Transmission Rebuild Questions

[Hu Ryde]

I have a 5-speed that first gear pops out no matter what I do. I'm guessing it's shift fork or intermediate shaft bearing. I have bought several new parts: evo 1-2 fork, steel shift rails, bearing kit, TRE spool, clutch fork/pivot ball, has new clutch/flywheel. Is there anything else aside from synchros I should look into replacing?

What are the part numbers for individual synchros for the dealer? I called and all they wanted to sell was the complete kit. $200+ no thanks.


DIY Trans info:
Various Rebuild Resources:

http://www.twingles.com/ideck/rebuild3/dretranny.htm

http://www.galantvr4.org/rhertz/Man...epairSchool.ZIP

Various Parts Sources:

Master Rebuild / Synchro / Bearings
http://www.drivetrain.com/mitsubishikm4_5spFWD.html

Hard Parts / Rebuilt Trans
http://www.teamrip.com/awd.html

Bearings
http://www.rsgear.com/BrgKit02.pdf

Misc Parts / Forks / Seals
http://www.diamondstarmotorsport.co...lineparts.shtml

Are there any sources for modding the transmission while it's apart to help extend it's life or strengthen it? Grind stress points, etc.. It would be great to see this available online.

Please don't tell me to take it somewhere to get it rebuilt. I want to do it myself. I have built several GM automatic transmissions and feel comfortable with the challenge.

 

[Rx3]

I think you should stop guessing and take the tranny apart first to find out exactly what is wrong. No sense buying parts only to find out that they won't fix the problem, or weren't broken in the first place.


Since you are doing it yourself (for the first time?) , once you get it apart and identify what is wrong, then you can assess what to replace, and if you are up to it, what to modify or strengthen. Taking it apart first will give you a good barometer on how difficult (or not) certain things may be to replace.

 

[Hu Ryde]

I agree with what your saying but I am going for minimal downtime. Since the car is still driveable (just no first) I don't want to start taking it apart. I'm 99% certain it's the shift fork considering everything else is fine.

The reason I'm getting parts ahead of time is because most of the stuff is an online order from TRE or other sources.

This would be my first DSM trans rebuild, I have done several auto SyTy transmissions. This should be cake.

 

[Whitetal]

I had a tranny that wouldn't let me shift into fidth. I found out it was the shift fork. It was worn out. The metal was worn away like some millimeters so it would not shift the selector all the way into fidth and when the gear spun, the dog teeth would just knock the selector back.