Transmission rebuild

[rjkoop]

So I have a grinding issue at high RPMs going from 1st to 2nd. I have to let the RPM come down to below 2500 RPM or it will grind. Other than that tranny works fine. So looks like a synchronizer ring and a tranny rebuild is in order.

My question is regarding removing the tranny. I wasn't looking forward to removing the tranny from below. Would it be easier (in some ways) to just remove the tranny with the engine from the top? Or is that a crap load more work? And would I need to remove the head before attempting to remove the engine or can the engine/head/tranny be removed together?

I just hate lying under the car but don't want to create a huge amount more work for myself.

Or would most just say live with it and don't rebuild the tranny for a relatively minor issue? I'm kind of torn!

[ORFORD2004]

Why do you want to unplug everything on the engine when you need just the transmission? No benefit except for the 2 upper bolts. You can reach them from under with universal joint and about 2 foot extension. Just unbolt the driveshaft at the donut and move it away. Remove the 3 bolts under the shifter and the nut under the cap. You can now remove the shifter from the top. Remove the 2 or 3 bolts of the starter. Remove the 4 bolts from the engine and you pull it back. Remember to unplug the battery and clutch cable.

[rjkoop]

Why do you want to unplug everything on the engine when you need just the transmission? No benefit except for the 2 upper bolts. You can reach them from under with universal joint and about 2 foot extension. Just unbolt the driveshaft at the donut and move it away. Remove the 3 bolts under the shifter and the nut under the cap. You can now remove the shifter from the top. Remove the 2 or 3 bolts of the starter. Remove the 4 bolts from the engine and you pull it back. Remember to unplug the battery and clutch cable.

Doesn't sound too bad. And I did just rebuild the top end of the engine and it's working well. Don't want to muddle with that. Thanks for the words of wisdom.

Richard

[Nanonevol]

Don't forget to take this off (between trans and motor lower) like I did and couldn't figure out why the trans would not back off the motor!

Follow my rebuild here:
http://www.fiatspider.com/f15/viewtopic ... 13&t=29245

[rjkoop]

Don't forget to take this off (between trans and motor lower) like I did and couldn't figure out why the trans would not back off the motor!

Follow my rebuild here:
http://www.fiatspider.com/f15/viewtopic ... 13&t=29245

Hehe! Great picture. Yep, I've noticed that piece before. Any words of wisdom on the rebuild? Hopefully I won't get over my head on this one. I guess there are a few specialty tools you need for this job.

I hate the fact that you have to be 100% perfect and can't really see if it works until it's installed and drive it though the gears. I'm pretty methodical so hopefully that will be to my advantage on this one.

Richard

[ORFORD2004]

I did mine with no special tool. I bought a bearing kit on ebay and all synchro from one of the vendor.

[Nanonevol]

The rebuild part was actually kind of fun. The taking out and putting back in not so much. It has to go in and come out at an angle. Going in I angled the shift knob end up into the car first and then brought the bellhouse end up. Then it can be a bit of a trick to pull it forward lined up just right. I used two jacks and levers and straps and such to position.
I don't think you need to do the rebuild 100% perfect but yeah, I had some anxiety that it wouldn't work and I'd be doing it over. Didn't happen! Whew!

[DieselSpider]

I you replace the clutch while your at it be sure to be fussy about aligning it with the tool provided and use the correct grease on the pilot bearing.

Sometimes gear grinding is from issues with the pilot bearing/bushing which is discussed in the following WIKI:
http://www.crankshaftcoalition.com/wiki ... d_bushings

[rjkoop]

Weather is getting about 0 degrees C so going to tackle a few jobs before the Spring driving begins. So 1st up I'm going to remove the transmission and replace the 1st to 2nd synchro ring and any other worn parts I see.

Going to try to take pictures and hopefully I'll video the entire process to help others to know what to do... or what not to do (!)... if they want to tackle the job.

Richard

[rug]

Weather is getting about 0 degrees C so going to tackle a few jobs before the Spring driving begins. So 1st up I'm going to remove the transmission and replace the 1st to 2nd synchro ring and any other worn parts I see.

Going to try to take pictures and hopefully I'll video the entire process to help others to know what to do... or what not to do (!)... if they want to tackle the job.

I'd love to se how easy or hard this is to do by yourself! I will problably need to replace the 2nd gear syncro soon and possibly also the input shaft bearing.

/C

[Nanonevol]

If you're just an average backyard mechanic like me, it's fairly challenging. But it is rewarding and no real special tools needed.
There are some videos out there on You Tube.

[rjkoop]

If you're just an average backyard mechanic like me, it's fairly challenging. But it is rewarding and no real special tools needed.
There are some videos out there on You Tube.

I think I'm up for the challenge!

Started today. Removed the speedo cable and reverse indicator. Got all the bolts loosened up on the bell housing and starter from underneath. As expected the driver's top bell housing bolt was the worst but only took about 20 mins and lots of extensions! No rounded/stripped/broken bolts which is what my big worry always is when doing a job on the car for the 1st time.

Tomorrow I'll remove the guibo (spelling?) driveshaft connection and I'll support the transmission with a low profile jack, remove all the bolts (including starter), support bracket and then hope I can move it back from the engine without too much prying. And hope I'll have room under the car to move it back and lower it enough to get it out.

And yep, I've watched the videos. They're quite useful for sure. I think the one special tool I'll need is the one to remove the bearing from the shafts. At least that's what he used in the video.

Richard

[ORFORD2004]

I think the one special tool I'll need is the one to remove the bearing from the shafts. At least that's what he used in the video.

You can do the grease trick

[MattiR]

Hi Richard,

I took it as a challenge as well to renew all bearings and gaskets due to grinding noise. With Shop manual it is not so difficult. Some tricks needed to remove and install the two spring washers.
I had to tilt the gearbox heavily in order to get it out. Bellhousing is touching the car body, and not possible to pull straight backwards. I replaced clutch and the bearing in crankshaft as well, and the flywheel was lightened a bit.
Now I am installing the gearbox back, but looks like I did not align the clutch carefully, so need to wiggle the gearbox away again. And I do it all on garage floor without a lift. Great fun though!!

Good luck with your efforts!!

[rjkoop]

I think the one special tool I'll need is the one to remove the bearing from the shafts. At least that's what he used in the video.

You can do the grease trick

Tell me more... What is this great trick you speak of???

Richard