I've begun to finally put one of these repro S&R gear sets together. Still scouring my parts stores for some good parts to use with it, but so far I have almost everything to put a nice box together.

Cleaned up a chillcast case and chain front cover


The primary housing was machined to accept an standard industrial bearing, and it was shimmed accordingly to get the proper positioning.


Input shaft with new bearing fitted


Fitted to the case with retainer


Next was setting up the pinion with a solid sleeve instead of the crush sleeve. Several attempts later. I got it the correct dimensions and pulled 15lbs on the pull gauge. I believe it was 0.739". I'm using an early 5-speed chill-cast pinion housing.




Just fitted to the case and am checking pinion depth. Looks like I'll need to remove some shims


Next up correcting the pinion depth and putting in the gear stack.

By the way, does any one have a 4 speed manual they could scan or have an exploded view? I just want to make sure I don't forget any of the little plastic spacer bits that seem to be in the 4 speeds!

Jordan , I don't think there are many plastic bits in there. There is one plastic thrust washer on the cluster gear and one brass / bronze one. other than that the only plastic piece is inside the chain drive cover that flow oil into the main shaft , sort of like in a 5 speed. I have all the 99 900 shop manuals with the 4 speed pages in them. Also there is the little tube inside the output shaft gear of the primary gear set. want to borrow the book for awhile? I can try copying some pages if you want.

Thanks Gary. Those are the pieces I was talking about. If you could scan and/or send me some pages with toque specs and a diagram, that would be great. Not that many parts, but I sure don't want to mess it up.

One more

Gary sent them to me as well, thanks guys!