I just have a couple simple and not so simple questions when it comes to rebuilding 2nd gen s4 transmissions. I have a S4/na car with 220km's on the transmission and i am wonder what it takes to rebuild one of these things. I am no newbiw when it comes to mechanics as i am allready on my 3rd succesful rotary engine rbuild and multitudes of piston engine rebuilds *most of which were bike engines. * I have a full shop and real FSM, Now for the questions... When you rebuild a transmission what all do you replace, ie will i need syncros, bearing and seals and everything but the layshfats and actual main gears? Or can i get away with replacing just what need to be replaced... The Transmission is still working quite fine now but i would like to keep it that way and now that the car is getting ragged on more now that its not owned by a 65 year old man i would like to have some reliability to the car this including the transmission.
Are there any special tools or procedures i should need or be warned of before i pull this thing apart or is it fairly straight forward like the rebuilding of a rotary engine? .... Maybe its just me but the idea of whats inside the transmissions really makes me cringe at the thought of trying to rebuild one properly and haveing the right tools to spec and check specs.

Well thank you for anyone who can shed some light on this subject for me.

Keith

 

I don't know how much input you're going to get in the 2nd gen forum. People tend to just drive their car until the tranny breaks/grinds too much and then buy a used tranny that's in decent shape.

 

you'll need a press to install the bearings.
and i think the rebuild would be fine with a new 2nd and 3rd syncro, front and rear bearings, and new seals.
that is exactly the rebuld thats going on the tranny that came out of my car. the front u joint broke and the shaft hit the tail housing and broke it. so, were going to replace that with one from a tranny that had a gear explode. then do the above rebuild.

 

how much is the tranny rebuild? vs another tranny offa somebody else?(i have an 88T2)

 

Yes, you do need a special puller for the rear main bearing if I remember right. I did mine in my 88 gxl. In addition to the main bearings and seals, I strongly recommend the needle bearings that link the input shaft to the main shaft. When I pulled mine apart, I noticed considerable flex there. I had trouble going from second to third (grind, hard resistance). I did not replace my synchros as the ones in there look nearly new.---this car has been babied by previous owners. I strongly recommend getting the Haynes AND the FSM. There are minor details that aren't shown in one, they are shown in the other. I also got the shift rods reversed initially when I was putting it back together, and the FSM turned out to be the true road map to this one.
As a suggestion, I filled mine back up with NEO, at the recommendation of a shop up in Canada. I'll never go back!!!! SMOOTH------

Good Luck, I think I invested around 350-400 for the repair cost in bearings and seals

 

Good to hear some of the replies, i have multiple trannies to play with and i know it may sound dumb to rebuild oneif i have more then one but theres something nice about haveing somthing you built and you know what went into it, giving it a little bit of self gaurentee. I have multiple pullers and and custom tools from past projects and making tools does not bother me. Does anyone know where i could buy a general rebuild kit, ie all the seals gaskets and bearing that get replaced in any rebuild? i have always found buying a kit like this saves some money usually and makes life so much easier as you dont haveto go order every single little thing.

Thanks for the information, anymore will still help!

Keith

 

To my knowledge, I don't think there is a general rebuild "kit" for a tranny. YAH, it sucks, but I had to piece mine together between R/B and OEM Mazda parts. Don't forget new pilot bearings and seal too, you'll need a slide hammer to extract the old one, I found one with inside diameter expandable jaws--worked great. I think I gave 40 for it. And perhaps a new throw out brg too, just in case the clutch is ok.

Good Luck,

I might add, if you have a digital camera, take pics from right after you pull tail shaft housing, until all apart. especially the proper setup on the shifter rods. Then, if there is any confusion about what went where, viola', pics lay out the road map to re-assembly.

 

The FSM gives a decent how to on rebuilding, along with the special tools needed. The special tools are what have kept me from attemting this, that and the 5 spare trannies in the basement.

Only problem was, last summer I changed the tranny 3 times until I found one I was happy with.

Honestly, if your present tranny is in good shape, leave it alone. The 2nd gear synchros seem to be what usually goes first, that and the input shaft bearing. Not slamming 2nd gear and making sure your pilot bearing is good will usually increase the longevity of the tranny.

 

where did u get ur rebuild kits/parts from?

 

I had my transmission rebuilt a few years ago at a cost of $600 Canadian. It was rebuilt because it ran dry of oil. They replaced the bearings, input shaft and cluster shaft as well as the seals.