hopps

So, does anyone have any information or guidance on how to replace the seals and syncro's on a 5speed tranny? I figure the seals are pretty straight forward, but the syncro replacement is where I get kinda lost. Is there a write-up anywhere?

Thanks guys, I appreciate any help and information you guys can give me

Darwantae951

Use the factory manual. It shows disassembly/reassembly of the transaxle.

redline7921

I did my sycros and seals a year and a half ago over the winter. If you are interested in doing the job you will need:

- a puller of some kind (you may have to grind some material off in order to fit it under the gear)
- heavy duty snap ring pliers
- 10mm cheese head
- various metric sockets
- a torque wrench capable of approx 100 ftlbs cant remembember the exact torque for the 10mm cheese head
- there is one bolt in addition to the cheese head that are one use only, so have new ones
- hydraulic press
- thickness gauge

Take your time, take LOTS of pictures before taking things apart. There are quite a few small parts that are easily lost if you are not careful.


All that being said. The car shifted very smooth but some other issues came up and I am still trying to figure out the issue. I had some vibration above 3k rpm, felt it through the shift lever. I think it might be the clutch or torque tube, still haven't figured it out. Another year on jack stands not much time to work on the car these days.

Have fun.

Oddjob

As mentioned, the Factory manual is necessary. No other source, instructions, or "cheat sheet" is available that I am aware of.

3rd, 4th and 5th synchros are easier to get to (on the input shaft). 1st and 2nd synchros are harder to get at, as the pinion shaft is more difficult to disassemble (this is where the press is needed).

hopps

Thanks for the info guys. And sucks that 1st and 2nd are harder to get to..as those are the ones giving me the most problems. Approximately how many hours did it take for you guys to complete the job? Kinda not looking forward to it, but it's gotta be done soon

Oddjob

Hard to say for a first time thru it. Not including dropping and reinstalling the trans, leave yourself all of a good 6-8hrs of solid tinkering. It takes some screwing around w/ gear pullers (as mentioned by redline), and the little detents on the shift rods and the detents and spring clips on the sliders can give you some fits the first time you have it pull apart and pieces fall out.

Need a good work bench and a big vise. Soft jaws (alum or brass) are needed, or maybe can get away w/ using wood blocks.

redline7921

Here are some pics from when I did it.