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I'm rebuilding a T5Z gearbox at present and I can't remove the 5th gear, even with my 12 ton press. Unfortunately, it's jammed and a workshop today couldn't get it to move with some heat and their shop press. Has anyone had this happen before? Do I need to use a 20 or 40 ton press? One guy thinks some burrs from the snap ring slot have caused it to jam.
If I cut it off does anyone have a spare one they want to sell?
_________________ AU2 XR8 with Raptor VL, ported Yella Terra GT40P heads, Scorpion 1.6 RRs, XE264HR-14 Comp Cam, ceramic coated Hurricane Headers, 60lb injectors, Walbro 255, 200cfi cats, 3" exhaust & Snow Performance water methanol injection |
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| snap0964 |
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You're only removing it to replace the main bearing ??
_________________ 96 XH Longreach 'S': LPG, Alarm, 3.23:1 LSD, Cruise, Trip Comp, ABS, Power Windows, Mid Series Dome Lt, Climate Ctrl |
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{USERNAME} wrote: You're only removing it to replace the main bearing ?? Yes, and the synchros? behind it. The input and output shafts had excessive freeplay. I can order another one from the US but that will take at least 2 weeks to get here.
_________________ AU2 XR8 with Raptor VL, ported Yella Terra GT40P heads, Scorpion 1.6 RRs, XE264HR-14 Comp Cam, ceramic coated Hurricane Headers, 60lb injectors, Walbro 255, 200cfi cats, 3" exhaust & Snow Performance water methanol injection |
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| snap0964 |
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Looks like a usual spline setup - tried cleaning the snap ring area with a dremel ? Inspect the splines too.
12 ton should move it you'd think. I've got a couple of old EA (non WC) mainshafts here - all the mainshaft gears are same as WC mainshafts, it's the countergear gears that gives the different ratios - not sure about the later ones. Need to do a count of teeth to see if the 5th gear matchs up - obviously you need to sort out why your existing gear isn't coming off, as getting another one on may have the same problem.
_________________ 96 XH Longreach 'S': LPG, Alarm, 3.23:1 LSD, Cruise, Trip Comp, ABS, Power Windows, Mid Series Dome Lt, Climate Ctrl |
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The gear is now stuck tight and it won't move either way.
 I'm concerned that if I use more force to press the gear off, the splines and gear may be damaged. If I try cutting the gear off with a grinder & Dremel, the splines might be damaged. And, the gear has a blue tinge after the workshop heated it up.
_________________ AU2 XR8 with Raptor VL, ported Yella Terra GT40P heads, Scorpion 1.6 RRs, XE264HR-14 Comp Cam, ceramic coated Hurricane Headers, 60lb injectors, Walbro 255, 200cfi cats, 3" exhaust & Snow Performance water methanol injection |
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| 66 coupe |
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as a last resort try hitting it with a hammer and punch to try shock it, if its been heated and not moved and then cooled, it will probably be stuck to the shaft even further. Spray a heap of CRC / WD 40 and try knock it back on with hammer and punch
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I tried a chisel and hammer already but nothing moved. Looks like the gear has to be cut off.
I've just bought two T5 boxes in pieces off eBay to source some parts as I want to get the ute on the road ASAP. Oh well, something to do over the next week I'm off work... 
_________________ AU2 XR8 with Raptor VL, ported Yella Terra GT40P heads, Scorpion 1.6 RRs, XE264HR-14 Comp Cam, ceramic coated Hurricane Headers, 60lb injectors, Walbro 255, 200cfi cats, 3" exhaust & Snow Performance water methanol injection |
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| ranga83 |
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where abouts in Melbourne are you? I have a t5 sitting at the mother inlaws that I haven't got around to rebuilding yet.
_________________ ef futura, pacemakers, 2.5inch catback, k&n panel filter and 3.45 lsd. extractors/cat, ticky head, custom cam grind, t5. now onto cosmetics. |
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| snap0964 |
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{USERNAME} wrote: The input and output shafts had excessive freeplay. Really bad ? The I/P and O/P shafts usually do anyway.{USERNAME} wrote: If I try cutting the gear off with a grinder & Dremel, the splines might be damaged. And, the gear has a blue tinge after the workshop heated it up. The heat may've affected the hardness. You can run a grinder cutting disc (try a 1.2mm thick one) in a groove between teeth, carefully cut down til you're near spline thickness, use a chisel in the cut to split or expand it. You may need to do same on the other side. Do a teeth count so you know the spare 5th gears are compatible - if the box you've got is an AU one, the mainshaft I think will be longer than an earlier one, so try not to damage it.
_________________ 96 XH Longreach 'S': LPG, Alarm, 3.23:1 LSD, Cruise, Trip Comp, ABS, Power Windows, Mid Series Dome Lt, Climate Ctrl |
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@ ranga83 - I've purchased a dismantled V8 T5Z and 4.0L WC T5 box already but thanks for the offer. Have to pick them up on Sunday.
@snap0964 - I just received a master overhaul kit from The Gearbox in the US and plan to do a proper rebuild. The input shaft had that much movement in the box, it's a wonder no teeth were broken off inside. The box is stripped down to a bare case now. Even the reverse idler had chipped teeth (from a poorly adjusted clutch I think) by previous owner. It's a 31T 5th gear which I presume is a 0.73 ratio. Yes, it's an AU V8 box I've go so I'll probably cut the 5th gear off now (very carefully).
_________________ AU2 XR8 with Raptor VL, ported Yella Terra GT40P heads, Scorpion 1.6 RRs, XE264HR-14 Comp Cam, ceramic coated Hurricane Headers, 60lb injectors, Walbro 255, 200cfi cats, 3" exhaust & Snow Performance water methanol injection |
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| ranga83 |
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I would be interested in the WC box if you want to part with it when you have finished with it
_________________ ef futura, pacemakers, 2.5inch catback, k&n panel filter and 3.45 lsd. extractors/cat, ticky head, custom cam grind, t5. now onto cosmetics. |
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{USERNAME} wrote: I would be interested in the WC box if you want to part with it when you have finished with it Ok, I'll keep that in mind. I haven't found anyone who wants to sell individual parts secondhand in Australia. Even the wreckers only want to sell the gears, etc new (which are overpriced IMO).
_________________ AU2 XR8 with Raptor VL, ported Yella Terra GT40P heads, Scorpion 1.6 RRs, XE264HR-14 Comp Cam, ceramic coated Hurricane Headers, 60lb injectors, Walbro 255, 200cfi cats, 3" exhaust & Snow Performance water methanol injection |
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| snap0964 |
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Yes, everything is overpriced in Oz - gears and bearings, so buying in the states is a good call.
Buying unfinished rebuilds for spares is a good call as well. You can clean up burrs, etc off hardened metal, like gears with a sharpening stone. Brass Synchro rings can use fine files - the reverse brake synchro will most likely have burrs a plenty - the teeth won't be triangular any more  You can use a spare 5th gear synchro instead.Not sure if the later fibre lined synchro rings are better than plain brass in terms of shift quality. You'll be surprised how much better they shift when you've cleaned them up in those areas - you just can't get that sorted only with better oils, etc.
_________________ 96 XH Longreach 'S': LPG, Alarm, 3.23:1 LSD, Cruise, Trip Comp, ABS, Power Windows, Mid Series Dome Lt, Climate Ctrl |
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