[Healeys] Mating the overdrive to the transmission

[warthodson at aol.com]

 Michael,We do have a spare trans output shaft & we have watched your video & made a wire tool to retract the pump plunger. We have verified that the plunger is fully retracted & the splines are aligned. The spare shaft goes in about 1/2" (all the way in) further than the one that came out of the car. Gary
    On Tuesday, June 20, 2023 at 07:12:20 AM CDT, Michael Salter <michaelsalter at gmail.com> wrote:  
 
 Although one may be difficult to find there is no substitute for a spare gearbox 3rd motion shaft for this job.The spare shaft is used to align all the internals then, using my special tool to hold the pump plunger retractedhttps://precisionsportscar.com/laycock-de-normanville-overdrive-installation-tool/ it is a simple task to lower the overdrive onto the gearbox. 
M
On Mon., Jun. 19, 2023, 11:41 p.m. Bob Spidell, <bspidell at comcast.net> wrote:

  There is a bronze thrust washer that has to be perfectly centered to get that last 3/4" (#148 in this diagram):
 
 https://mossmotors.com/ahy-041-overdrive-unit-bn2-thru-bj8
 
 You can wiggle it around with a long screwdriver, or use a suitable 'drift' to center it. Your best bet is to sit the O/D on end and lower the gearbox onto it; gently rotating the gearbox while lowering. First time I did this I must have got lucky, but danged if I can explain this (see attached photo). Most recently I fought for a couple days then threw in the towel and took gearbox and O/D to BCS which, fortunately, is only a half-hour away. David and his mechanics had a novel technique I've not heard described anywhere; basically, he removed the pump completely--it's only two screws IIRC--and split the O/D into front and rear sections and tipped the gearbox and O/D up--gearbox on bottom--then had two of his mechanics pull the sections together with huge channellock pliers while David rotated the output shaft to 'feel it in' (you had to be there).
 
 Good luck. Make triply sure you have the pump cam oriented correctly, or you'll get more experience with this process than you probably want.
 
 bs
 
 On 6/19/2023 6:18 PM, warthodson--- via Healeys wrote:
  
  I spent the day assisting a friend trying to mate his OD to his transmission. The car is a '63 BJ7. The overdrive & Trans. were pulled to replace a few internal trans parts which was done & we did not run into any issues. We can get the OD to within approx. 1/2-3/4" of mating to the trans, but cannot close that gap. We have confirmed that the oil pump roller has been fully retracted. What are we bumping up against & how do we get past it? Gary Hodson  
 
 
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