Manual 3 speed rebuild help

[Kauaiman]

I am trying to get shift rails out and the expansion plug on the end of the second/third shift rail is stuck. Do I keep hitting it with a drift or has someone have a better way. I know this is kind of technical,but I’m sure some of you have rebuilt the 3 speed and may have some advise. Thanks. I need the shift rail out so I can replace the shift linkage rubber seals that are leaking.

 

[DirtDonk]

I did it many years ago as my first gearbox rebuild, but honestly I don't even remember an expansion plug. You already have the Allen set-screws out of the shift forks, correct?
I don't remember having any trouble with mine in regard to getting the rails out after that.
Maybe my model trans (there were at least three different generations on Broncos) either didn't have them (not likely) or they were so young at the time, they just didn't give me any grief taking them out.
Since this was 30-ish years ago, that's the most plausible scenario.

Good luck. I'm sure someone will chime in with their experience.
Oh, and only on certain versions could you remove the input shaft assembly through the front bearing retainer. At least the one in my '71 needed to be pulled out the top cover.
It was an extremely awkward maneuver in fact. But it came out.
Would have been nice if it had followed the instructions and come out the front!

Paul

 

[Kauaiman]

Thanks for the reply, the service manual says the plug should come out by tapping on the end of the shift rail, but it doesn’t want to budge. I have the set screws out. I might take it to a local transmission shop and ask them. Don’t want to just wale on the shift rod,but that may be the answer.
.

 

[DirtDonk]

Sounds like they may be a little stuck, either from age, or maybe a PO was in there and sealed them off with some sealant or shellac type stuff.
Interested to hear what it takes to get them out. The shafts can handle a bit, so not to worry about a little persuasion. But I'm with you, in that i wouldn't just wail on them until the caps come out. Best to use finesse.

Good luck.

Paul

 

[sprdv1]

Best to use finesse.

This...^^^^

 

[Readhead]

God this goes way back .... there was something about twisting the shift rail because of a detent ball

 

[Kauaiman]

You are correct. I used a small magnet to take the detent ball out. The shaft moved easily til it hit the expansion plug. Slide right over at first,so I know nothing is holding it up. Keep ya posted when I get it out.