Warner T-90 Transmission

Transmission Water

Transmission Rusty Interior

   Removed the transmission and transfer case from the engine and drained the oil. At least it was supposed to be oil. The contents of the 'anti-freeze' jug came out of the transfer case - it was actually more oil than water. The tan pan contains what came out of the transmission - if there's any oil there I couldn't find it. Never, ever leave something outside that you plan to use with the expectation "I'll move it in just a few days." Two years later you'll probably have a picture to match mine.

After removing the shift tower it was clear that the water level had become high enough to soak the bottoms of the gears. I had planned on replacing all of the gears if I could find them. Now it looks like there is no choice in the matter.

  
 

Countershaft Gear Set

  

This is the Countershaft Gear Set. The rust is pretty obvious on the three smaller gear surfaces. Not unexpected considering this gear was immersed in water for quite some time.

Willys Part Number: 640405
Teeth Count: 33-26-19-14

 
 

Output Shaft and Gears

  

This is the Main Shaft complete with Clutch Hub, Synchronizer, Second Speed Gear, Sliding Gear (1st and Reverse), Bearing Adapter, Bearing, and Main Drive Gear. After disassembling it looks like the Synchronizer, Second Gear, and the Sliding Gear have to be replaced due to rust. The shaft itself appears to be reusable. The main drive gear looks to be in great shape - figures since that gear will be replaced if I follow through with adding an overdrive. Once I get a chance to take pictures of the individual parts I will post them also.

Willys Part Numbers:
Shaft, Main: 640390
Adapter, Bearing: 644552
Bearing, Rear: 644551
Bushing, Second Speed Gear: 640400
Gear, Second Speed: 640398
Gear, Sliding: 640401
Synchronizer Unit: 640391
Rollers, Main Shaft Pilot: 640786 (14)

Teeth Count:
Gear, Second Speed: 22
Gear, Sliding: 29

  
 

Input Shaft

  

This is the Main Drive Gear complete with Bearing Retainer Oil Seal and Main Drive Gear Bearing. One of the synchronizer blocking rings is still attached. Inspection showed the bearing is toast. The Gear itself might be reusable. The blocking ring has a split by one of the notches. Additional pictures will be available later.

Willys Part Numbers:
Gear, Main Drive: 640428
Bearing, Main Drive Gear: 643721
Oil Seal: 645980
Washer, Oil Retaining: 640893
Snap Ring, Large (.0625): 640782
Snap Ring, Small (One of):
.086 Thick: 640783
.089 Thick: 640784
.092 Thick: 640785
.096 Thick: 640894

Teeth Count:
Gear, Main Drive: 18
 

Reverse Idler Gear

  

This is the Reverse Idler Gear. There is no doubt that this gear needs replacing due to rust.

Willys Part Number: 640417
Teeth Count: 16

  
 

Oil Collector

  

This is the Oil Collector. A good cleaning and this part should be able to be reused.

Willys Part Number: 640413

  
 

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Copyright © 2000 David Hoelzeman
Last Updated: April 21, 2001