Too far gone? (T-90 teardown and rebuild)

[bmorgil]

gm has you on the right track. Any surface that bearings will be running on, will not tolerate pitted surfaces for long. Your bearing surfaces need to look good with no damage. Under the bushings you can get away with a little more pitting but not wear. No wear (oversize) is allowed on the bushing or bearing surfaces. On the gear teeth themselves rust damage if it has gone thorough the case hardening of the tooth, will cause issues. Pitted rough gears are noisier. If the clutching teeth on the gears are worn, shifting and staying in gear will become a problem. If the bushings or the main shaft are worn, shifting will again be affected. Discoloration is not a problem. Some wear is OK. Your reverse/first slider needs a better look. Lets see some more pictures of it. Rust has a way of just ruining a transmission. Unfortunately on the T90 in a Jeep, a lot of them sit out in the weather. If the boot is torn or leaking in the least bit on the shifter, water runs right into the transmission. Even if it is protected, if has been sitting a long time condensation will do its worst. This is why there is a "time" specification on lubrication changes, gotta get the water out.

The best advice here would be "when in doubt, throw it out". It is truly a "pay me now or pay me later" situation. If you are looking to get it moving, I have seen some pretty bad stuff go back to together, and kind of work. There is of course a correct way that will return it to it's original function and performance.

You can add more pictures. You can only add so many to each post however. Just add a few posts in a row.