004 trans rebuild: Where did I screw up?

[dphdo]

Greetings all! OK where did I screw up? Everything went fine until I put in the final drive shaft. I put on the 15mm bold and "E-Clip" (as I call it). I put on the final cap, and now the shaft has about 1" in "end-play." This can't be right is it? Is this cap all that prevents this shaft from moving forward? I've checked Haynes with no help on this.

HELLLLLLLLLLLLLLLLLPPPPPPPPPPPPPP!!!!!!

SMILES
Dale

[raygreenwood]

What exactly did you do to the transmission. What do you call a rebuild? There are several things that can cause this.

1. The hub with the splines that grips the main shaft is pressed into the main shaft ball bearing. That ball bearing is held into the secondary housing with a large snap ring. If the snap ring was not properly installed the hub moves fore and aft.

2. The flat portion of the shaft that the threaded end protrudes from must push all the way into the splined portion of the hub until it is right up against the "E" clip. The E-clip is a depth stop. If the shaft is not pushed all of the way in....the 15 mm nut...which is a lock nut...will simply lock up against the e-clip. It will NOT pull the shaft in. You must push the shaft in correctly first.

Also bear in mind....this transmission is one of the simplest to work on because of its layout and the fact that for the most part....the most part....you can work on it without special tools and jigs.

But....it has a handful of flaws that must be addressed it it will be a short life. And...unless you exactly measured a few things in the differential section....its very very hard to set straight simply because the tools to measure with properly...do not exist. You need to make a few bits and pieces to measure where the differential is...with reference to the case...before disassembling.

I have rebuilt more than a handful. Let me know how you progressed. Ray

[dphdo]

Thanks Ray, I checked everything, and still there is about a 1" wiggle fore and aft with the drive shaft. It's almost acts as though the rod it too short! Is the end cap all that prevents the shaft from moving forward? It looks like on the drawing in Hayne's (figure 6.5) there should be something between the cap and shaft. I don't know, it's very frustrating.

When I take the round cap off, the drive shaft slides forward easily (it does stop at about 3/4 of the way when the other splines hit the 4th gear splines.

Any other ideas?

SMILES
Dale

[raygreenwood]

There is nothing between the cap and the lock nut. If the lock nut touches the cap...it will drill a hole in it in about a mile...as me how I know

The E clip fits into a groove. If the E-clip is not in the groove there will be problems. There is only one possible problem. Its going to be one or the other.
1. The shaft is not all the way backed up against the E-clip.....or....2.the E-clip is not in the groove.

How to tell?

If the splines are sliding out int view (toward the front of the car)....when the shaft slides that 1"....the E-clip in not locked in the groove.
If the splines are not sliding out toward the front...then it is simply that the flat portion of the end of the shaft is not against the E-clip. Ray

[dphdo]

...AND the award for stoooooooopidist type 4 mechanic goes to........ MEEEEEEEEEEEEE

I'm so proud (sigh)

I thought the "groove" everyone was talking about was the space between the splines on the shaft and the bolt: But nooooooooo. I didn't know the groove was in the hub (as I'll call it) of the 4th gear splines. Oh well, live and learn.

By the way, while I was rebuilding this trans, I bought another "junk one." and used the best parts of both. ANYWAY, does anyone want or need 004 parts cheap - or free (just shipping)?

SMILES
Dale

[raygreenwood]

Tell me what you have? Is the diff still in the case with mainshaft?Ray