- Mon Aug 25, 2008 4:21 pm
#67284
So your tranny grinds into 3rd gear, as many of them do. This is usually the first to wear out. You can buy another used transmission, but who knows how long it will be before something goes wrong with that one. I chose to fix the problem in my 93 si transmission instead of buying another one, even though the price would have been about the same (for the 3rd/4th gear synchro set), plus a few extra hours of my time.
Rebuilding a countershaft or mainshaft is not very complicated. You just have to be careful and pay attention. It is a lot like building a huge sandwich... you have your bottom bun, ham, salami, cheese, lettuce, tomato, pickes, mayo, top bun. Those things must go in a certain order. The countershaft must be pot together exactly as it was or you'll have big problems. You'll need a clean work area with enough space to lay each part out in the order you removed it. Then all you have to do is pick up each one in order and put it on the mainshaft, just like building a big heavy metal sandwich. When installing the new parts, a thin coat of oil should be applied, don't put them on the mainshaft dry. Also don't drop anything on the floor. Very tight tolerances and precise teeth make this work. it could be easy to damage these parts, so pick a good work space to start because you don't want to move everything once you start taking it apart.
This thread is just to help you get familiar with the parts & assembly of the mainshaft. Before doing this yourself, have a manual in front of you. By reading on, you agree that I am not responsible for any damage you do to your vehicle.
First I'm going to take it apart.
First you'll need to remove the large ball bearing on the end. Mine pulled right off without tools, but you may need a bearing puller.
You'll need a puller similar to the one shown above. There's larger bearing pullers that will also work. They put the pressure over a larger area vs 3 points like the one I rented from autozone. So if you are using the type I am, be very careful not to let it slip and damage any teeth on your gears.
notice I put an old nut between the point where the threaded bolt at the center of the puller contacts the mainshaft. This is to keep the pressure from damaging the shaft itself.
Now the parts have been loosened with the puller, they can be removed.
First remove the 5th gear synchro sleeve.... (already on table) and the next piece I'm looking at removing is the 5th gear synchro hub.
Now I removed the 5th gear synchro hub which the sleeve slides on/over. The gold piece we're looking at next is the 5th gear synchro.
Remove the synchro (synchro spring is attached to it) and now we're looking at 5th gear.
Rebuilding a countershaft or mainshaft is not very complicated. You just have to be careful and pay attention. It is a lot like building a huge sandwich... you have your bottom bun, ham, salami, cheese, lettuce, tomato, pickes, mayo, top bun. Those things must go in a certain order. The countershaft must be pot together exactly as it was or you'll have big problems. You'll need a clean work area with enough space to lay each part out in the order you removed it. Then all you have to do is pick up each one in order and put it on the mainshaft, just like building a big heavy metal sandwich. When installing the new parts, a thin coat of oil should be applied, don't put them on the mainshaft dry. Also don't drop anything on the floor. Very tight tolerances and precise teeth make this work. it could be easy to damage these parts, so pick a good work space to start because you don't want to move everything once you start taking it apart.
This thread is just to help you get familiar with the parts & assembly of the mainshaft. Before doing this yourself, have a manual in front of you. By reading on, you agree that I am not responsible for any damage you do to your vehicle.
First I'm going to take it apart.
First you'll need to remove the large ball bearing on the end. Mine pulled right off without tools, but you may need a bearing puller.
You'll need a puller similar to the one shown above. There's larger bearing pullers that will also work. They put the pressure over a larger area vs 3 points like the one I rented from autozone. So if you are using the type I am, be very careful not to let it slip and damage any teeth on your gears.
notice I put an old nut between the point where the threaded bolt at the center of the puller contacts the mainshaft. This is to keep the pressure from damaging the shaft itself.
Now the parts have been loosened with the puller, they can be removed.
First remove the 5th gear synchro sleeve.... (already on table) and the next piece I'm looking at removing is the 5th gear synchro hub.
Now I removed the 5th gear synchro hub which the sleeve slides on/over. The gold piece we're looking at next is the 5th gear synchro.
Remove the synchro (synchro spring is attached to it) and now we're looking at 5th gear.
Last edited by teal_dx on Tue Sep 02, 2008 3:13 pm, edited 2 times in total.
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My 1992 SOHC Turbo Hatch
My Youtube Channel: 6th Gear Garage
My 1992 SOHC Turbo Hatch
My Youtube Channel: 6th Gear Garage