Can I slide My 4-Speed together with the Cluster Gear already in place?
yes it is possible; but as you found out, very tricky. see note-3
After my first one; I ever afterwords just leave the cluster in the bottom.
But that requires a new trick; namely to get the pin in from the back.
To do this, I first install the empty tail onto the empty mainbox which I set face down on the bench. Then the tail has to be oriented upside down with the cluster-pin hole showing. Rotate it so that you can put one bolt in any hole and still see the pin-hole. Snug it in. Then attempt to insert the pin. Most factory cases I have worked, the pin goes in, but in some cases you might have to clearance the tail to allow the pin to slide on by. My Passon case needed a touch of clearancing.
My bench has a large hole in that accepts the front bearing, without letting it (the input gear) drop out.
So in goes the cluster with the thrust washers, then the input. Then the rear gasket and upside-down tail, then the pin. After the pin is in, I just rotate the tail and install the rear bolts, and finally, install the FACTORY snapring onto the front bearing followed by the retainer.
This method is easy-peasy, requires no heat, and is as good as foolproof. I've done hundreds of 'em.
NOTE-1
the front snapring, that is supplied on a New bearing, as installed on the bearing, will NOT fit into the retainer and if you try it, you will break the retainer. The Factory ring is significantly more narrow and; is a special item to this trans, as is the rear bearing, if a 308.
Note 2
Just make sure you align the thrust washers after you slide the cluster over, lol.
Note-3
The Passon way? Vaseline will not work at room temperature. You need a grease that is less temperature sensitive. And I put the brass ring on the input gear and leave the retainer off so I can push the input gear as far out of the box as it goes. I stand the case on it's face with the input gear hanging thru a hole in my bench. I do not shift the front slider forward yet. I mark the slider with a paint-marker as to where the struts are . Then I stand the back end up vertical, then hoist it up and in. I used to do that with one hand and steer the slider into place with the other. But, I'm 69 now, so probably couldn't do it even with an Aluminum tail, lol. If you can't do it, I suggest putting a couple of blocks on the rear face prior to dropping it in, then steering the struts into alignment, before dropping the slider around third gear.
The other option is to do this with everything lying down, which works too, until you snag a roller going into the input gear, lol. Then you get to start over, except sometimes you can't feel a roller flip out and it gets shoved into the cavity at the front. I like to know where those stinking rollers are at all times.
