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Author Topic: Car transmission rebuild.  (Read 10686 times)

Offline dawesy

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Car transmission rebuild.
« on: March 30, 2015, 04:03:11 PM »
Thought I'd share the rebuild I've just done on my MR2
Enjoyed doing this. Can't wait to put it in and put it to use.
It came out of the car looking like this

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/51021CBE-FD97-4557-8091-36DA95C3F89F_zpspuluq4ol.jpgCar transmission rebuild.
 :no:

The casing was stripped down and sent for Vapour blasting and came back looking like this

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/5E42E878-6AC9-43D2-A7E8-7071BBC2B35B_zpsambxuk3q.jpgCar transmission rebuild.

I also sent the bolts and brackets to a local platers and had them Re-gold passivated

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/4B754770-9275-4832-AB05-7EA4968D58AC_zpsycr3ibwk.jpgCar transmission rebuild.

Looking at some of the bearings, I wasn't happy with them. They were smooth enough but pitting was evident. I priced up the Two taper bearings on the output shaft and the roller on the input shaft and it came to over £500! :shocked:
A friend at work put me onto Cobra Transmissions in the States who do complete rebuild kits or bearing and seal kits. As I'd already Bought a new first gear synchro (the old one had cracked leading to the crunchy first) I went with the bearing and seal kit, This comprises both Diff bearings, Both output shaft bearings and both input shaft bearings, Plus Driveshaft, Input shaft and selector seals. Came in at just under £500 incl shipping.

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/BF0C8043-92CC-46C5-B4F0-6C18A93ABD2E_zpsispit4e5.jpgCar transmission rebuild.

Assembly was started after everything was stripped and cleaned.

(Output shaft)
http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/1D1AD5E8-1F9C-4DB8-8B20-83736826C3FA_zpsmfy2wevo.jpgCar transmission rebuild.

(New outer races installed)
http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/9F989AE5-F45F-47A3-A3CD-0671F1A811A0_zpspz4zg50x.jpgCar transmission rebuild.

Then all Bearing preloads checked and found to be well within tolerance

(Shafts and selectors installed)
http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/BA41F8F2-04E4-46BD-932F-ACEA36706506_zps9uc4nifl.jpgCar transmission rebuild.

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/98D45CDF-9D79-49FB-B7B0-8C911295F695_zpsyim4oihq.jpgCar transmission rebuild.

Correct Threebond sealant used
http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/BE0BE804-B9E6-4B9D-B766-D38785008ED0_zpsmiyomxzn.jpgCar transmission rebuild.

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/07FCD04C-B3F2-4600-8F19-9346B10E4D22_zpshabeosh1.jpgCar transmission rebuild.

Re-assembling the 5th gear syncro lead to this
http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/ACD67244-CD83-4412-9F93-DCE4DA977656_zpsqjvhzyb5.jpgCar transmission rebuild.
Its a complete PITA to get together, However I won!!

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/A348F12D-0991-4551-A8B7-26F7285B58AE_zpsqsglngkt.jpgCar transmission rebuild.

And that was that. Some final shots all back together. I'm just waiting for the bellows on the selector to come as mine were shot.

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/3F9D87DC-572E-4DE9-B53F-84E6D9033711_zpsvm8lphfb.jpgCar transmission rebuild.

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/8DA1372C-FCA6-41D3-8579-1E12145D8D2D_zps6fwhtcxu.jpgCar transmission rebuild.

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/05F5F790-1ADE-4E1D-8EA8-C75210634091_zpsapgqjtga.jpgCar transmission rebuild.

http://i80.photobucket.com/albums/j183/dawesy_2006/E153%20rebuild/0593EF1D-D410-4BD8-906A-9D3C4F83C09B_zpskl3ublqt.jpgCar transmission rebuild.

Thanks for looking. [emoji4]
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Lee.
wishing my workshop was larger :(

Offline John Rudd

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Re: Car transmission rebuild.
« Reply #1 on: March 30, 2015, 04:18:20 PM »
Kewl.... :clap:

Stripped and rebuilt a few gearboxes in my time but not to the point of changing bearings.....Although I've changed syncro parts that were worn,replacing them from salvaged boxes.....
The old Borg Warner overdrive units were easy too.....
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Offline DavidA

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Re: Car transmission rebuild.
« Reply #2 on: March 30, 2015, 04:30:51 PM »
It's a long time since stripped and rebuilt a gear box. In fact,  since I stopped working on Fords.

Citroen, Peugeot and Renault just seem to keep on going.

Dave. :D
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Offline NormanV

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Re: Car transmission rebuild.
« Reply #3 on: March 30, 2015, 04:34:26 PM »
I had to rebuild the gearbox on my Landrover many years ago due to a broken layshaft. For the first few hours that I drove it after the rebuild I was delighted with the precise snappy gear changes but then it went back to its usual floppy self.
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Offline Arbalist

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Re: Car transmission rebuild.
« Reply #4 on: March 30, 2015, 05:34:20 PM »
Nice job. I can't believe the price of the bearings though, what are they made from Gold?!
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Offline Stilldrillin

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Re: Car transmission rebuild.
« Reply #5 on: March 30, 2015, 05:52:40 PM »
That's much too nice, to put under a car! 

Well done Lee!  :clap: :clap:

David D
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David.

Still drilling holes... Sometimes, in the right place!

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Offline dawesy

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Re: Car transmission rebuild.
« Reply #6 on: March 31, 2015, 03:30:39 AM »
Thanks guys.
Stripping it wasn't pleasant, there's something repugnant about old gear oil :D
Yeah I was shocked too. I tried a few bearing suppliers but met a dead end. I seems that these are specific to this gearbox. Simplybearings were told by Nachi the manufacturer that they couldn't supply them to them! Talk about a monopoly. 
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Lee.
wishing my workshop was larger :(

Offline Lykle

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Re: Car transmission rebuild.
« Reply #7 on: April 02, 2015, 02:09:14 AM »
This reminds me of the first time I did anything mechanical.
A friend gave me a cardboard box filled with the parts of a Mini gearbox.
Have a go, he said.

Took me a while, but eventually, it came together in working order. Or so I thought. I found one more part, a little pin, hiding in the box. Took it all apart,m put it back together again with pin. It worked.
Took me about a month, as I had never seen a gearbox, let alone the parts.

This job, is on a completely different level, great work!
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Lykle

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Offline vtsteam

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Re: Car transmission rebuild.
« Reply #8 on: April 02, 2015, 10:18:56 AM »
Very fine work, Dawesy! That thing is beautiful.  :clap: :clap:
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Offline dawesy

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Re: Car transmission rebuild.
« Reply #9 on: April 02, 2015, 10:42:51 PM »
Thank you.
I like puzzles. I once had to do a car for a friend who had taken it to a garage. They had stripped the top half off but for some reason (can't remember what now) they wouldn't carry on. So it came to me with half the engine in a box in the boot. Figured it out eventually [emoji4]
Try and get it fitted this weekend weather permitting. 
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Lee.
wishing my workshop was larger :(
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