Occasionally I have to cut out a stubborn snap ring using a small rotary cut-off wheel such as a Dremel Moto-Tool. Step 14: Install Shift Shafts Apply assembly lube to the shifter shafts and install them in the cover. When forks are worn as much as this one, shift quality can diminish. Seems today lots of guys have to order a kit consisting of every part that can be replaced, before they'll take anything apart. Another common repair is a rear seal change.
I see they do offer forged synchro rings and that is what you are supposed to look for. Step 31: Take Out Shift Shaft Seals Use a small flathead screwdriver to remove the shift shaft seals in the side cover and tailhousing. New M22 Gearsets in Custom Ratios. Never strike the input shaft itself. Step 2: Install Front Bearing Place the slinger on the input shaft and tap on the front bearing.
Put the tail in place and use a felt-tip marker to indicate the center point on the shaft. The new case design also corrects sloppy alignment of the input and countershafts. An example would be P4D23B. New combs are harder and much better than the older ones. It debuted in 1963 Chevrolet full-size cars and Corvettes, and was originally available with two first-gear ratios: 2.
It was actually built in December of 1967 for the 1968 model year. Step 13: Position Internals for Sidecover Installation Position the 1-2 slider forward in second gear, and shift the sidecover 1-2 fork into second. The first four numbers were the model designator, followed by a 3-digit component part category, followed by a 3-digit unique identifier. With the guide pin in rear bearing retainer aligned retainer. This is something that you cannot do with the dummy shaft method. Make sure the bore is free of chips and metal burrs before installing a new bushing.
Remove forward or inside reverse idler and thrust washer. This causes a whirring noise heard only in first gear. All wide ratio transmissions are designated M20 and close ratio transmissions are designated M21 or M22 depending on the gear set. Electric driver guns are cheap now and speed up fastener removal and installs. It can never be taken for granted that the installation of new parts guarantees a fully functional and problem-free unit. And if you like this, let us know because we have several Muncie transmissions in the garage and will do some in depth tech on rebuilding them if you want to see more.
Last Updated: November 2, 2009. You can be sure that in those years a great number of transmissions have been assembled out of spare parts and cannibalized. This makes for thicker and stronger gear teeth, and as a result, the input shaft can transmit more torque. Step 8: Prep Gears for Assembly I always grind a 45-degree chamfer into the front of the forward reverse-idler teeth because some sliders hit them when in first gear. Next, place the 1-2 assembly and the first-gear sleeve, and press it into place as a unit. .
There are also two different counter shaft diameters, early and late. You will disassemble it later. Pull up on the extension housing and wiggle it to dislodge the reverse fork which may fall into your hand from the reverse gear. Step 5: Remove Lock Pin The reverse shifter shaft lock pin is a No. Step 22: Install Rear Reverse Idler and Parts Install the rear-reverse idler, thrust washer, and idler shaft in the main case. By May 2003, we were building complete new Muncie-style transmissions with all-new components. Step 14: Position Speedometer Gear An easy way to determine correct speedometer gear position is to make sure it is close to or on center in the speedo hole of the tail.
Make sure the seal is square in the bore and that you drive it in evenly. Step 6: Remove Rear Bearing Use snap-ring pliers to spread the rear bearing retaining ring open and then tap the bearing with a hammer to dislodge it from the ring. Step 5: Install Countershaft Install the countershaft with the flat side facing this position. B First-Gear Sleeves All these gear sleeves have the center tapered in for oil collection. Small parts include needle bearings, snap rings, thrust washers, needle spacers, front nut, oil slinger, reverse detent spring, reverse detent ball, strut keys, and strut key springs. Main Section Assembly Step 1: Install Bearing Assembly into Input Shaft Support the input shaft so that it is facing downward and drop the new caged bearing assembly into it by lining up its cardboard sleeve to the bore and pushing it through. Sometimes you can pry on this and remove the bearing.
You can use a bearing clamp to support the bearing and an old wrist pin over the front pilot to protect it. Muncie 4-speed Transmission Group 4. Sidecover Disassembly Step 1: Remove Spring Notice the positions of the cams and the spring. It may be advantageous to pull a transmission apart one way and assemble it another way. Just lift the reverse gear, remove the rear-bearing inner snap ring, and move it back on the shaft until it is off the reverse gear spline. If you think you are going to reuse them, mark the position and orientation of each fork so they can be reinstalled in the exact position. Lack of a pilot bushing or severe misalignment of the transmission and engine crankshaft usually causes the outer bearing race to crack.
From 1967 to1968, the serial number began with a number designator for the year, and then a letter designator for the month. Tilt the top of the cover down and catch the upper parts of both shift forks in their respective sliders first, then lower the cover into place. If something is worn, replace it. I had pretty good luck with Paul Cangialosi's video series and web site. Did they just want a three speed, did they not have a proper shifter so they always had third gear, or does isolating it just have them use it as a 2 speed, like maybe a stump puller, monster truck, deal.