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Well, a few days ago one of the parts of my car wore out. It's got 213k miles on it (at least, odo went bad at 204+). I've done lots of work on the car since I got it two years ago and I guess if it had to be something, this isn't the worst thing that could have happened.

Generally when I have had transmission problems in the past with cars I'd take it to a specialist. There's a local guy I trust and whenever I see a diagram of a transmission it just looks like a swiss watch with all those gears and stuff, so I've been intimidated to try anything in there.

With this car I promised myself I'd do all the work on it (since it was purchased as a project anyway) and I've learned to do lots of new stuff from clutch replacement to carpeting to some electrical things to seat re-upholstery and all have been interesting and fun to do (more or less ).

So now down to the work at hand: The other day the stick in my car didn't give me any resistance when I tried to go into the 1-r shift plane. It had previously been really weak when returning from 4-5 to 2-3, so I think it was wearing out and it finally went. There is also a leaf-type spring that I've read usually wears out for the reverse lock-out function as well, so I plan to replace both of these items.

I've had no shifting issues so I don't plan to reinvent the wheel and although some would say it's foolish with this many miles, I don't plan to buy a rebuilt or even rebuild it all myself.

So my notes will be here as I work through it, please feel free to comment if or offer up advice or assistance.

Here's an annotated and slightly cleaned up diagram from the WSM.

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Trans removal, start of disassembly

Posted 11-04-2008 at 01:13 PM by Mike Frye
Well in the past few days I got some help from Adam who came down to get me past my nervousness and just pull the damned thing!

We got the cross member dropped and everything seemed clear except the bolt on the collar between the drive shaft (high speed shaft?) and the transmission. The bolt wouldn't drop out because it was hitting the rear edge of the TT. We also couldn't get any play on the trans moving back.

It turned out that a) There are 6, not four 17mm bolts holding the rear of the TT on the trans and b) the bolt will just fall out when you start to ease the trans back.

Click the image to open in full size.

After posting on here a couple of times, I got up the courage to just walk the trans back (really pry it back) the bolt fell out and before the trans got to the end of the tunnel, the drive shaft dropped out of the end of the spline on the trans and it was free.

After a few anxious moments of steadying the trans on the jack (with some plywood on it to level out the high spots) I was able to lower it down.

I didn't have to support the TT, it just stayed there an inch above the TT support bracket by the cats. I also didn't have to turn the tranny at all, it just came straight back until it cleared the shaft.

The first thing I found when I opened the cover was this:
Click the image to open in full size.

This is the reverse lockout mechanism and the little C-shaped piece is supposed to be in that groove. If it's bent I'll have to get a new one. I have the spring for under it, but the lockout piece itself is stuck there right now.

Here's what it's supposed to look like (thanks Errka):
Click the image to open in full size.

Anyway, I'm moving forward with the disassembly and hopefully over this weekend I'll have it all on the bench and I'll know what parts I'm going to replace.

I hope I remember where everything goes...
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