The PO had a screw loose.

I bought a 47 2a a few months ago that had a known leak from the front of the tranny. My thinking was a front bearing seal and possibly a bad bearing. I had it out the other day for a run around the block and heard a metal to metal sound from the the tranny. I was with another buddy so he towed me home.

The t-case shifter lever pin was frozen so I separated and remove the t-case with levers attached.



With the t-case out and room to work I was able to removed the pin.



With the tranny out the issue was clear



Here is the missing bolt

 

You wanted to rebuild it anyway? The loose retainer probably didn't do the mainshaft needles any good. Makes one wonder how long ago that thing was apart-before Locktite?

 

Yes, planned to rebuild the tranny and t-case = (shift housing was loose as well). The engine was rebuild along with new clutch.

After removing about 30 pounds of grime.

 

one never knows what one might find.

 

When I separated the t-case I found a tab that had broken off the housing. I had an extra housing from a later 60s with its own shaft just had to swap from a fine thread castle nut to a course lock nut.



I found an oil seal in place of the felt seal when I removed the front flange. I replaced all the gaskets and seals and used loctite on all the fasteners.



I checked TDC and found the flywheel was off 180 so I corrected that as well.

 

I removed the zerk.

I couldn’t agree with you more concerning the maintenance, and it crossed my mind again when I was removing the t-case out from under the Jeep with the levers attached.

 

Guess that is one way to keep the levers from rattling and you don't need the springs anymore.

 

I’m using the pin and zerk fitting from the newer housing I installed. There was only one lever spring so I’ll have to hunt for one more.

Question, does the reverse idler gear and shaft need to be removed from the T-90 to install the counter shaft gears? I emptied the case without removing it.

 

nope but I'd remove it to inspect the shaft and bushing/bearings in the gear.

 

Thanks for the reply Nick,

My initial attempt to remove the shaft (from inside the case out) wasn’t successful, but while I’m waiting on the 2nd gear to be delivered I’ll give it a second shot.

 

The shaft has to be driven out to the rear of the case. I used Rick Stiver's rebuild guide and the guide on the Novak site when I rebuilt my T90 and D18. Here are the links:
http://www.willystech.com/wt/T90RebuildGuide/T90rebuild.htm

http://www.novak-adapt.com/knowledge/t90_rebuild.htm

 

It can only go to the rear when driving it out from inside the case.

 

I installed a new second gear along with a small parts kit that included new bearings and blocking rings. Shifts through all the gears fine should have it in tomorrow.