trying to take apart my t90 trans

I am trying to take apart my t90 in a '65 CJ5 but am having big problems. I bought it from a guy who put a fiberglass body on it and I cannot get the shifter out. It is slipping out of second gear and I was trying to fix it. Is it possible to take off the transfer case and work on the trans under the jeep and not pull it completly out? I think I only have to change second gear in the trans. If you have any ideas I would really appreciate it.

Halz

 

That I know of, you will have to take the shift tower off to be able to do any work inside the T90. Is the tub keeping you from getting inside there? If so, you may have to lift the tub to get to the tranny.....

Any other thoughts guys?

 

the tower has to come off so the trans will slide out from the bellhousing
if the tower won't come up through the floorboard, then modification/enlargement of the opening is needed IMO
you will have to remove the trans and disassemble for any gear replacement needs

 

Pops out of 2nd? If the down time cuts into your summer driving --IMO, top it off with oil and drive it if not noisey. Popping out of 1st or 2nd (or both) is considered practically normal operating procedure on these old T90's.

If it's not driveable, rebuild it. Sounds like you will need to unbolt the tub.

 

wow that would be alot of work to take off my tub. It shows the second gear in the rear end off the transmission so I thought I could take off the transfer case and work on it from the back end of the transmission without having to to drop it. If anyone thinks that is possible let me know. Every time I put it in second it doesn't grind it just falls out of second. The floor of the tub has carpet already down and I realy don't want to cut it to make the hole bigger. I appreciate everyones opinions thaks alot.
Halz

 

Don't torture yourself with the thought of a "ship-in-the-bottle" rebuild idea. A T90 is easy to rebuild on the garage floor and has a VERY specific <but simple> order of assembly. I know, I often forgot a step and had to go back 3 steps (ask Jerry, he will vouch for my repeated goofs). After a successful rebuild, you will be able to do it next time by memory but the shifter has to come off.

You only need to unbolt the tub from the frame then jack it up. Slide a 2x4 in between. You should be able to unbolt the shifter. It's like installing a body lift -- an hour or less should have the tub loose.

 

From what I can see from my jeep and the service manual I was just flipping through my vote is the trans must come out. You said the tub was glass, I know it sounds like a bad idea at the moment, but how about breaking out the saws all and making a small access port around the trans between the frame rails. You can then get a can of fiber glass resin and some tape and glass the cover back on when you are done with the trans rebuild. Fiber glass repair is cheap and easy.

another option to cover the hole would be to cut it out, then replace it with a metal acces cover.

Before you cut holes however just plan it out a little. I have worked with fiber glass often and its easy, but never tried to build a dog house cover over a glass jeep body before. It may leave a weak spot that is prone to body cracking. Its just an idea so far.

BTW.. off topic, but Old Bill, the yoda with the Sith Happens T shirt is Awesome, I was literally laughing out loud.

 

nope
it's actually at the front of the trans, as the 2-3 synchro assy is behind the m/drive gear.
Do you have a pic of your body floor or trans hump?
the transmission needs to be removed for repair IMO

 

I had the same problems with my t-90 and I ordered all new parts to rebuild the transmission. But the real problem was in the shift tower. It has poppit balls that are spring loaded that help hold it in gear. My second gear spring was busted and had no tension on the poppit ball. The only problem was that the rebuild kit came with the poppit balls but no springs. I had to rob from another shift tower. Mine would stay in gear under power but the minute I let off the gas it would slip into neutral. Several people told me that was common but after replacing the spring it works like a champ

 

Need to remove the 6 bolts that hold the shifter assembly to the trans case. I assume you don't have access to these bolts....in which case you really only have two options (A. lift the body or B. modify the fiberglass tub). I would opt for option B, as this will provide for future serviceability. (my opinion only...).

As far are rebuilding, this site has multiple links to detailed directions on how to rebuild the t90. Follow them exactly and you'll only dive into the trans once (unlike Jon and I...)