The replacement manual transmission.
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The inside of the bell housing wasn't too bad.
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And then we removed the tailstock cover and said some colorful words. The signs of wear were obvious. The little "bucket" in the top left corner is supposed to be a free-flowing oiling chamber. Not with all that sludge.
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One of the old gears is on the left. The new gear is one the right. Um, I think the old one is missing, like all of its teeth.
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Again, the old one on the left, new one on the right. The bottom gear is worn to almost nothing.
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This is the rebuild kit that we purchased, with the bearings and seals.
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And these are all the other parts that we took off the F-150 to make the swap work:
- Rear Drive Shaft (purchased new)
- Manual 5 speed trans
- Engine plate
- Front Drive Shaft
- Transmission Tunnel Cover
- Transmission Brace with side pieces
- Transfercase shifter for the shorter shift linkage
- Pedal Assembly
- Shift Boot
- Steering Column and cover
- Shift Lever
- Flywheel, clutch, pressure plate (purchased new)
- Throwout Bearing (purchased new)
- Master Cylinder
- Instrument Cluster for the automatic transmission blanking plate
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The gears and seals on the work bench, during the rebuild.
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The two worn gears as they are supposed to be working together. No wonder this truck had transmission problems. During this rebuild, we determined that the transmission had been rebuilt at some point and the builder used too much silicon. The silicon actually plugged up the oiling passages in the transmission, ultimately causing the transmission to eat itself due to lack of fluid.
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Now that the manual was ready to be installed, the automatic transmission was removed, crated, and shipped back to Monster for diagnosis. According to them, they took the whole thing apart and checked. Apparently the bands showed symptoms of low transmission fluid. However, the rest of the transmission did not show the same sypmtoms. So they would warrenty the transmission, fix the bands, and return it to us. So we will either sell this on to someone who needs it to recoup some of the money dumped into the vehicle so far. Or find another vehicle to put this trans into.
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Finally, the Bronco was able to move itself around with ease. 13 months to repair this "buy-n-drive" vehicle.
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The first trip was to the corner gas station for a few gallons. Then we were supposed to drive it around the local area for a few weeks in "shake down" trips to get it ready for inspection and to figure out what else was wrong. Well, I'm sorry to say - that worked. Seems the throttle body is sticking in whatever the last downward position the throttle was left in, i.e. wide open. And the front ball joints were going - the driver lower had play and all the others had torn boots.
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