Finished my postmortem on the transmission. Looks like it was the diff that caused all the problems. It'* the source of the brass. Looks like it contacted the diff cover shaving off the shavings I found in the pan.


Metal shavings, most likely from the diff pin on the speed sensor.


Took the oil pump apart, it turned very hard.


Can't really see it in this picture but I found brass flakes in the pump. I cleaned it up real good.


Cleaned it all up and then put it back together.


Once all back together the oil pump turned freely. The brass flaks must have been binding it up just a little. I found the strainer screen at the oil pump to be filled with debris and had a big rip in it. I'll have to find a spare and replace that. Then it'* just a new set of channel plate gaskets and close it up. I'll also have to find another diff. I may just use my spare 97 diff and output shaft. Then this trans will be ready to install as a stock transmission.

Those scratches in the diff cover look like they could be diff pin or even a prior diff failure. The flow of fluid is from the diff area back to the pan and then up through the filter to go back through everything again.

You mention that this is ready to put back together and have as a spare. I would be concerned about the screen being broken and the chances the fact that the unscreened fluid that was pumped through the valve body which may have lodged something in the various valve bores and passages. With the color of the fluid in that diff cover and the abusive driving style that you mention, I'd be checking the clutch packs...especially input and 3rd gear as well as galling of the sun gear. Since you have it on the floor and apart, a full tear down and checking of all seals, clutches, parts etc would make sense.

I have a new screen that will go in next time I open it. At that time I also plan to pull the clutch packs and inspect everything further. Just need time to remove the engine from the stand and mount the trans. It will get one further cleaning and closed up for the final time. The trans only has a few years on this build. I did find something rather odd though. When putting it back together I could not find the 2 thrust washers that go between the valve body and the gears. And it'* not like me to misplace something. I had to go in to my spare parts box and get them. Kind of makes me wonder if they were ever there. I don't recall removing them.

Thrust washers in the valve body to gears? Do you mean the one metal and one plastic (I think) that you goop to the channel plate and one sits over the drive gear and the other over the driven gear? Any gouges or rub marks in the channel plate? I'd think those gears and the chain would ride the case cover (channel plate) if those weren't in place.

Yes, those are the ones. I didn't see any gouges, but I was limited on time and didn't notice until I was putting it back together, so didn't look real close.

Browing some of my pics, chain wouldn't ride the case. but the reluctor wheel would.


And you'll know if it does


And if the diff really starts to check out.. the needle bearings in my Gen 3 LSD looked like this

At first I thought they might have left with the gears when Chris took them home. Still possible, I'll have to ask him. Here'* a picture right after I remove the valve body.



Neither thrust washer is there. And they tend to stay on the gears more then on the case.

Looking again, that'* the wrong transmission, that'* the one that went in the car. I can tell because the drive chain is wrong. The one that came out had a single 1" chain, that'* a double chain.

And it'* cleaned up with the new metal gaskets on it.