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Old 01-13-2008, 08:49 PM
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Psychosis5150 Psychosis5150 is offline
Yugo aficionado
 
Join Date: Dec 2006
Location: Dousman, Wisconsin
Posts: 75
Ok, so the donor trans has been pillaged for it's parts, now follow the same steps on the "good" one. When you pulled the pinion shaft out you will see a thin spacer behind the bearing flange. This is how you set the proper gear contact pattern, by adding or removing spacers. Mine went together with just the one that was on the donor shaft. I'm far from a pro here so like I said before take some time and do a little reading on the subject... Ok, ready? Before reassembly you will need to clean the gasket surfaces, and purchase a new gasket for the rear housing, part #31337AA120, and while your at it 2 new pins to hold the front axles onto the diff stubs part #905190005. Also some black gasket sealer, like hondabond, or similar. With parts in hand, slide the "new" pinion shaft into the good trans, and reinstall the 4 bolts into the flange. Then the tube around the input shaft if it came off. Next I coated a few teeth on the new diff ring gear with white lithium grease to check the gear lash. Install the housing, tighten the bolts, and give the pinion shaft a few good spins both ways to rotate the gears. Then pull the diff housing back off and see where the teeth on the gears are touching. The clean spots should be centered on the ring gear teeth, if they are towards the tips you need to shim the pinion gear more, and if towards the valleys remove some shims. Like I said, I'm no pro. Take your time, and do some research and you'll be fine. Once your satisfied with your gear lash, apply some sealant to both ends of that tube around the input shaft, and around the diff housing, and bolt that puppy back on! Now you can install the gear on the back end of the pinion shaft, thread the nut on, and put the transfer clutch back on. Lock the trans back in park, and tighten the nut down. Next put the rear housing back on, don't forget the wires for the solenoid, make sure they are out of harms way. You should be ready for the fun job of putting your repaired trans back in the car now! The time it takes to get that beast back in place should allow the sealants to set. Also you should put a new trans filter in while your under there. I'm pretty sure there is a write up on how to pull and reinstall a trans in the how to section. Hope this helps, and feel free to ask questions, or add corrections if I missed anything.
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