Thread: gear set, 4th gear hub, channel plate gouged! help!

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  1. #1 gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    OK so i tore my trans apart today and found one of my thrust washers was trashed between the gear and channel plate, my 4th gear hub was rubbing the chain gear. Both gears have some rash on them from this and the 4th gear hub has rash on it and also the channel plate. Any ideas on what caused this?!?! The chain and gear set was a 7/8th 2.93 ratio.....

    channel plate


    4th gear hub


    drive gear (this is where the bushing was trashed) i removed the retainer clip, it was installed.


    driven gear
    Last edited by kawasaki22106; 04-04-2013 at 10:17 AM.
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  2. #2 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Donating Users GMR Badass's Avatar
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    Edit...I take that back. If that pic was taken how you found everything there is a chance that with the bushing being destroyed on the drive gear that it has cause the driven gear to "walk" toward the driver side of the car causing some issues. Still wouldn't explain the interference between driven sprocket and 4th clutch hub.

    As far as the bushing that goes between the drive gear and channel plate I am going to have to stick with installation error. Did you even find remnants of the bushing? was is ever put in the trans? Without it, it's going to cause damage just like you have pictured.

    Additional Edit....Where is the drive sprocket retainer clip that holds the sprocket in place on the input shaft?
    Last edited by GMR Badass; 04-04-2013 at 10:39 AM.
    1999 GTP 2dr - Whipple 537whp.....for now
    1998 GTP 4dr - ST2, Cartuning PT61, IC - SOLD
    1999 GTP 2dr - SIX, GenV, Headers, TEP Trans, E85 - SOLD
    1997 GTP 4dr - 3.4, 1.9's, 3" DP, P-log - SOLD
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  3. #3 Re: gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    i found everything gouged like this when i pulled the channel plate off. i removed the retainer clip it was installed, and yes i found remenance of the bushing so it was installed but decided it didnt want to be in there any more and committed suicide lol

    btw this was a tim king trans with only 1600 miles on it
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  4. #4 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Turbo is the way to go. BillBoost37's Avatar
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    Hi John...

    Drive gear bushing IIRC is plastic. Pat said you guys found pieces of it, so it had been there at some point. If there wasn't enough trans goo on it to hold, it may have gotten mashed upon install. Unless the welds on the reluctor tore it up over time, tough for that to happen if the pin heads don't usually hurt it.


    4th hub to gear. Should not be possible with the plastic bushing there. Put them together outside of the trans and see if they hit. I bet they don't. Which means they must have gone in looking like that.
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  5. #5 Re: gear set, 4th gear hub, channel plate gouged! help! 
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    The bushing that goes in between the channel plate and drive gear is known to fall out of place during installation if you're not paying attention. I always use a big goop of petroleum jelly to make sure that the bushing stays oriented and in place during installation. If it was out of place or not seeded properly the bearing would have been destroyed shortly after first start up.

    Were the sprockets also purchased from Tim King. Because with the additional information about having the drive sprocket retainer clip in place they only way that I would see that the driven gear would have interference with the 4th clutch hub would be an issue with the specifications for the machining of the sprocket for the 4T65E application.

    No comment on Tim King.....other than I will never do business with him.
    1999 GTP 2dr - Whipple 537whp.....for now
    1998 GTP 4dr - ST2, Cartuning PT61, IC - SOLD
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    1997 GTP 4dr - 3.4, 1.9's, 3" DP, P-log - SOLD
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  6. #6 Re: gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    no i purchased the chain and gear set from zzp and gave it to him. my trans had a hardened 4th gear hub from factory so he reused it.
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  7. #7 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Donating Users GMR Badass's Avatar
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    Your driven gear is not machined properly IMO....Here are a couple pic for reference as to what it should look like. Notice that your spocket has a ridge right in the area where you are having the interferrence issue.


    1999 GTP 2dr - Whipple 537whp.....for now
    1998 GTP 4dr - ST2, Cartuning PT61, IC - SOLD
    1999 GTP 2dr - SIX, GenV, Headers, TEP Trans, E85 - SOLD
    1997 GTP 4dr - 3.4, 1.9's, 3" DP, P-log - SOLD
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  8. #8 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Turbo is the way to go. BillBoost37's Avatar
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    You know Greg, some people label them by teeth. That way when the diff ratio changes..the writing isn't wrong.
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  9. #9 Re: gear set, 4th gear hub, channel plate gouged! help! 
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    Pic was stolen from the internet. Just showing the example of what the driven sprocket machine surface was supposed to look like.
    1999 GTP 2dr - Whipple 537whp.....for now
    1998 GTP 4dr - ST2, Cartuning PT61, IC - SOLD
    1999 GTP 2dr - SIX, GenV, Headers, TEP Trans, E85 - SOLD
    1997 GTP 4dr - 3.4, 1.9's, 3" DP, P-log - SOLD
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  10. #10 Re: gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    greg im not seeing what you are seeing....
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  11. #11 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Turbo is the way to go. BillBoost37's Avatar
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    Use the outer set of holes as a reference point. On your ZZP high quality part..that bevel is right at the hole. On the other pic...it's been machined much further back
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  12. #12 Re: gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    got ya now..... well this sucks
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  13. #13 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Donating Users GMR Badass's Avatar
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    In between the red lines you'll see that there is an extra ridge that should have been removed during the machining process. Which is exactly where the 4th clutch hub is rubbing on the driven sprocket. Green circles are what you should reference as far as the distance it should have been machined.
    1999 GTP 2dr - Whipple 537whp.....for now
    1998 GTP 4dr - ST2, Cartuning PT61, IC - SOLD
    1999 GTP 2dr - SIX, GenV, Headers, TEP Trans, E85 - SOLD
    1997 GTP 4dr - 3.4, 1.9's, 3" DP, P-log - SOLD
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  14. #14 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Turbo is the way to go. BillBoost37's Avatar
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    Greg..you are informative...
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  15. #15 Re: gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    time to head to the garage and look at my 1" chain/gears and compare..... i am gonna check and see if the 4th gear hub is hitting as well like bill said so see if it happened now or was from earlier wear that tim didnt tell me about....
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  16. #16 Re: gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    there is clearance issues there for sure, my 1" gear fits fine but the 7/8ths rubs. so that explains the 4th gear hub but would this cause the drive gear to grenade the bushing and rub the channel plate? and is my 4th gear hub reusable or should i buy another one.....
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  17. #17 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Donating Users GMR Badass's Avatar
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    Cause of the bushing to rub on the channel plate is going to be cause by install error IMO. If it falls out of place or is crushed during the install the bushing wont last 10 miles.

    Replace the 4th clutc hub. You're talking about a huge turbo build with a 1" GMR chain........why cheap out on a part you get can get new for $35.
    1999 GTP 2dr - Whipple 537whp.....for now
    1998 GTP 4dr - ST2, Cartuning PT61, IC - SOLD
    1999 GTP 2dr - SIX, GenV, Headers, TEP Trans, E85 - SOLD
    1997 GTP 4dr - 3.4, 1.9's, 3" DP, P-log - SOLD
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  18. #18 Re: gear set, 4th gear hub, channel plate gouged! help! 
    Turbo is the way to go. BillBoost37's Avatar
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    I say keep the 4th hub. Nothing ever touches it where you have that "mark" on it. It's not a structural or strength probably from the mark on it. Call it a character mark.
    I drink..so consider that when reading my posts.

    2010 Audi A6 Dual IC's
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  19. #19 Re: gear set, 4th gear hub, channel plate gouged! help! 
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    Fine Bill....keep it in there....How do the splines look on the other side of the 4th clutch hub. If there is signs of wear, for sure replace it.
    1999 GTP 2dr - Whipple 537whp.....for now
    1998 GTP 4dr - ST2, Cartuning PT61, IC - SOLD
    1999 GTP 2dr - SIX, GenV, Headers, TEP Trans, E85 - SOLD
    1997 GTP 4dr - 3.4, 1.9's, 3" DP, P-log - SOLD
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  20. #20 Re: gear set, 4th gear hub, channel plate gouged! help! 
    SE Level Member kawasaki22106's Avatar
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    no signes of wear on the splines, take note to the close up pic of the 4th hub teeth though, i never seen one in person till now do they look ok? to me it looks like they got little marks in them but the marks are all uniform on every tooth....
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