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A bad reverse pinion or bad reverse pinion bearings have been the death knell for many a classic-900. The price at a shop locally to have a transmission rebuilt is approaching $7000 and let's face it, it's still cheaper to buy a nice running 900. So, what is there to do? Well, if the first gear is too torn up you are just rebuilding your transmission, but if it's just a bad reverse pinion or reverse pinion bearing there is hope. I recently met a gearbox with a really destroyed pinion and I noticed it's easy to change the pinion with the gearbox still in the car with just a handful of common tools. Below I've detailed how to have a pinion out of a car in under an hour. The instructions assume a junkyard car that is jacked up and gearbox drained, so your car has a couple extra steps.
Remove gearbox filler tube bolt (if fitted) 10mm socket.
Remove the larger side cover from the passenger side of the gearbox (12mm socket).
Remove the differential cover, 12mm socket and wrench for a couple of the top bolts near the steering rack. This is easier with the transmission in first or third gear.
Using a 1-1/4" socket and impact wrench or long breaker bar, remove the drive axle nuts.
Using a 17mm socket and wrench then drift punch and hammer, remove the 2 bolts from the upper ball joints. If you can't pry the upper ball-joints out easily, go ahead and remove the two bolts from the lower ball joint as well.
Loosen the inside drive axle boots (flat blade screwdriver or 7mm nutdriver)
Remove both disk/rotor assemblies, disconnect or cut the brake lines to get them clear.
Remove both drive axles.
Remove both inner driver flanges, 12mm socket and a 16"+ extension will remove most of the bolts, use a wrench for the hard-to-reach ones.
Disconnect speedometer cable.
Remove inner drivers, you might need a prybar or chisel to separate them from the gearcase. If you care about putting the gearbox back together then keep the shims with the correct flanges. You might also need to lift the differential to get the second inner driver out.
Tilt and remove the differential.
Remove the singe bolt holding the shaft-lock in place (14mm socket and long extension).
grab the shaft end with pliers and twist/slide the shaft out. The gear will drop under the fork and into your waiting hand.
Edit/Delete Message
posted by 73.252.15...
, Wed, 30 Jan 2019 06:45:47
, Wed, 30 Jan 2019 07:19:52
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