Project Save My Bacon - 99 manual trans swap with minimal help

[Buurin]

Objective changed - I could not lift the pig high enough and had to send the swap to a shop. Car and bad transmission has returned and this project is now about rebuilding the bad one.

With today's arrival of the last of planned parts, so begins my project to swap out a broken transmission without help. Yes, Buurin will be saving Little Pig's bacon on my own.

A few upgrades would also be done:

MWR lightweight chromoly flywheel
ARP flywheel bolts
Exedy ST1 clutch (up from OEM replacment grade)
Speedsource front+rear poly mount inserts + long pushrod + stainless steel clutch line

The beginning and why this was needed: Took a beating, will need major tranny work soon

This thread would be a log. I'll ask my questions in the original thread.

MWR Chromoly flywheel


NINE POUNDS!


All the parts



Tools bought for this occasion

[Buurin]

Objective changed - I could not lift the pig high enough and has to send the swap to a shop. Car and bad transmission has returned and this project is now about rebuilding the bad one.

So this new project started last night with taking out the first transmission case segment. I don't have brass punch on hand so I lodged a 2x4 on the case projections and tapped on it.

Pics to come.

With the case and drain plug off I see that the 5th driven gear is now scraping on the plate. I also find major teeth chipping on the differential ring gear. That thing has to go for sure. Have to check the output shaft as well.

[PhatRoyale]

Let me know how those SS front+rear poly mount inserts turn out and what you think of them.

Mine are still sitting in my basement collecting dust.

[Buurin]

Originally Posted by PhatRoyale

Let me know how those SS front+rear poly mount inserts turn out and what you think of them.

Mine are still sitting in my basement collecting dust.

WHAT!? Should have bought yours instead.

[sam333]

Originally Posted by Buurin

Objective changed - I could not lift the pig high enough and has to send the swap to a shop. Car and bad transmission has returned and this project is now about rebuilding the bad one.

So this new project started last night with taking out the first transmission case segment. I don't have brass punch on hand so I lodged a 2x4 on the case projections and tapped on it.

Pics to come.

With the case and drain plug off I see that the 5th driven gear is now scraping on the plate. I also find major teeth chipping on the differential ring gear. That thing has to go for sure. Have to check the output shaft as well.

What are you using for a manual and have you found a good source for parts?

[PhatRoyale]

Originally Posted by Buurin

WHAT!? Should have bought yours instead.

What makes you think that they're for sale?

[Buurin]

Hey didn't hurt to throw that out, lol

[Buurin]

I started tearing into the transmission tonight.

First I finally managed to remove the vehicle speed sensor.




Yes that is a slide hammer


Then the transmission.


First remove the clutch release fork pivot. (19mm socket)


Then backup light switch (27mm) and vehicle speed sensor (above)



Then remove shifter shaft lock bolt, 4 bolts and shaft. This lock bolt is 24mm in 2001, but a lot smaller in 1998. Go figure.





Look at all the crap inside the cover!

Pull one of the axle seal while I'm at it. Yes, that's the same slide hammer.

More crap exposed


5th gear. 40T driving 29T, so 0.725


Output shaft has a notch for staking the lock nut. Stick a screwdriver/chisel here to loosen it.


After that, undo lock nut with 27mm socket. Torque is 87 ft-lbs so you need lots of leverage AND engage two of the gears to make sure the two shafts lock together. Engage them by sticking a 1/4" socket extension into where the shifter shaft is.


Shift fork #3 is seen removed here. Set bolt is 10mm socket and loctited.

Tap out the snap ring on 5th gear synchro. Lacking the proper "SST" 5th gear driven gear and 5th gear synchro can be pulled like this:

5 synchro sleeve

5 driven gear


Too late in the night, to be continued...

[sam333]

What manual are you using and do you have a good source for parts?

[Buurin]

Originally Posted by sam333

What manual are you using and do you have a good source for parts?

I'm going by the factory service manual. I'm currently doing inventory of damaged parts to replace, then it's to dealer for parts.

[Buurin]

Now I'm struggling with the FIPG on the tranny case, have a hard time separating it.

Ran some quotes by the dealer and these few must-be-replaced part already ran me $600

differential ring gear (all chipped)
output shaft rear ball bearing (has disintegrated )
5th driven gear (one side all scraped, gouged down the middle)
5th gear (gouged down the middle)

Who knows what else I'll find inside also needing replacement after I crack open the case. Figuratively and probably literally.

Someone says I can buy upgraded transmission innards. Where?

[sam333]

Nice collection of pullers. Doing it yourself is great, even if you spend a few bucks you know it was done right.
Does the dealer carry all the parts needed?

[Buurin]

After I pulled the 5th driven gear, this became exposed...


In place of the output shaft rear bearing, I find this crap:


This is how my 5th driven gear looks like. Should I replace it?




Pull the other axle seal, again slide hammer is your friend, and more metallic crap


Remove 16 bolts, 3 of them from inside bellhousing



I should have the housing free soon...

[sam333]

This is like one of those saturday matinee cliff hangers( you got to be old to get that reference).

[Buurin]

Originally Posted by sam333

This is like one of those saturday matinee cliff hangers( you got to be old to get that reference).

The matinee that I know is on Tuesday.

After 3 days I finally have the transmission all apart. The final drive is all chipped to hell, meaning the output shaft is toast too.

Gear ratios after I counted the teeth:
(driven/drive=ratio)
1. 38/12=3.166
2. 40/21=1.904
3. 38/29=1.310
4. 31/35=0.885
5. 29/40=0.725
R. 39/12=3.250
Final drive: 67/18=3.722

3rd and 4th gears are relatively intact. Before the incident it didn't shift that smoothly either, but I have not seen a known good vs. known bad synchros so I don't know how far gone they are, or if they are still good.

My guess at a post-mortem would be the rear output shaft bearing disintegrating, causing it to shake which then send gear chips everywhere and ruining everything in sight.

Pics to come.