T4 Borg Warner Transmission Rebuild (Assembly)

T4 Borg-Warner Transmission Rebuild

Assembly

I cleaned up the transmission and all the parts (which took forever) and now have to put everything back together.  I purchased a rebuild kit to replace some of the most common worn parts.

As with my last post, this was the first time I rebuild a transmission, so bear with me on this.  It was also hard to take good pictures while working on this.  

I recommend following a rebuild manual if you can.  I took some pictures of the steps to help clarify the assembly.  First step was to cover everything in transmission fluid and start putting it all back on the output shaft.

 Put on the inserts and springs onto the 1st reverse synchronizer sleeve.

Slid the blocking ring onto the output shaft. 

Slid on the 2nd gear

Then the thrust washer 

The new snap ring goes into the shaft to hold the gear and washer on.  This was hard to put on, but once it does go on it sits on this grove.

 Assembly steps continue.

Next I installed the blocking ring (left) and 1st gear

The new roll pin goes in to hold on the 1st gear.

Next the thrust washer and the bearings (this picture has the bearings on backwards.  I fixed that later)

On the other side I slid on the 3rd gear, the blocking rings, and the 3rd - 4th synchronizer assembly.

I then slid the output shaft back into the housing.

Once the output shaft was put in, I slid the input shaft on.

 To temporarily hold everything on, I bolted the input shaft retainer onto the housing.

I did not get a picture of it, but before I put the retainer on, I removed the shim from behind the bearing cup inside the retainer.  Removed the shim so that I could measure the play of the whole assembly.  I will explain that later. 

 Installed the reverse lever back inside the housing.  Used a little gasket sealer when torquing down the bolt.

It is not seated yet, but the bottom of the reverse lever needs to sit in the reverse sliding gear.

Used some Transmission Lube (basically petroleum jelly) to hold this thrust bearing onto the outside of the adapter assembly.

Slid the bearing cover on the output shaft.

I then bolted the adapter assembly onto the transmission and bolted it all down and set the transmission on end.  With this gauge, I measured the play in the whole assembly.  All you do here is carefully stick a screwdriver on the bottom of the lower gear.  Then lift it up with the screw driver and measure the play.  Continue this with different size shims (behind the input shaft retainer) until you have almost no play.

(I know that was a bad explanation.  Just follow the  manuals.)

 The old shim ended up being the best one to use.

Time to bolt everything down for good.  Used this gasket maker for the input shaft retainer. 

Torqued down the four bolts to spec.

You need to make sure this marking faces the top.

Purchased new plastic inserts for the shift forks.  They just clip in.

Align gaps this position before installing onto the transmission.

In the transmission, make sure everything is in the neutral position.

Applied gasket maker onto the housing. 

Slid the cover onto the transmission and bolted everything down.

Then installed the adapter assembly

Before installing, I put the ball, spring, and offset lever into the assembly.

With a screwdriver I carefully slid the lever on until the holes were lined up.  

Installed the new pin to hold it all into place.

Here is the shifter.  I am not sure if I will replace or just clean up.  I will worry about this later.

Prepped the transmission for paint.

Decided to go with a high temp aluminum paint from Eastwood (Aluminum Blast).  After multiple coats I was finished!

Just to compare, here is a "before" picture from when I pulled the transmission out of the jeep.