T4 Borg-Warner Transmission Rebuild (Disassembly)

T4 Borg-Warner Transmission Rebuild
Disassembly

As I said before, I am trying to keep as much of the jeep stock as I can, which includes the transmission.  I thought about replacing it with a T176 or a T18, but decided to keep the original transmission for now.  Maybe if this ever breaks down or I mess up rebuilding it, I will upgrade the transmission.

This is my first time ever breaking down and rebuilding a transmission, so bear with me on this one.  It was also a little hard to get good pictures of everything, so this post is not going to be my best.  If you are using this as a reference, then it would be best to follow along with a rebuild manual.

Here are a few before pictures of the transmission with the Dana 300 transfer case attached.  This is after I pressure washed it.

First thing I did was remove the transfer case.  Just have to remove all the bolts attaching it to the transmission.

Here are some of the bolts I removed

Once all the bolts are out, I lightly taped the transfer case with a rubber mallet to get it off.

Its off.

Removed the wires attaching the two.  Just pointing them out for reference in these pictures.

These are just more pictures for my reference.

Next I removed the shifter by removing the bolts and pulling it right out.

I then went ahead and took the bolts off the case cover.

Used a pinch pin and hammer to remove the roll pin attaching the offset lever to the shift rail

Using my thumb I carefully pulled the lever forward a little so that I could remove it.

The detent ball, spring, and roll pin came out with it.

I then removed the housing.

I then removed the cover plate by pushing it forward a little and then lifting up.

All the gears were in good shape, but I decided to break it down anyways to clean it up and replace a few parts.

First I removed the reverse shift lever.  Pulled the clip out first.

Then removed the bolt holding the lever onto the housing.

Pulled everything out

I then removed the input bearing retainer by removing the four bolts holding it on.

Then pulled out the input shaft

Few pictures for reference before I pulled it out.

Pulled the blocking ring off the output shaft.

and this shim.

On the other side I pilled off the bearing cup.

Took off the clips from the blocking ring.

Pilled out the whole output shaft from the housing with all the gears

Going the leave the reverse gears in the transmission because it is a lot more involved to remove.  I don't have a need to rebuild this part of it.

This is where the clips were removed off the blocking ring.

Pulled off the Synchronizer Assembly

Pulled off the blocking ring.

Pulled off the 3rd gear.  (Sorry the picture is upside down)

Removed the snap ring that holds on the 2nd gear.  This was very hard to remove. 

Pulled off the thrust washer.

Then slid off the 2nd gear.

Next was another blocking ring.

With a screwdriver, I slowly walked out this spring that holds the reverse sliding gear.  There is a spring on both sides.

Slid off the reverse sliding gear.

Removed the clip inserts.

Then removed the bearing in the other side of the output shaft.

Attached to the bearing was another thrust washer.

With pliers and a lot of frustration, I pulled out this pin that holds on the 1st gear.

Once pin was removed I pulled off everything else.

Everything is disassembled.  Now its time to clean and put back together.