Possible Dead Tranny.

[numlock666]

I'm posting this for a friend with a 90'AWD. Here's the scenario, I had a clue his Tranny was going out soon so we started shopping around for a new one. Today he calls me at 10a.m. saying its making a "weird" noise, not being very descriptive thats all he told me, so I say park it and I'll be out there to check it out. Long story short he didn't listen and kept driving.

Heres what I see, I took the the linkage off of the tranny to be sure it wasn't a linkage/shifter issue and tried shifting manually at the selectors. It was very hard to get it to pop out of 3rd but when I got it to, the car still wouln't budge (us pushing it, well at least trying to). Another thing to note is that I started the car with the clutch in, gave it gas up to 4K and slowly let out the clutch and it just stalled out the car. So this is a really big paper weight.

Its been eliminated that its not a Clutch/engagement/disengagement issue. Not a likake/shifter related issue. The car wont go in any gear other than 3rd with the car off.

My guess is that the 1st-2nd slider hub broke and a peice is jammed in 3rd gear (why the car is a mean paperweight). Can enyone chime in on this specificaly JacksTransmission. We are probably going to get another beater tranny and I'm tearing this one down for my first Tranny rebuild.

Pretty experienced with Engine builds but never worked up the guts to take apart a tranny. It's going to be a good learning expereince.

 

[twicks69]

1st thing, 90's are different than 91-92 trannies for shafts, gears, etc.

More than likely, you are looking at much more than just a 1/2 hub/slider issue. It sounds more like a failure of the intermediate shaft tapered roller bearings, which then hand grenaded the trans.

I wouldn't expect ANYTHING to be reusable. Take it apart, and take pictures of the carnage.

You will want some prybars, flathead screwdrivers, an impact with a 36mm socket (end shaft nuts), a punch set to remove the roll pins, and to straighten out the end shaft nut punchouts before spinning them off the end shaft, 10, 12, 14, 17, 22 and 24mm sockets, a pen magnet, some picks, snap ring pliers, brake clean, shop towels, etc.

Here is a good FAQ writeup on dissassembly/rebuild of a 1G transmission for help:
http://www.vfaq.com/mods/Trannyrebuild.html


I would reccomend finding a late 1991/1992 AWD transmission to either replace the broken one, or to use as a core for rebuilding.

The center differential, intermediate shaft, and 3rd/4th gears are different along with 5th gear assembly, 5/R fork, and the trans end cover.

 

[numlock666]

Had a hunch the 92-94 trannies were different, but as far as bolt-on goes? Will it work. I had thought the spline count on the axles/input shaft/transfercase or something was different? Is it. If not then thats what we'll do, just get another and call it a day, take our time rebuilding this one and save it for a rainy day. Also would like to learn about it because I have plans for an AWD conversion on my 95' and would like to build the tranny before putting it in. His tranny is just going to be a expendable test subject, if it works, sweet, if not I learned a bit. Win-win

EDIT*
Just did some more research, turns out the transfercase input shaft is different but interchangable so it wont be too bad.

 

[twicks69]

Had a hunch the 92-94 trannies were different, but as far as bolt-on goes? Will it work. I had thought the spline count on the axles/input shaft/transfercase or something was different? Is it. If not then thats what we'll do, just get another and call it a day, take our time rebuilding this one and save it for a rainy day. Also would like to learn about it because I have plans for an AWD conversion on my 95' and would like to build the tranny before putting it in. His tranny is just going to be a expendable test subject, if it works, sweet, if not I learned a bit. Win-win

EDIT*
Just did some more research, turns out the transfercase input shaft is different but interchangable so it wont be too bad.

That isn't a problem, it is actually referred to as a transmission output shaft though.

In circumstances where you would do the output shaft swap on the car, these directions would be the ones to follow without the removal of the transmission:

All you need to do is disconnect the snapring and pull off the viscous coupler; then, catch the little detention ball on the shaft and be sure to replace it when putting it back together; there is a keyed spline on the viscous coupler that lines up with this detent ball when reinstalling it. Be sure to either get a new snapring from Mitsu, or Shep (John), or TRE Trans (Jon), or JacksTrans if yours reinstalls loose. You take your chances by using a pliers to bend it back into shape if you were rough with it taking it off. If that snapring doesn't go back on tight, it can go bye bye WITH your viscous coupler through the transmission case; or toss the output shaft through the transfer case -- FUN!

Then, just remove the transfer case, pry it off, then slide out the output shaft. Now take the other output shaft and slide it back into the transmission--it should be very easy to do. Then reconnect the transfer case, and reinstall the detent ball, viscous coupler, snapring, and end cover, then refill with gear oil.

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In your case, drain the tranny, and pull it out. You can have some fun dissassembling it, and keeping the output shaft for the replacement transmission.

 

[numlock666]

Thanks for the info, I'll be posting with how it goes and what actually went wrong. Bets anyone?

 

[twicks69]

betting on intermediate shaft tapered roller bearing failure, then total hand grenade of the trans.

 

[numlock666]

told him to remove the small stuff, tranfercase, and get it up on jackstands. Will be pulling it this weekend. We'll see how it goes.