rebuild transmission

[jfindlay]

I have a 1988 GL series wagon, 4WD with a manual transmission which is
quite worn down. I want to take a few days and rebuild the
transmission myself.

What unforseen difficulties am I ignorant of? Can I buy a bearing
replacement kit at the local auto parts store? Will I be able to put
all the parts back together easily? Can I pull it off the block and
power train without special tools? Can I hold it up with one hand
while bolting it on with the other? Am I crazy to want to do this?


Justin

 

[mulder]

I have a 1988 GL series wagon, 4WD with a manual transmission which is
quite worn down. I want to take a few days and rebuild the
transmission myself.

What unforseen difficulties am I ignorant of? Can I buy a bearing
replacement kit at the local auto parts store? Will I be able to put
all the parts back together easily? Can I pull it off the block and
power train without special tools? Can I hold it up with one hand
while bolting it on with the other? Am I crazy to want to do this?


Justin

I don't know the particulars of that transmission, but in general to
disassemble and rebuild gearboxes successfully you need special tools
to get things apart and back together, as well as to set the critical
clearances. If you don't have these, and have never done this type of
job before, I'd highly suggest doing a lot of research before
proceeding. Depending on your budget, your best bet here may be to
find a good used trans from a junkyard or to have a qualified shop
rebuild yours.

 

[johninKY]

May be a good idea to experiment on a junkyard transmission first. Just a
feeling but I think without any experience or manual you are headed for
trouble. Sometimes what seems to be a worn out transmission is in fact
just the shifter in need of new bushings. This model also has a history
of loosing a spring in the shifter mechanism which causes the shifter to
flop around.

 

[Carl 1 Lucky Texan]

I have a 1988 GL series wagon, 4WD with a manual transmission which is
quite worn down. I want to take a few days and rebuild the
transmission myself.

What unforseen difficulties am I ignorant of? Can I buy a bearing
replacement kit at the local auto parts store? Will I be able to put
all the parts back together easily? Can I pull it off the block and
power train without special tools? Can I hold it up with one hand
while bolting it on with the other? Am I crazy to want to do this?


Justin

Ask in the proper forum at www.usmb.net . Likely someone there has
rebuilt the same tranny and may have suggestions.

Carl

 

[S]

Hi Justin!

Am I crazy to want to do this?

It's not a trivial undertaking. The easiest solution, as Mulder
suggests, would be to find a serviceable replacement at a salvage
yard.
If you do decide to attempt a DIY rebuild, you will want to find a
large clean table indoors somewhere to work on. Also find an exploded
view of the tranny; make several copies, and keep notes on 'em as you
disassemble.
Be absolutely sure you have removed all of the case bolts before
attempting to separate the cases; there is at least one hidden bolt
IIRC. Everything must be spotless before you begin reassembly, and
this alone can be a challenge unless you have access to a decent parts
cleaner. Probably the only "special" tool you will need will be a dial
indicator and magnetic base for it; anything beyond that is beyond the
scope of a DIY project, and best farmed out to a transmission shop;
this would include reworking the input/output shafts to replace the
synchros, and probably at least a couple of the bearings will require
a shop press and appropriate fixtures as well.

Unless you are pretty stout, you will want a transmission jack for
removal/re-installation. If you're working w/o benefit of a car hoist,
it's probably easier to pull the engine and transmission as a unit,
and separate them on the floor.

Do the clutch, pilot and throw out bearings, and rear main seal while
everything's apart, and it might even be worthwhile to replace any
questionable axle boots as well.

ByeBye! S.
Steve Jernigan KG0MB
Laboratory Manager
Microelectronics Research
University of Colorado
(719) 262-3101