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Output flange-what else should I replace


Guest Anonymous

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Guest Anonymous

I finally got around to removing the output flange on my 02 this weekend. I am going to replace the output flange, rear transmission seal, flex disc, flex disc nuts, and transmission mount. Anything else I should replace while I am at it? I just might have it back on the road in time for the Midwest O2 fest.

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Guest Anonymous

Why are you replacing the flange, is it cracked? Beware that there are two types of flange, each for a different type of mainshaft--coarse spline and fine. The coarse spline setup is prone to loosen and wear, and many of them have been replaced with fine-spline. Also note that there are two diameters of seal, and it's not obvious to the naked eye. The later fine-spline seal is something like 1mm or 2mm larger in diameter--when installed on a coarse-spline flange, it seems to fit but will always leak. With most parts houses, if you just call and ask for a seal (or a tranny seal kit) you will get the later rear main seal, and you will have to ask specifically for the coarse-splined version.

Also check the three bushings that support the shift platform--two up top (which are still available, like $2 apiece), and one on the diagonal strut (not available, replace with washers). Loctite the socket head cap screws back in place. Also look at the universal joint connecting the sections of shift rod. Using new pins can improve the shift feel.

Mike

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Guest Anonymous

I've found that it's better to replace the bolts with a full new set once in a while. I went through a period of breaking bolts one by one, until I finally got fed up and put in new ones. I've found that the fully threaded ones seem to work better than the kind that have part thread, part smooth shank. The latter will break at the base of the threads.

Mike

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Guest Anonymous

It is a coarse spline flange that came loose. In fact when I seperated the flex disc the nut that holds the flange on fell to the floor. Would I be better off replacing it with a fine spline or another coarse spline flange - and why?

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Guest Anonymous

If it's a coarse-splined flange and it came loose, odds are your mainshaft is trashed The splines on the shaft wear more quickly than those on the coupling. It used to be that you could pick up a retrofit kit, comprising mainshaft and flange, for less than $200. Now it's about $600. Ouch. Best bet is to pick up a later-model tranny, or an early one that was fixed under recall (BMW replaced many of the defective shafts within the first few years). The best trannys to get are the '76 units, I think. They went to the fine-spline somewhere around late '75 or '76. If you're inclined to go with a 5-speed conversion, now is the time. However if you pull the tranny and take off the rear seal carrier, and if inspection proves that the shaft splines are OK, then check the flange splines and see if perhaps the whole thing can be buttoned up again. The nut has to be tightened and loctited, and the locking plate must be in place correctly. Doesn't hurt to use loctite on the splines either, I suppose. Generally, though, if you've driven much with a loose flange, the shaft is toast. Makes a nice paperweight--very shiny.

Mike

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Guest Anonymous

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....I'm a WI local-get in touch and I'll be happy to assist you in whatever way possible. I've got tons of tranny spares(output flanges or a whole tranny if you want)and the tools to do the shtuff.-Bob

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