I'll have a race report later, but this weekend would have been a lot more enjoyable if I weren't having serious issues with 3rd gear, so I think it's time to look at rebuilding my own transmission. I've got the FSM, but any guides/gotchas/etc?

PaulC

 

If its like a 1st gen (which I believe it is). Youll need one hell of a gear puller and socket. You have to use a long puller (like 2ft) to pull one of teh gears off the mainshaft, and before that you need a really deep socket (like 2ft long) to remove the nut first. I made my socket by halving a socket and welding the ends onto a pipe to lenghten it. And I used barstock steel to extend the jaws of my gear puller to reach the gear. Look in the FSM and youll see pics of these special tools.

 

FD tranny is similar. Bar stock notched for the bearing pullers, and a good work area, because there are little ball bearing-like pieces that fall out that you have to be careful of.

I had the help of an experienced mechanic while rebuilding the 5th gear synchro of this tranny. The rest of the tranny is the same as 5/R, just deeper in the casing, and there are a few special procedures when you go down that low, IIRC, using shims or some shim kit...

Regards,
--Ashraf

 

Ive done lots of work to my FD tranny and making the bearing puller was the hardest part. I followed the shop manual and things went smooth. Also it really helped to use an impact wrench along with the modified bearing puller to get those bearings and gears off. Using that impact wrench the gears "jumped" right off.
mike