My Tranny Teardown

[sleepydsm]

Tonight I finally took up the task of tearing down my broken 1992 AWD manual tranny. As some of you may recall, the tranny seemed to lock up, i couldnt go into gear, the clutch disk was destroyed.
I have to say tearing down the tranny was extremely easy. The only challanges I came across was getting my viscous coupler off (it was on there really good), getting the 3-4shift fork/input shaft off, and the center diff took a little bit of effort.
So what happened with my tranny? A very small pin that holds a shaft in my front differential broke, which cause that shaft to drop down enough to let the broken pin out. That pin got caught in the front diff's gear teeth which then put a small crack in the case. That crack let all the fluid go, which cause the tranny (I assume the bearing) to overheat and seize up. That then cause the center shaft (with a big nut, next to the VC) to have the end gear right where the nut threads on twist off. All because of a little pin breaking.
Once I saw the shims, I visually understood them. Also, everthing in the tranny looked great! Aside from one fucked bearing and a magnut covered in gobs of metal mush, and mushy deposits of metal all around the case. I also seem to be missing one of the two oil guides.
I had a blast tearing it apart!

This actually looks repairable...

-Kevin Swalchick

[1slowdsm]

I've been waiting to tear my broken tranny apart for about 1/2 year now, but I dont have the right tools for the job. Gotta Vfaq it someday and take it apart. Would Shep take a broken tranny as a core that has been taken apart and put back together, but still broken?
How long did it take u to take the tranny apart? It really does seem kinda fun taking it apart, but I've never done it so I'm only imagining it...haha

[blageo23]

It took us about 3 hours(Taking our sweet ass time). Special tools-Gear puller. Thats all you need. I was really fun even watching him take it apart. Got to see how stuff worked a little better.

[GVR-4579]

Be sure to get the screen that mitsu intentionally left out. its supposed to increase tranny life alot and it is really easy and cheap to put in. I dont think they put it in till the 2g's

[sleepydsm]

Where would that go in the tranny? Im sure if I had one I could figure it out?

[GVR-4579]

It goes on 5 studs/cast nubs that are set into the tranny already, i think it goes on the "middle" piece but i dont remember for sure. It is somewhere in the larger part of the case tho more near the bell housing end.

http://www.teamrip.com/TRE%20AWD%20REBUILD%20SERVICES.html

if you look at the picture next to where it says team rip engineering on the right, its the bottom right part in the picture. It comes on 96 and newer transmissions but will go stright into all other transmissions the mounting studs are already there

[joesushi]

I have two trannys that need to be torn down to get at seals. Where could i get a gear puller? also, the big nuts on the end of the gear shafts(lol) have had a section kind of crimped so it wouldnt loosen up. Do i replace these with new nuts or reuse the old ones when putting the trannys back together?

[1slowdsm]

Hmm...where would I get this Gear Puller? I might do take mine apart this summer...it sounds simple enough, right? Man, just looking at those prices for those trannies make me wanna cry. I wish I could afford one right now...heh heh.

[sleepydsm]

You can get a gear puller almost anywhere tools are sold.

You can just impact those big nuts right off, they're 36mm. You should replace them when reassembling.

[sleepydsm]

Luckily for me I work at a shop so I have access to really nice tools, and pretty much any tool I'd ever need.