Another thing I got accomplished recently was the rebuilding of Rusty’s T-96 transmission. It’s been a couple decades since I’ve rebuild a T-90, but I think a person could follow a T-90 side shift guide when rebuilding the T-96 (I didn’t think of this until after I was done — instead I used an old rebuild manual from the late 60’s that has rebuilds of 35 different styles of transmissions). Once again, I thought I had more pics, but I didn’t. So, this isn’t a step-by-step overview.
I took this photo at the beginning of the tear-down to remember which way the speedometer gear should face. The lack of a transfercase is part of what makes this rebuild different from most other jeep transmissions.
Here’s the transmission with the input shaft pulled forward. My first gear and second gears were a bit worn. 
Once I removed all the gears, I discovered the reverse gear had a broken tooth. 
Close up of broken tooth. Thankfully, Charles Tate had sent me a box of T-96 parts that included a reverse gear. I was also able to replace the entire bottom cluster, first gear, and second gear. That saved me some money!
To remove the side shifters, a pin has to be tapped out. I was able to remove the 2/3 gear shifter, but not the first/reverse unit. Since there was no critical reason I could see for removing the first/reverse mechanism, I left it as is and cleaned up the housing.
Normally, I’d paint the housing before assembly. However, with time being an issue and lacking enough warmth on the rebuild day to properly paint it, I will paint it at a later date. 
One other unique thing about the T-96: it requires the use of a special speedometer cable that is also used for Jeepsters and wagons.
Hi Rusty, I have a T-96 from a Gibson tractor . 46 or 47 I think. it was left outside under a tree for 25 plus yrs so water got in through the shift tower. I got the aenl Wisconsin back together and runs and starts like a new one. my question is are you familiar with T 96’s set up for a Gibson? mine is in pieces or id send you pictures, the input shaft has a collar on it for a 48 teeth # 50 chain drive and the tailstock is short w/no speedometer gear hole. any help is greatly appreciated. the cluster, input shaft, reverse gear, syncros, 1 st & 2 nd gear is all kaput. the only decent parts still good are the case and main shaft from the rear.
Hi Norman,
I want to apologize for missing this comment. I see that you asked a question about the T-96 on April 22. I am not familiar with how the t-96 was used in a tractor.
I did some research. Based on this website ( http://www.tractorfriends.org/lawn&gardentractors/gibsontractors/Gibson%20Tractors.html ), the T-96s are the same. Quoting the post:
“A number of tractors were issued with Chevrolet transmissions and Plymouth differentials; however, others were used as available, including Borg-Warner T-96 transmissions–the same as those used in Willys Jeeps, AMC, Crosley, Ford-Falcon, and Studebaker automobiles, and Economy Power-King garden tractors, amongst others.”
The above quote suggests they are the same, though it’s possible that the principal shaft is different.
On April 27 you asked a second question about the tower. Given the quote above, it seems plausible that your tower might work, but I have never tried adapting a tower to the T-96.
If the tower in fact works, it would be something I’d like to report to eWillys readers. Someone might find such a conversion useful.
Sorry I can’t be more help,
– Dave
I have a T-96 trans out of a 49 Jeepster an looking for the shift rods that go to the trans to the steering column. Do you have them or now were i could get a pair
Paul,
I’d try the https://www.thejeepsterman.com … they might have what you need. Note that as I understand it, the shifting rods were slightly different between the DJ-3As and the Jeepsters. Whether the Jeepsters and the CJ-2A column shifters were the same is not something I know offhand.
– Dave
I have a 1950 Jeepster with a T96. Not shifting correctly, and after multiple adjustments to the shift rods (also replaced the bushings that fit in the fork levers), I am still not satisfied with it. Shifts up OK, but no way to shift from 3rd to 2nd. Even shifting up, I hear a little gear noise. Also adjusted the clutch.
Question….I plan to take it apart to see if the synchronizers are bad. Can’t find any dedicated service info on this. Might someone have a manual I can get a copy of?
Thx
Vic
Vic,
This link provides an exploded view of the transmission: https://www.kaiserwillys.com/t-96-transmission
Unfortunately, I don’t have the vintage transmission booklet with me (it’s about 200miles away from me) that included the directions on how to rebuild this. I looked for a rebuild guide on the web, but couldn’t find anything.
My feeling is that the T-90 rebuild is pretty similar:
T-90 rebuild: https://www.youtube.com/watch?v=TdBD659UQOY&t=12s
Side shifters: https://www.youtube.com/watch?v=c9qS8UkfY7A
I hope that helps.
– Dave
Thanks much
BTW, does anyone have a Borg Warner parts list for a T96. Like to cross reference Willys part numbers with BW
Thx
Hi Victor,
Maybe this will help?
This link has a parts list that includes parts numbers for each transmission part (it’s under “TRANSMISSION GROUP 17”: http://www.jeepsurreygala.com/?page_id=1133
OTHER LINKS:
https://www.kaiserwillys.com/t-96-transmission
https://shop.willysamerica.com/T96-1C-Transmission-s/2034.htm
https://walcks4wd.com/transmission/t-96.html
– Dave
Thanks for your thoughts and suggestions. I do have the T96 Willys part numbers, but some of the transmission parts suppliers I have contacted can’t cross reference them. These guys often have parts at 50% to 70% less then the Jeep sites, and I like to try them for parts.
I was thinking that for the benefit of the group, if we could ever find a Borg-Warner parts list for these various transmissions, it would be an invaluable resource. I even reached out to Borg-Warner to see if there is anyone who manages their archives who might be able to help. If I find anything, I’ll post it.
Thx
Vic
I’ve rebuilt two T-96s (both with overdrive) in the past five years. In both cases, after a few months of driving the cars (two different ones) and working fine, the trans would no longer go into 3rd gear.
Am I doing something wrong in my rebuild? I could run through all the gears no problem with them on the bench and when I initially installed them in the cars they worked fine. I also replace the pilot bushing in the flywheel on both vehicles. I just seems strange that I would experience the exact same symptom on both. Any suggestions? (I haven’t pulled the second one out to inspect it yet)
I haven’t heard of that problem with the T-96, but it does seem strange that you would encounter that same problem with both transmissions. If it is a column shift, is it possible the problem is with the shifting linkage rather than the transmission itself? That’s the one thought I have …
– Dave
Thanks for the reply David. I have all of the linkage disconnected and am using just the levers on the side of the trans and it will not go into high gear. I even tried gently tapping it with a hammer – it will not engage high gear. Looks like I’m going to have to pull it and see what’s wrong inside.