Please help ASAP!!! [home gearbox "repair"]

[1fast97gsx]

As you may or may not have heard I had my trans rebuilt and the guy did a shitty job siliconing it so it was leaking out of the casing. He offered to fix it but said it would take a while because he'd be working on it "whenever he can get to it" ... so I decided to do it myself. I rebuilt my own motor and helped with others, but I've never took apart a trans. I didn't think it could be too difficult though.

Anyways, I got it all apart and all the cases seperated. I put it all back together in reverse order ( I think I did it right ) ... but it's VERY hard to move the gear selectors into 5th and reverse. Since 5th gear was the gear I totally pulled off maybe I did something wrong when putting it back on? And also when in neutral ... isn't the input shaft supposed to spin freely with fairly little force? I tried to spin it clockwise and I was turning pretty hard and it just wouldn't turn. Did I somehow lock up something inside the trans to cause this problem with 5th and Reverse and to keep it from spinning freely in neutral. Does anyone have a picture of all the parts and how they are assembled inside the trans so I can compare and double check everything? What should I look for that would cause these problems? Please help me I want to drive my car again!!!! Thanks.

 

[1fast97gsx]

Ok does anyone just know if the input shaft is supposed to spin freely if the trans is in the neutral position ... IMO it should, but mine doesn't do that at all so something has to be locked inside the trans right?

 

[crashed97tsi]

ok I just installed a m lsd insert. It was my first time also takng apart a trans. The gears are a little rough, but they don't usually have a prblem gonig in. If I remember correctly, all three shafts spun when the tranny was in neutral. As far as what could be wrong, make sure you got all the races and shims on correctly, the bearings etc. It really wasn't that hard. Good luck man

 

[1fast97gsx]

Do you have a link for a diagram of everything or pictures of how it all goes together? I'm 99% sure I did it right ... but obviously not .

 

[crashed97tsi]

sorry man, best I can offer is you describe to me what your unsure abot and I'll look in my shop manual and try to help you out. I noticed that everything shifts easier when you put all the casings back on, if that helps at all

 

[1fast97gsx]

yea that's the wierd part ... I took the end case/ cover off again and it shifts better now and the input shaft spins fine in neutral..... maybe 5th gears aren't pressed down far enough? Can you get a diagram of the manual online so I can make sure I have everything in the right order? I tried searching but couldn't find anything anywhere. Thanks.

 

[dsmcrazyspiff]

i can tell u exactly what it is. on the end cover there is a spring that clips in if it is not in the right spot u will have the prob u are having, there are two hook type things on the spring they must go into the recessed part of the cover u will be able to see it
good luck

 

[crashed97tsi]

yeah thats the wave spring, it goes on the reverse cone or some shit. The black thing that is on the outer cover. SOrry man, no go on getting anything online. I don't have a scanner. Just out of curiosity, how are you tightening down the bolts? I don't think it would be a smart idea to just wing it on the tranny torque specs.

 

[1fast97gsx]

ok I'm thinking too that is has to be that wave spring ... I'm going to take it apart again tonight and take a look at it. The 2 big nuts at the top of the trans are supposed to be around 105 ft lbs right? I never actually pulled that wave spring off but maybe somehow it got shifted or something I'm guessing. Also .. I hear the viscous coupling is supposed to come off really easily. I can't get mine off without a puller. Thoughts on that?

 

[dsmcrazyspiff]

you are very lucky if u can get the vc off without a puller of prying on it
dont worry it is very common for it to be hard to take off. if someone dosnt believe me call john shepheard