like that!

If you have a known to be good gearbox why not fit the mainshaft from the broken gearbox into it? It'll save you the bother of pulling reverse gear out, and with used gearboxes it is always better to not mix and match gears but keep them all together as a set.

Regards


Pete

Brass Doodads....OK... I guess they are steel. Actually, I still don't know. I only used the magnet to fish out the steel balls that locate the selecter rods...and to fish out all the little bearings.

The Vclassics page that Shayne posted was most helpful. There they call them doodads "dogs". Syncro dogs to be specific. I like dogs, so....dogs they will be from now on.

Further details to follow in yet another thread...

-Matt

Yeah, put it back together, yer gonna have fun. Use a 3/8" extension to drive the reverse shaft out from the front of the box. Use your old tranny as a guide aaannnd: http://www.vclassics.com/archive/tranreb.htm