I went to Lowe's, found the pipe hangers, and picked one that was about 2" round. Then I went to the threaded rod of the hardware section, and bought a couple pieces of the size that fit the hangers. Then I set it up like in the picture.

"JD to Rescue" helped with some great tips, including one I just learned today: when removing bearings from the gearbox, you can carefully take 2 pry bars (one in each slot where the puller jaws fit) and lift the bearing straight out. I wish I had thought of that, and will do it next time!!

Dave

 

Thanks for the tips. The "JD to Rescue" worked easily on the counter bearing. I got the rear main bearing off with a heavier 3 jaw puller the I found in the garage and good size breaker bar to turn it. Finally down to the broken 5th synchro and waiting for the parts.

Did your 5th gear show any wear on the part that lines up with the synchro? Mine shows a little on the points that match the ones on the synchro. Hope I don't have to replace the 5th for this.

Tom

 

My 5th gear looked good. However, my 5th clutch sleeve did not - all the teeth were slightly deformed so that they had a sharp edge. If your 5th gear clutch teeth are damaged, the sleeve is what caused it.

Dave

 

You are right about the 5th clutch sleeve. The teeth are fairly worn and having it apart I can see why. That will get replaced too. The real question that remains is how much wear/damage is ok on the 5th gear. I assume the damage was caused by the crunching when the synchro was broken. With a good synchro will that be protected or continue to wear or cause problems. I will replace 5th gear if necessary, but don't want to spend the $ if I don't have to. (I have the feeling I am grasping at straws here)

Tom

 

I dunno without seeing it. Got a digital camera? Are the clutch keys or 5/R hub damaged at all?

Maybe take it to a tranny shop and ask for their advice. The few transmission shops I have talked to were very open and friendly.

FWIW, I also updated the Disassembly document for anyone who wants the latest version.

 

Clutch keys are fine. 5/R hub shows no damage and almost no wear. It was replaced previously by Mazda around 25K ago when they did the 5th synchro for the PO. I studied the clutch teeth more and talked to some others with a lot more trans experience than I. On their advice I went ahead and ordered the 5th gear. I would rather spend the $170(!!) at Malloy then have to pull the tranny again. The tranny (w/60K) has been shifting perfectly other than 5th so I feel OK about fixing it right for now. I will catch the rest when I do the full rebuild sometime down the road.

 

Great write up.

 

I just wanted to thank you again. I did the 5th synchro and also the 5th/rev. chutch sleeve and 5th gear using your writeup and the FSM. Your writeup and pics were a great help and now the car shifts smoothly and quietly in all gears. Your posts are a real asset to the FD community.

Tom

 

as anybody found a technique where i can re use the 41mm lock nut other than buying the $95 tool or destroying the lock nut?, i tried a pipe wrench but its not going too well

 

scratch that, does anybody know how to get the dynamic balancer off of the input shaft?

 

What do you mean by removing the dynamic balancer from the input shaft? The input shaft is part of the transmission. Do you mean the counterweight on the back of the flywheel?

I would not reuse that locknut. I suppose if you could cut away the originally staked area you might manage to use it again and stake a different part of the nut collar, but that's asking for trouble.

David

 

Reviving an old thread but I'd love to have the link live again so we can access that rebuild writeup. Any chance on that Dave?

 

There seems to be working PDFs in the Internet Archive:
https://web.archive.org/web/20050908...esaman.com:80/


Maybe someone should host it elsewhere?

 

7Suns,

Thanks for finding David's write-up / how-to on the internet archive!

Cheers,
George

 

No prob, yw.

I really think users should be more familiar with the internet archive/wayback machine.
Considering how old posts on a forum like this can be, it's not too uncommon for pictures and links to go dead.

 

I'm attaching an excel spreadsheet I was able to make from dgeeseman's profoundly helpful PDF parts cross-reference. (Really, IMO that cross-reference document is one of the most useful and significant contributions available here - he put an amazing amount of effort into collating it all).

Some notes on this Excel version:
- It allows for re-ordering of the parts by assembly or disassembly FSM page and reference.
- Since it is editable, one can enter specific details for a particular transmission, so there is an easy way to make a record of what ended up getting replaced
- I've included some extra information about an aftermarket bearing kit (google "BK199 transmission") that is available for most of the big bearings (although I don't really recommend buying it).
- I also fixed some minor errors, and added extra comments and annotations here and there. I didn't make any effort to distinguish between text I added and dgeeseman's original, so if there is a mistake somewhere just assume it came from me.

 

Nice! Glad you have it up here for posterity!

The 5th gear job isn't super tricky but it IS scary doing it the first time.

Dale

 

http://www.billsdiscountgarage.com/f...isassembly.PDF
http://www.billsdiscountgarage.com/f...ionandMisc.PDF
http://www.billsdiscountgarage.com/f...Reassembly.PDF
http://www.billsdiscountgarage.com/f...sReference.PDF
http://www.billsdiscountgarage.com/f...Reference.xlsx

put that excel file up there too for safe keeping, this domain should be around for 500 years.

 

Uploading the files to a google drive folder for posterity
https://drive.google.com/drive/folde...k1?usp=sharing