Hi, again. I am looking for repair ideas and checking if I am on the right track with repairing my SOS transmission. Most of the parts I need are no longer available according to the local Ford dealer. Judging by the prices of a few parts that are still available, I doubt I could afford them anyways!Pictures at: Link Pic 1: This is the shaft from my spare transmission. The original shaft all but useless. There is some light pitting from rust on the small end of the input shaft. This runs in a hole in the end of the next shaft. The planetary gears should help support the alignment of the 2 shafts also. Should I turn the end down and press a sleeve over it? The bearing surface between the spline and the seal ring has very light un evenness from rust, but nothing very deep. Would polishing with 600 and finer grit be good enough, or should I have the surface turned down and metalized? pic 2: The direct drive clutch has grooves worn into the bore where the oil seal rings run. I am thinking of boring this out and installing a sleeve. pic 3: Choose the part with less wear. The part on the right has mild surface rust on non critical surfaces, but less wear where it counts. pic 4, 5, 6: The planetary gears. The gears, needles and axles from the rusty spare transmission are pitted. If I get new needles from a bearing supply house, what kind of steel should I use to make new axles. What sort of hardness / hardening process? Thank you, Dave
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