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Old 01-03-2004, 03:09 PM   #1
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Default How-To: Take Apart a Transmission

"]Click the image to open in full size.
I spent a bunch of my day on saturday, sitting by the lake, drinkin some suds, getting my white-*** sunburned.
Click the image to open in full size.
Sunday, I decided that it was time to break into my tranny, the mainshaft bearings are bad, and some part of the reverse mechanism is damaged. So i'm going to try to repair it myself and sell it/trade it, i really want a Si transmission for the better gearing, and to throw some more goodies at it when I can.
(Pardon the bud-light physique)
Click the image to open in full size.
Here is the speed sensor, it comes out with 1 10 mm bolt, this is actually a d-series speed sensor, yours may look different. Remove please.
Click the image to open in full size.
Then remove the brackets from the housing, the reverse sensor, etc, etc, everything that bolts to the housing, (the mount if you're a lazy bum like me.)
Click the image to open in full size.
At this point, it should look a lot like this (except not shiny, and minus the cluch fork.)

Click the image to open in full size.
This is the best ******* magazine i've bought in a while. It has the complete write up on how to dissasemble the tranny, i actually used it here, so buy this.
Click the image to open in full size.
At this point, you will need to remove the 1/2 drive plug on the top of the tranny, i used my breaker bar to do it, and twisted it on out.
Click the image to open in full size.
There are 2 bolts on the bottom of the tranny, (underside), remove them, there is a little spring and ball bearing in there with each, remove them, these do something to the shift forks.
Click the image to open in full size.
Here is what they look like when they are out.

Pretty neat actually.

Then there is one more bolt on the top side (from perspective of in the car) of the tranny, next to where the mount goes(under, see 5th picture), remove it, this holds it all together or something, it's a weird bolt.

Then remove all the 12 mm bolts all the way around the housing, and get some pliers, or separaters, or something. There is a clip in the top of the housing, where you removed the 1/2 inch drive plug. You separate that, and then break the housing loose, and it all comes apart.

Yay, here is the finished product.

Click the image to open in full size.

I'll update more with pictures of the repairs, etc as I do it. That was all I could handle for today, as I cut my thumb open putting undercar neon on my sisters expedition.
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Old 01-03-2004, 03:10 PM   #2
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Default Re: How-To: Take Apart a Transmission (Plan B)

Note: for whatever reason, the original thread was deleted, a mixup pretty much. So I am re posting it.

1: i sold the transmission, never fixed it.

2: Yeah, i look funny.

3: The magazine is several months old now, so you will have to find a friend that has one.

4: That's it.
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Old 01-03-2004, 03:23 PM   #3
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Default Re: How-To: Take Apart a Transmission (Plan B)

nice writeup....

i might go pick that mag up today.....Click the image to open in full size.
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Old 01-03-2004, 04:33 PM   #4
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Default Re: How-To: Take Apart a Transmission (Plan B)

You know after i saw the original thread, i ran out and bought that issue.

Yesterday was the first time i ever disassembled a tranny (GSR), and it was definitely alot easier than i ever imagined it would be.

Thanks bro... Click the image to open in full size.
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Old 01-07-2004, 12:51 PM   #5
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what happened to the rest of this thread?
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Old 01-07-2004, 01:08 PM   #6
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Yeah I read this a while ago as well when it was first posted up. Good write up. I remember the first time I dug into a tranny about 3-4 years ago. Damn was I scared. But just a few things to chime in:
1. Never have anybody else touch your tranny once it is apart besides you.
2. Don't drink and try to assemble the tranny. Most likely you won't assemble it right ----- Click the image to open in full size. on me for doing this.
3. When pulling the mainshaft and countershaft out, it is a lot easier to either zip tie or duct tape them together. It makes everything so much simpler when keeping everything organized
4. And last of all, make sure the bearings in the casing (mainshaft most importantly) are clipped in the wall of the bearing casing. Sometimes these will often fall out and you will be wondering why the shaft won't go all the way in.

Great write up Plan B
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Old 01-07-2004, 02:01 PM   #7
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Default Re: (JDMH22HATCH)

Great write up !!! I will be rebuilding a B16 tranny very soon, does anyone still have that article and able to scan it and send it in an email??
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Old 01-07-2004, 02:04 PM   #8
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Default Re: (DaX)

It was accidentally deleted by a mod, i had it on another board, so i was able to recover this much
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Old 01-07-2004, 03:46 PM   #9
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Oh well. I'm about to reassemble my tranny tonight. All new bearings/seals/oil guide plates are installed, all that remains is reassembly and refilling with GM Synchromesh.
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Old 01-08-2004, 04:07 PM   #10
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Transmission is completely back together. I'll be installing it within the month [hopefully] so I'll post back then.
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Old 01-08-2004, 05:10 PM   #11
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*finally* pictures...

First off, this is what happens when you don't replace that main shaft bearing that's making all that noise:

Clutch housing. Bearing seat destroyed. I couldn't even get the mutilated main shaft seal out. This leaked on the clutch and destroyed it
Click the image to open in full size.

Outer race of main shaft bearing. A piece of the inner race [that slung itself to pieces] wedged underneath the outer race and pushed it into the spinning gear, which promptly ate into the bearing.
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Click the image to open in full size.
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Old 01-08-2004, 05:17 PM   #12
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It's amazing what simple green and a toothbrush can do.
Click the image to open in full size.
Click the image to open in full size.

Completed rebuild on S1 transmission
Click the image to open in full size.
Click the image to open in full size.

Previous owner ran over a curb and cracked the case. When I bought it it was JB welded. I scraped that **** off, drilled the ends of the cracks out, and had it aluminum welded.
Click the image to open in full size.

mmmmm....synchromesh
Click the image to open in full size.

All that was replaced [couldn't find the other oil guide plate though for the picture]. From left to right, top row: Mainshaft clutch housing bearing, countershaft clutch housing bearing, mainshaft end bearing, countershaft end bearing, three mainshaft needle bearings. Bottom row, left to right: Mainshaft oil guide plate, countershaft nut. I also replaced every seal on the case.
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Old 01-08-2004, 05:24 PM   #13
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^I'm having the same damn problem. Clutch just started chattering, and housing is leaking also. ...joy.

WTB: ANY D-series tranny (93+) that's in decent shape.
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Old 01-08-2004, 05:31 PM   #14
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does anybody have the link on here where the guy took the internals apart?
i know it's on here... i just can't find it
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Old 01-08-2004, 05:38 PM   #15
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Wish I'd have had the digital camera for the teardown, I know it would have helped many people on here.
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Old 01-08-2004, 06:00 PM   #16
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damn... go get a digicam and do it again Click the image to open in full size.
do you think you could you just give me a quick run down of the steps to get the diff out? were there any special tools you needed? also what loctite are you supposed to use?
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Old 01-08-2004, 07:55 PM   #17
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did you reuse the mutilated clutch housing?
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Old 01-09-2004, 05:55 AM   #18
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No I did not reuse the mutilated clutch housing. That was a D-series tranny I had that blew up.
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Old 01-09-2004, 05:59 AM   #19
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Quote:
Originally Posted by jwn7
damn... go get a digicam and do it again Click the image to open in full size.
do you think you could you just give me a quick run down of the steps to get the diff out? were there any special tools you needed? also what loctite are you supposed to use?
I will probably be rebuilding my Y1 tranny in the near future, and I'll have a digital camera on hand for it.

Plan B's description of the teardown is very similar to taking apart a B-series transmission. Having a HELM on hand helps out greatly. If you're just going to be replacing the differential, remove all the bolts from the housing, remove the big plug on the back, use some Eaton Style Spreader Pliers to open the snapring, and separate the cases. If you're not going to tear down the shafts, duct tape them together [or tie them together]. Take out the shift changer assembly, the reverse shifter assembly, and the reverse idler gear and shaft. Then pull out the whole assembly of mainshaft/countershaft/shift forks, and set it to the side. The differential assembly should just slide out. You'll need a bearing puller to get the bearings off the diff, and don't forget the ring gear bolts are LH threaded.
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Old 01-09-2004, 08:50 AM   #20
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thanks man. i'm a little scared to do this... i'll just go real slow and make sure i don't have any bolts left over like i usually do Click the image to open in full size.
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Old 01-09-2004, 09:54 AM   #21
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are you doing a D series or a B series? There really aren't that many parts...the B series is even more simple than the D series.
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Old 01-09-2004, 12:21 PM   #22
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i'm installing a quaife into a d16y8 tranny. what color loctite should i use on everything?
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Old 01-09-2004, 03:05 PM   #23
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no loctite needed. use blue rtv.
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Old 05-02-2004, 07:18 PM   #24
 
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TRANE A/C Click the image to open in full size. that is some good **** there!
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Old 05-02-2004, 08:19 PM   #25
 
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Why put ground effects on a expedition? its a suv!
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