engine and drivetrain The autopsy results are in...

[SteveK535]

Carl at Korman Autoworks just sent me a picture of my 4 speed's output shaft. Looks like the drive flange had come loose at some point in the car's past and worn off the splines. Carl said the PO or the PO's mechanic smacked a fine spline flange onto the already damaged course splined shaft and green Loctited it in place. Its not clear what the cause of my noise was, as he said the bearings were not excessively worn, but its possible that this condition had something to do with it, maybe some imbalance that caused wear. Korman is now looking for a donor transmission to get an output shaft from. They are NLA and were ~$900 bucks when they were. Well, I guess the hopes for the rebuild complete before the end of the week is shot.

[lilmo]

That must have required quite a bit of hammer.

[Collinster742002]

Crazy. Don't you just love when morons attempt repairs? I just spent the better part of my weekend rewiring the console after some monkeys installed a stereo ($600) back in the early 2000s. Wires wrapped in alum foil. It's hard to find mechanics who know what they're doing with these cars.

What noise was it making? Mine whines in 1st, 2nd and 3rd; 4th is pretty quiet however. Haynes manual says it's just bearings/bearing holders that wear out, and that it's not a cause for concern. Looks like in your case it is a lot more severe than just bearings.

It also says in there that just replacing the bearings doesn't always fix the problem; that every gear must be checked for wear and what not.

At least it's not the crappy Auto box

Sorry your box is like that, man.

[SteveK535]

It was making what I thought was a bearing related noise synched with drive shaft speed, not engine rpm, so it was the same no matter what gear I was in or even if I was juts coasting, so it would be on the output shaft end of the box. Hard to describe, but it was a once per revolution noise that kinda sounded like a ball that was damaged in a bearing race. I still think it was excessive bearing noise due to one that was going, but this news is suspicious.

[M3M3]

that is an ugly output shaft......

this is a normal 2002 4spd? did you know people practically give those things away when they covert to 5spd? known good ones can be had for less than one hour labor costs at korman....

sounds like you are already into this one for more though....

[SteveK535]

The way I look at it, once its rebuilt it will be a known good one. Everything else is a known crapshoot. But I hear what you are saying, I decided to do this being well informed. I have nothing against the 4 speed, I don't do a lot of highway driving with it, so going to the expense of a 5 speed conversion with another unknown transmission didn't interest me.

[jerry]

here you go:

http://www.ebay.com/itm/250936438624?_trksid=p3984.m1438.l2649&item=250936438624&viewitem=&sspagename=STRK:MEWAX:IT&vxp=mtr

your welcome.

NM/NA

[SteveK535]

That's what I love about this board!! Thanks!

[Zorac]

if your going with a 4 speed, try find a late model one with fine splines on the output shaft so you dont have that problem again. i had the same problem a month or so again, the course splined shafts, like yours, have a tendency of doing what you pictured.

[Harv]

Hold on. That's a

Never mind.

John

[SteveK535]

Ya beat me to it.

[MarkCT]

Steve:

What part of CT are you in? I am down south near Stamford.

Mark

[SteveK535]

North Stonington, SE corner.

[eurotrash]

I have 3 4 speeds (242s??) from early cars. I can pull the flanges if you need. To see the splines..

[M3M3]

North Stonington, SE corner.

i am from that area.....i used to live off exit 91, on flanders road. halfway between 95 and us1.

also lived in groton long point and glastonbury. still get up there regularly to visit friends and family.