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#How to rebuild a geo 5 speed tranny install
#How to rebuild a geo 5 speed tranny manual
#How to rebuild a geo 5 speed tranny free

With drive wood dowel, usa soft hammer to hit the front end of

Then remove the front cluster bearing, snap.#60 ,.

Next, remove the cluster rear bearing retrain clamp #33.

The rear gear just slides off, showing the cluster rear.

(seeĭrawing #1 blow for ID comments, like #32) Remove the rear gear first, take of bearing after snap ring off #32 end.

To remove the cluster, (bottom gear ganged cluster set).

Remove the reverse idler gear next, now that the bolt.

See the cluster, there, we will do that next.

Lift out the main shaft, it just lifts out now.

Seen in the factory manualĪbove, if too narrow the synchro cones are gone, worn to zero.

Write down that magic gap, number on paper.

Use a pry lever, (plastic) move the gear slack forward and measure the magic gap, (the factory tool is Unobtanium status)

Remove the bell housing and front bearing pinion shaft cover.Ĭase after removing its bolts.

(is that leaking? if yes, the seals inside are bad.) Gaskets or sealants, 4wd, it's dry here, and has an air vent on theīottom center. Transfer case is removed by taking off all mount bolts at XfrĬenter dry section case, by removing all its bolts.

You must remove the 5sp shifter base extension housing, so.

Turned blue is overheated and are no good.) 4wd steps. My Journal: (At each step I inspect the parts for damage or gears Specs: (from FSM) My page is no subsitutute for any FSM made. (for sure the transfer case will give you a bath in GL4 (gear lube API grade 4).Ģwd 5sp box, is total different deal, it will leak, if it is not drained) (in my case, were MISSING)īoth cases empty of gear lube GL4. Seal leaks at end of 5sp or front of transfer case (seals bad?). The 4wd car center casing runs dry, and has a bottom drain to warn you

#How to rebuild a geo 5 speed tranny manual

(same code as VIN year and engine year code!) USA rules.įactory shop manual for this tranny /tranfer case box and axle gears, are The year code is stamped, on the top leading edge of mainĬase. (how to stop the endless tide of GL4 leaking. This is Just my crude journal, of my rebuild, day1 ownership back inĢ007. The 1989 to 1998 box can be interchanged, but not the transfer case (output splines different) do not swap transfer case across the 1996/95' year line or the rear prop shaft will not fit. Removal with just a gear pulller works, if too short?, useĬhains, (I have a press but found most steps, need no press) Having a bearing wedge plate helps. (but they are interference parts, (bearings) and these can and 2nd gearĭo Use pipes (have lots of sizes on hand, metal, PVC and EMT) to press at the center boss of the bearing.(only)Įven a set of pipes and a rubber mallet can sometimes assemble this box If only one gear grinds (1 of 5), that is usually a bad synchro ring, (prove clutch cable isīad now or maladjusted, do not waste 10 hours labor pulling the transmission,etc)

#How to rebuild a geo 5 speed tranny free

SetĬable free play NOW and a new cable NOW. If all gears balk? that is a bad clutch, it drags. (use and electronic stethoscope to hear who makes noise, Tranny or Transfer case?. Story, not above., but if it makes noise only moving, change out the U-jointsįirst. If the tranny whines in netural, it does have bad bearings.

Test above, this is a bad flywheel bearing, (pilot tip bearing) If the trans (clutch really) makes noise with foot on the clutch pedalĭeep pressed, but never with clutch pedal lifted, (foot) and passes the T/O Throw out (T/O) bearing (assumes free play in cable is at spec at both On clutch, taking up slack gently pressing clutch pedal? ), that is a bad If the trans area, makes noise with light foot Inside ,where no human can see, and stick.

#How to rebuild a geo 5 speed tranny install

If the synchro's grind or baulk? Install a new clutchĬable, as all cables, now are bad, this old, after 150k miles, they get a groved