Part 5 Rebuilding the O/D Section: Installing the Output Shaft/Planetary Gear/Overdrive Direct Clutch in the O/D Case

Now that I've got the overdrive case ready, I can install the output shaft assembly into it. First I need to install the governor on the rear of the output shaft.

Start by inserting the governor drive key into its slot in the output shaft. It's a half-moon shaped key. This is just rearward (or up) from the front output shaft bearing.



Now slide the governor, seal-side facing rearward (or up in this case) down into the shaft. It can only interface with the key one way. Make sure the governor bottoms on the shoulder on the output shaft.

Now install the governor weight/governor valve assembly in the governor. Slide the retaining shaft and governor valve into the bore of the governor and small hole through the output shaft.



Push the governor valve into the governor. A little assembly lube is good here.



Now put the governor weights on the other end of the shaft. Again, a little assembly lube.



Push the weight into the bore.



Slide the e-clip on the end of the shaft. Make sure it's secure.



Install the associated snap ring in the governor housing to hold the weights in place.



Here's the weight assembly all buttoned up.



Now, to finish of the governor, slide the governor snap ring down over the end of the output shaft and secure it in its groove. It can be a little difficult to get over the speedometer drive gear teeth.



Now I'm ready to install the seals on the governor. The old seals were steel locking type. They were a paaain to get off. They tend to get caught up in any little groove in there way.



The new seals are teflon type with angled overlapping ends. I located the ends/seams 180* from the adjoining ring. This photo just shows the seals in place.



Now spread some assembly lube in the seal grooves. This will hold them flush enough for assembly into the governor support that's installed in the overdrive case.



Now install the seals in their grooves. Again, I alternated the seams 180* from each other. The assembly lube holds them in their grooves nicely.



Now I take the special tool I made for compressing the clutch spring, turn it over, place it on my bench, and set the whole output shaft geartrain assembly on it.



Now I'm ready to slide the overdrive case down over the output shaft assembly. Before I do that I spread some assembly lube on the governor support surface. This is the area the governor seals contact.



Now slide the overdrive case over the output shaft assembly. Be gentle when the governor seals contact the governor support. I use some large snap ring pliers to expand the front bearing locating ring. The case will slide down over this when it's expanded enough. Kind of a "clunk" to go that last inch.



Now you can see that the case actually went too far past the locating ring. The groove is about the ring.



Just lift up slightly on the case and the snap ring snaps into place. You can see here that it's fully seated in its groove on the front output shaft bearing.



Now install the cover and new cork seal for the locating ring access slot.



A little RTV on the threads of the screws will keep the leakies away.



Now, while the assembly is still in this position, I spread some lube on the teeth of the speedometer, or VSS, drive. Access is easy through the hole that the VSS drive gear mounts in.



I found some scrap 2x6 lumber in my shop and drilled a 1 1/2" hole in it.



Then turned the assembly over and stuck the protruding end of the output shaft in the hole. This is why I didn't drive in the rear seal yet.



Now the assembly is ready for a little more work on the front (top) end.



Next: installing the overdrive clutch assembly.