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**Goach2** · 11-25-2019, 11:44 PM

So, no response yet, which is fine, but here's an update while we wait.
Pulled off the hitch and whatever these other things were tonight:

https://photos.app.goo.gl/fCeU5dRRNEj63UNk8

**dirtdobber** · 11-26-2019, 09:55 AM

That's a neat looking rig. I don't know anything about the transmissions used in those machines.

You ask for direction - a best plan of action. The answer depends on what you want this machine to be. I personally like to know my machine inside and out, particularly if I'm relying on it to get me way out in the mud and back. So I tear things completely apart and then reassemble, repairing and repainting and improving functionality along the way. Hopefully someone will be able to tell you whether or not the transmission is ok or junk. Good luck and keep posting pics.

**Goach2** · 11-26-2019, 10:19 AM

Thanks DirtDobber, I agree, going through it piece by piece will provide the best knowledge of the machine and I will keep posting as I go, to hopefully help others. I'm just looking to clean it up and repair/replace whatever needs to be. I think at this point I'm going to try and remove the body to get everything cleaned up and the transmission likely swapped out. If anyone can offer any tips on that, I'd be very greatful. Thanks!

**john swenson** · 11-26-2019, 06:31 PM

they are cool looking machines and seem to be quite capable offroad .. some neat videos under terra jet aatv. viddeos. johnboy va.

**Goach2** · 11-29-2019, 12:28 PM

A couple of updates: Looked a little closer at the tranny and it's more broken than I originally thought:

https://photos.app.goo.gl/CHfgZS5c7sahXxSR7

I unwrapped the spare transmission and it appears to be a different year...

https://photos.app.goo.gl/KLgV1SPWJKqq7y1K8

Can anyone say if there's going to be any compatibility issues?

Also, the bearings and seals are missing, but the shaft is really messed up:

https://photos.app.goo.gl/aV8ZM62hJM4RhhJC7

I think I may have to open the case to get it out, the 'Hub' sleeve thing looks pretty chewed up and might even be welded to the axle. I hope the hub in the original tranny will be compatible.

I've also been trying to get the axle out of the vehicle. The bearings and sprocket and collar have all been loosened up and seem to slide pretty good, but the axle in the tranny doesn't want to budge. I'm trying to hammer it out the driver's side, but I can see the key on the right and it doesn't seem to be moving at all. Been spraying it often, but any other tips?

https://photos.app.goo.gl/51oy81fGXXkz4PSX7

Also, I had to cut the driver's side bearings out...

https://photos.app.goo.gl/Y81bx2VBjXDAJ2k9A

**Goach2** · 11-30-2019, 10:55 AM

Had my helper giving me a hand tonight, he's super excited and looking forward to getting it running.

https://photos.app.goo.gl/rB7Vtx85ZRWUhKf39

Also, I haven't been able to budge the axle at all in the trans. Based on the tools that I found in it, I'm going to have to assume that this is where the previous owner gave up. I put the puller assembly on it that I found, to keep tension on it and I've been spraying and pounding away at it.

https://photos.app.goo.gl/Ld2vdkamAxxks4wv5

I'm going to try and get it to slide to the passenger side, because I think the key may be distorted and jamming it in place. Then I will try and get it to go to the left and out. I tried heating it last night too, but it's cold out and just seemed to make it sweat, which may make it worse!

Open to any suggestions!!!

**Goach2** · 12-03-2019, 10:44 AM

Still banging away at it. The shaft has not budged at all in the tranny. It has been suggested that I heat it more, to try and loosen it up. Not sure if there is danger of me warping it or anything, but I will give it a try again. I'm wondering if it's the bearings in the side of the tranny that are stuck and I should try popping them out first????

**liflod** · 12-03-2019, 11:42 AM

I wouldn't risk damaging something that you can't replace. If you can take more of it a part, your're better off.

**dirtdobber** · 12-03-2019, 11:56 AM

I wouldn't risk damaging something that you can't replace. If you can take more of it a part, your're better off.

I couldn't agree more. Goach if you further disassemble it you might find the problem. I notice in a previous post you mentioned your heating the part was only making it sweat. This is completely ineffective. You need a substantial heat source that can apply lots of heat quickly -- to the right part. The problem is you don't know what the right part is (and neither do I). If a rusty bearing is the problem, you want the heat on the bearing race to make it expand, with as little heat as possible on the shaft to keep it from expanding.

**Goach2** · 12-03-2019, 12:02 PM

Thanks gents, should I try prying the bearings out then and cut them if I have to? I found this pic online:

https://photos.app.goo.gl/tvUhVdBPkq3YXcoPA

And it looks like there's not too much in the way if I need to smash the bearings out. Also, I think the heating of the axle was to allow expansion and contraction to break any rust up and hopefully get it moving....

**Goach2** · 12-03-2019, 03:38 PM

Well, I should have thought of this earlier, but I removed the seal on one side and now I can lube up the bearings real well and see if I can get them moving. Obviously, the seal would have kept the penetrating fluid from going into the case.

https://photos.app.goo.gl/bhUNQwxK6gDM9VQi6

Now to do the other side as well....

**Goach2** · 12-04-2019, 02:44 PM

Flipped the tranny up for a look underneath. I think I may be a little less gentle with it going forward...

https://photos.app.goo.gl/PairGceabkHuMtB28

Check out the bottom case bolt, where the gear wore it down...

**Goach2** · 12-05-2019, 09:54 AM

Well, one side got done. Bearings really didn't want to move. Hopefully I can still get the axle out of the gear sleeve once the tranny is completely removed. On to the next side...

https://photos.app.goo.gl/98oviRNy2zD74xjE9

**Goach2** · 12-06-2019, 02:27 PM

Right-half of tranny is out. It was already broken, so I cut it out, then I was able to slide the gears off the axle and pull it out. I still have to remove the gear 'sleeve' from it:

https://photos.app.goo.gl/HrkCtJfB9ksExT9i7

Now onto the tub for now. Does anyone know what the profile of it should look like? The bottom of the tranny was smashed, and may have to do with the way the tub is pushed in, in back. I'd like to pop out any dents that need to be, before it gets cleaned up and painted.

https://photos.app.goo.gl/aT3odwqryuuWpWd1A

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First Terra-Jet Project, for a Newbie

First Terra-Jet Project, for a Newbie

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