Removing intermediate gear from output shaft
 

I have been inventorying some tranny parts and want to remove an intermediate gear from the output shaft it runs on. I have the synchronizer assembly off and there doesn't seem to be any reason why this gear shouldn't just slide off, but it won't!! I don't see any pins or similar stuff called out in the Green Book. It turns fine on the shaft, but won't slide off!! Help!!!

Re: Removing intermediate gear from output shaft
 

On some of the early top loaders I have taken apart, there was a very small hole in that gear that you would insert a hardened pin into and depress a spring loaded pin. Then from the back of the gear, next to the shaft, there is a little flat bar/key that gets pushed forward. When this bar/key was pushed far enough forward or removed it would allow that gear to rotate enough to slide off of the splines.

Re: Removing intermediate gear from output shaft
 

Thanks! I'll look!! I have seen little holes across from each other, but imagined they were for oil!! I'll let you know!!

Re: Removing intermediate gear from output shaft
 

DD931, that's where you've got to get Mac's VanPelt's trans book. That will tell you all you've got to know about flathead trans, with part no. and everything. Walt

Re: Removing intermediate gear from output shaft
 

No joy. There are holes in the gear, but there doesn't seem to be a pin. I used drill stock for a driver. There is some sort of machined profile on the shaft in there, but there's no sign of a bar/key on either side of the gear next to the shaft. Is it on the back or on the spine side up in the spline somewhere? Is there an illustration somewhere? I don't find anything in the Green Book. It shows the gear and the shaft, but no internals!!

Re: Removing intermediate gear from output shaft
 

Walt - Thanks. I think you're right - I need Mac's book. I thought it would be easy!! That's what I get for thinking.

Re: Removing intermediate gear from output shaft
 

With your drill through the hole, then gently push down, you should feel a small spring trying to push back. Try using something smaller in diameter than a drill to push down, like a large paper clip wire. Depress the spring, Look for the bar, at the bottom of the gear it is flush to the sides of the gear and does not stick out. Get another wire to push the bar out, once it moves slightly you remove the paper clip wire and continue to push.

Re: Removing intermediate gear from output shaft
 

It is easy and you can do this before Mac's book arrives. Here is a picture on Mac's website. The picture at the top shows the spring and pin that must be depressed to move the bar/key that is also shown. There is a single hole between two gear teeth that must be used to push the spring loaded pin down. This second gear must be aligned by rotating it properly to be over this pin. You can use a 3/32" drift pin punch (recommend in Mac's book) to go through the hole and depress the spring loaded pin. I don't feel a paper clip is sturdy enough to do this but may be okay to push key back from front to back of gear.

http://www.vanpeltsales.com/FH_web/F...yncrotypes.jpg

I may also add some pictures here later. Good luck and you can do this!!

These pictures show the hole between the teeth on second gear. The key, plunger/pin, and spring. The hole in the output shaft for the spring and pin. The hole in the bearing/bushing that fits into center of second gear. All of the holes must be aligned to depress spring loaded pin and push key from front to back of gear.

Re: Removing intermediate gear from output shaft
 

JM - Thanks for spending all this time to help me with my challenge!! It's below freezing in my shop right now - I may wait a day or two before attacking it again!! I'll keep you all advised!