Rick Lee

We were only able to get the nose cone off today because we didn't have the 40 or 41mm (anyone know which?) impact socket to get that big nut off in front of the shift forks. Looks like I'm gonna have to round up a beat clutch disc to build a tool for holding the input shaft in place too. However, we did find some trouble.

Before


After


The nut my friend's hand is on was very loose and there was a good 1mm or so of play between the stuff on that shaft. In fact, I think that nut was only held on because it recesses into a bearing in the end of the nose cone and couldn't go any farther to come off.

However, you can see here that some of the (reverse?) gear teeth are bad and this will need to be replaced.



That's as far as we could go today until we round up more tools. Forks, gears and synchros looked new, however. We need to get to the lower gears to see what other damage was done farther down this shaft by having that loose nut that is supposed to be torqued to 150 ft./lbs. or so. What the hell could make that thing come loose five years after the nose cone was replaced (by TPC)?

More to come, though it might be a week or two before we get to it.

AOW162435

Shoddy work by TPC?


Andreas

Rick Lee

I'm not ready to blame them yet for something that just manifested itself after five years. However, I know they skipped the O-ring in my tensioning plate and used silicone goop instead, as I developed a leak there and installed the O-ring they left out. And they lost my transmission undertray and said they never saw it. But that's all water under the bridge now.

NP993

I don't think it's possible that a nut held on at 150 lb-ft could simply come loose over time.

Nollie

I'll be looking forward to progress. What are your plans while you're in there?

Rick Lee

Plans are to get the car back on the road ASAP. If I get away with minimal required parts, then I'll look into some upgrades. But if it becomes an eternal quest for rare and expensive parts, I'll leave it for another day and just be happy to have fixed this and learned a little about the G50's guts.

AOW162435

Sounds about right...


Andreas

Rinty

Nice Hexhead.

matt777

I would plan on changing all of the bearings with all of that metal floating around.

Rick Lee

Oh man, those bearings are expensive. So far everything looks very clean and only that reverse idler gear shows signs of wear. Hopefully, I minimized secondary damage by changing my fluid right after I noticed a problem and, since that didn't fix it, the new fluid was only in there for about 150 miles before I pulled the tranny out and drained it again.

Rick Lee

I've been thinking about this some more and can't figure out how/why anyone could have messed up that nut. AFAIK, TPC only replaced the nose cone, which I cracked in my track wreck. There should have been no reason for them to go beyond R&R'ing the nose cone. What the hell could have made that nut come loose?

chris walrod

Sometimes these nuts pop loose -- perhaps missed shift, overtorque event, not sure. In their defense, that nut doesnt have to come off to get the tail housing off. Unless they loosened it thinking it had to come off then forgot to torque it up since by that time they realized the casting slides right on over that nut in place. Out of sight, out of mind.

Anyhow, I have gbx tools, let me know if you'd like me to send them to you. Just need them back in three weeks or so

Rick Lee

Chris, I'd love to borrow some tools, but I fear I'll need them for more than three weeks. I just bought a 41mm impact socket and I have a beat G50 clutch disc on the way to build a tool for the input shaft. But I'd be fine using someone else's tool rather than building another one.

chris walrod

No worries, I will get them to you. A few special sockets, input shaft holder tool etc. Should be all you need provided 4th gear pulls off without the need for the long reach puller. Some pull off, some need the puller.

PM me your address, I will get it sent out Monday.

ReinerFink

Wow, Chris you are awesome.

Is the theory still a bent shift fork somewhere deeper down? I currently draw the line of my abilities at opening a tranny so I am very to see what happens.

-reiner