Very good information. I don't know if I have the guts to try this.

 

np dudes! the fsm is a very good tool. the 5 speed is a very simple machine to work on man lol.

I called up jack's today in hopes someone could answer my question about the shim but they never called back. I'm thinking of just keeping it the way it is. there isn't any play at all and that's all I'm worried about.

 

Another update!

 

Great news!

Got any tips on how to remove the trans/transfer case assembly??? That's what I'd like to know!

 

I followed this exactly, just so I didn't miss anything.

http://www.evomoto.com/tech_articles..._article_id=27

I purchased a box of zip lock bags, and every time I came to a part to remove, I threw the bolts and nuts and what not in the bag and labeled it. It made my job of putting the car back together much easier because I knew what went where!

 

nice write up man

 

Final update!

 

I give it 5k miles before it needs another rebuild. Lots of members have rebuilt their own transmissions with bad results, very few have had good ones.

Whats your experience with building transmissions?

 

None. First time. I followed the fsm, along with help from shops, and members. I'll let you know in 5k miles. I'm at 1k.

 

Btw I only replaced the input shaft bearing, nothing else. That's a very simple job. Either way, see you in 4k miles!

 

had the same damn problem with my '03 gsr. blew the input shaft bearing after a rough launch with my exedy twin. Ended up having to do pretty much this exact same thing. Wish this thread would have been around then! This is great info for anyone rebuilding a tranny.

 

New update!!! Over 5k later.

 

Thought I would revive this thread and update that it has now been 17k miles since this and I can safely say it works fine !

 

You have any pictures of the sliders and synchro gear wear. I just wonder how it compares, my 3/4 looked like this and it was shifting pretty poorly at high rpms.





Then heres a few pictures of my disassembly and reassembly process

 

i just read this, did he not preload the output shaft with shims? output shaft and Center diff are preloaded with shims you have to use solder and crush it measure it and use the right shim for the preload, the input shaft has end play. i also drilled a couple holes in my shafts for extra oiling to a couple bearings.

Take a look at my thread about transmission rebuild, you can see what worn parts look like.


Standard value:
Input shaft end play: 0.05 − 0.17 mm (0.0020 − 0.0067 inch)
Output shaft preload: 0.13 − 0.18 mm (0.0051 − 0.0071 inch)
Center differential case preload: 0.05 − 0.11 mm (0.0020 − 0.0043 inch)