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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.

Old

Conclusion

Posted 12-05-2008 at 01:27 PM by Mike Frye
Well, last week Adam G. came down and helped me put everything back together.
I ended up doing just the selector spring, the reverse lockout spring and the front seal (plus the mod to change the rear shift coupler from an allen-head set screw to a hex head screw.

The car runs and shifts perfectly, way better than it ever has.

I still have some other issues to deal with, but this one is solved.
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Diff removed. But wait, can't I just replace the spring?

Posted 11-09-2008 at 07:46 AM by Mike Frye
The other day I realized that the spring I need to replace can be done without completely disassembling the trans. It can be maneuvered out though a gap in the shafts so I didn't even need to remove the differential!

So I got that figured out and have been trying to work out solutions to two issues.

1. How to get the shift lever to return to the 2/3 plane when the 'old style' spring returns it to the 4/5 plane.
2. How to modify or strengthen this spring...
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Reverse lockout spring is replaced- diff cover off

Posted 11-05-2008 at 09:06 AM by Mike Frye
Well, I've got the diff opened up. I cleaned up the outside of the trans before draining it because I didn't want any of the crud from the outside to end up inside.

I guess the trans with the fluid weighs about 60 lbs or so. You can lift it by yourself, but don't plan on carrying it far!

I replaced the reverse lockout spring and put the cover back on to test it. To my layman's touch, it feels like that's the way it was before it went bad. It still rests between...
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Trans removal, start of disassembly

Posted 11-04-2008 at 02:13 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...
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post 2- continued

Posted 09-20-2008 at 07:42 AM by Mike Frye
I plan to replace the input bearing (not shown) as well as bearings #42 and #46 as well as everything marked marked 'gasket' (5) or 'seal' in this diagram (17, 19, 34, 49) or O-ring (31, 35) which I'm hoping are all part of the kit.

Once I get the part numbers for all of these I'll add them as well as pics as I work my way through.

Wish me luck!

BTW- I'm working from the 'Manual Transmissions for Eight Cylinder Model Series' training manual that came...
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