EJ gearbox overhaul

Includes clutch, transmission, propeller shaft,
universal joints, differential and rear axle.

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EJVince
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State: NSW

EJ gearbox overhaul

Post by EJVince »

Starting to pull appart my spare gearbox this morning that I bought second hand, thanks Harv for the loan of the tools. Should be interesting what I find, got a Rare Spares kit to put through it. Will take my time over next few weeks if I need to, so I get it right before swapping it with one on car. Also have new clutch throw out bearing and springs from Rare Spares, rest of clutch was overhauled not long ago but don't trust the bellhousing they put on.
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Errol62
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Re: EJ gearbox overhaul

Post by Errol62 »

I wonder why they put the slave cylinder on the passenger side for the EJ to HK boxes. Then of course they went mechanical and completely threw the baby out with the bath water. Later cable setup was a slight improvement but never as good as hydraulic.


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EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

Was fiddling around for quite a while looking at how the gears looked and worked, with cover on and off. Gears look the best I have seen in any boxes I have had, and at one time I had a few for parts years ago, they look better than the ones did in the existing box on the car when I took it off 15 years ago. The side cover to me feels great as is too going through gears nicely, changed that probably 3 times since I had the car, if neccessary down the track I have a new nos side cover and levers but no shafts and yokes, also have a new spring and bearing I got a while back.

I am going to proceed with removing speedo gear, this tool Harv let me borrow is pretty heavy duty, not sure how you would get the gear off otherwise.
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Last edited by EJVince on Thu Jan 20, 2022 7:26 am, edited 1 time in total.
ardiesse
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Re: EJ gearbox overhaul

Post by ardiesse »

Vince,

Dumb question: Why are you pulling the gearbox apart, when the internals are (obviously) in such fantastic condition? The only thing I'd bother checking would be the cluster gear needle rollers and the cluster gear bearing surfaces. You don't need to pull the speedo drive gear to remove the cluster gear.

The gear teeth look perfect - is there any sign of pitting on the faces of the first gear teeth (both sliding gear and cluster)?

And I learned something . . . EJ gearboxes use the early style of first-reverse sliding gear. The collarless first-reverse gear must have waited until the mid-EH revision of just about everything.

Rob
EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

Actually Rob, that's not a dumb question now looking at how good it looks once I opened it up, it was tempting I must admit to stick the side cover back on and try it on the car, although it hasn't been on a car for many years. But after 4 years of driving holding the gearstick with one hand to and from work, and turning 60 in just over a year, I thought why not put a repair kit through it, and this should be the last time I pull it off, should be like a new gearbox by the time I finish it 😊👌

Will be interesting to pull the one off the car eventually and open that up, bet it doesn't look anywhere near as good, despite getting a mechanic to reco it 4 years ago, waste of money that was, obviously decided to soon I was to old to work on the old girl.

Anyway, finished the day with it totally dismantled, might have got further but bloody humid on the coast here in Tathra today, hopefully get time to do more tomorrow or if not back into it next weekend.

The countershaft was really stuck, thought it was never coming out, reckon the ball bearing might have really got jammed in there or something.

Will post some more piccys as I work though it piece by piece.
EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

Errol62 wrote: Sat Jan 15, 2022 12:11 pm I wonder why they put the slave cylinder on the passenger side for the EJ to HK boxes. Then of course they went mechanical and completely threw the baby out with the bath water. Later cable setup was a slight improvement but never as good as hydraulic.


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I guess I never thought about that being that I have had this car for so many years, would be less pipe you would think if slave cylinder was on drivers side, must be a reason 🤔
EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

Didn't get time to do any more Sunday, but after work last night cleaned up the input shaft, and removed the bearing retainer which wasn't on earlier Holden's, I've done this before years ago so knew the best way, it's an incredibly tight fit so you chisel in anout 4 places without cutting through it, eventually this expands it enough so it slips off. Then I used Harv's little plate, put the shaft in the vice with wood under to cushion it's fall, tapped with a soft hammer and bingo the bearing was off. Then using plate and the pipe from Harv's 7A5 tool was able to tap new bearing in place. Turned my attention to new bearing retainer which I paid the garage to press on last time, spent a while trying to get that on by various means and it's part way on, but gotta admit I was starting to lose my patience last night, so will attack it again after work tonight, and try and think of a better way, maybe pipe and jack or something, but it really is a bugger of a thing to get on. Any ideas from anyone has who has done this before, I am open to suggestions.

By the way Rob, forgot to answer you about the teeth on the first and reverse slider and cluster, I see no sign of pitting.
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Errol62
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Re: EJ gearbox overhaul

Post by Errol62 »

Last Christmas bought myself a small cheap press about $120 and well worth it. Takes up space of course like everything but I’ve found many a use, including resetting leaf springs.


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Harv
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Re: EJ gearbox overhaul

Post by Harv »

I got one of the Supercheap presses a few years back. The frame is sturdy, and the 8t bottle jack has been reliable (despite it's silver frost paint). Great for bearings, and have found many a time that I'll look at a job and think "I really shouldn't be belting that with a hammer". It struggled with axle bearings, as the throat depth is not big enough. Bought some c-channel from Bunnings to extend the legs. The throat width can also be a limit at times, so bought some round rod that lets me extend the two throat plates out horizontally. A good set of sockets to use as press dies, and all good.

Cheers,
Harv
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EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

That's funny really, because a while back I was in Supercheap Auto and was wondering about that press, and the guy in the store talked me out of it, he said home mechanics generally don't need something that heavy duty, he said it was overkill. Anyway after wasting a lot of time last couple of nights after work experimenting with pipe, jacks, pullers etc I think I will do what I did with this job last time about 15 years ago and pay the local mechanic to press it on, this bastard is that tight a press fit I still wonder if the SC Auto press would do the job, and I agree with you Harv only so much I am prepared to belt something on.

After giving up on the above, installed new rear bearing, and cleaned up, inspected and reinstalled reverse idler gear, clearance of .013 between thrust washer and gear which is acceptable for worn parts.

I think next free time will look at 2nd and 3rd speed clutch hub and synchro cones.
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EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

Took the input shaft to a local mechanic on the way to work yesterday, he pressed the bearing retainer for me while I waited, and I watched him do it. Even with his press it wasn't easy I gotta say, because it is so tight it tries to not go on straight if you aren't real careful until it is on a bit, he took ot back off once and started again, anyway it is on now. The guy didn't even want any money, of course I insisted in giving him $20 to buy himself some beers or something.

I really think with this one, few people will have anything heavy duty enough at home to put it on.
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EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

So here's a question for the brains trust here. A few years back I picked up a new old stock first and reverse sliding gear on ebay, which is shown in the picture. The gears in the box look in good shape as I stated earlier.

So here's the thing, I really think this is the last time I will take the box appart, with turning 59 in a few days time. Is there any value in using this new gear, or am I better sticking with a set of gears that are evenly worn obviously but no chipping or pitting, should fit snug on the clutch hub?
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ardiesse
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Re: EJ gearbox overhaul

Post by ardiesse »

Vince,

Go with what you've got. The only reason you'd replace the first-reverse sliding gear is if it's got chipped teeth or other damage.

Rob
EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

Thanks Rob, I can always sell this on Ebay if I don't need it. That was my gut feel, but needed another opinion 👌
EJVince
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Re: EJ gearbox overhaul

Post by EJVince »

Spent a lot of time today working on the 2nd and 3rd speed clutch hub today, because I really think this is where a lot of stuff goes wrong. Needed a bloody good clean up, I know that much, but looked good when I finnished.

Interesting the differerence when you sit Rare Spares kit energiser springs, against the old ones, took a lot of fiddling around with the new ones till I was happy. At first the gears wouldn't ride over them. After a gew goes bowing them a bit was quite happy with the result.

Harv, the mainshaft replacer tool is awesome, works like a dream. Ran out of time again, as had my Covid booster this arvo, now no more for a couple of days I think.

Happy how it's coming along 👌
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