eldo transmission rear cover alignment

[harrytief]

I'm rebuilding the transmission for the new to me eldorado. The transmission came in several boxes and baggies that yielded "spares". I've shimmed the drum, replaced bearings and seals,  and bolted up the rear cover. The transmission binds as I rotate the input hub or output shaft, even in neutral. I'm thinking that the problem is a misalignment between the rear cover and the case. The rear cover does not bolt down easily and becomes a VERY tight fit at the bearing for the output shaft that splines to the drive shaft. I have tried several good bearings there and they test fit well on the shaft out of the box but become very tight when the trans is reassembled. The problem occurs as I fit the rear cover to the transmission with all shafts installed. As well, some distortion is occurring in the output shaft or bearing during refitting because the output shaft bearing in the rear cover that slid on its shaft easily in a test fitting  now binds in subsequent test fittings.
 One of the alignment dowels pulled from the case when I removed the cover. This occurred several times and the cover refit the case more readily without the dowel.
I have read that some early transmissions had alignment issues but a search here did not get me to any posts. Is what I describe an alignment issue between cover and box, or elsewhere, and how crucial are these alignment pins?
Any thoughts and thanks in advance.
Harry

[Antietam Classic Cycle]

The only transmission alignment issue I've heard of is the transmission not aligning with the engine case - clutch shaft not aligning with the crankshaft.

[Dick]

I wouldn't final assemble without the dowels in place. Test fit cover without shafts. Then test fit with layshaft/output shaft only. Keep going till you find the culprit. Good luck.

[Chuck in Indiana]

^^^^^ Good advice from both.

[canuck750]

I have had the same problem a couple times Harry.
Eventually I think it has come down t getting the three shaft assemblies true in the case and the shift forks engaged properly, also be certain you have the transmission in the right gear to mate the shift selector mechanism to the cover as you are fitting the cover (I think it needs to be in 1st but can't recall for sure).

I find getting the shift forks to be engage the selector drum and the gear sliders all at once to be an exercise in patience.

I heat the cover with a heat gun to get the bearings warm enough to expand a wee bit so they can slide over the shafts, especially the big caged bearings seems to be difficult.

Good luck

Jim

[Kiwi_Roy]

When I did my Eldorado I referred to this
http://www.thisoldtractor.com/guzzitech.dk/pdf/gearbox-rebuilding-john-noble.pdf
I also referred to a paper Pete Roper had written.
http://www.thisoldtractor.com/guzzitech.dk/pdf/gearbox-shim-pete-roper-new-tools.pdf
I probably had it apart a dozen times before I was happy, (had no spare bits) had to make an extra shim for one of the shafts to remove end play.
I suggest you put in one shaft at the time, test it then try another, Once you know they are all correct then put it all together. The return spring on mine snapped in two as I was putting it together, I reckon I dodged a bullet there.
I didn't have any special tools but replaced the input peg nut with a regular hex type.
Holding the gearbox while you torque up the nuts requires a bit of thought, this might be useful.
http://s1304.photobucket.com/user/Kiwi_Roy/slideshow/72%20Eldo/Gearbox
I had a spare clutch plate which I strapped to one of the housing bolts.