Manual Transmission Repair

1. Repairing a manual transmission is a difficult job for a DIYer. Repair requires the removal and reinstallation of many small parts. Numerous clearances must be accurately measured and, if necessary, modified using selective spacers, shims and spring gauges. Therefore, if there are problems with the transmission, a home master can also remove and install it, but it is better to entrust the repair to a specialist. You can try to get a restored transmission; in any case, the time and money spent on repairs will almost certainly exceed the cost of the rebuilt unit.

2. However, this does not mean that an inexperienced mechanic at home cannot restore the transmission. To do this, you need to have a set of special tools and work slowly, step by step, so as not to overlook something important.

3. Tools and fixtures needed for repair include: pliers for removing and installing inner and outer snap rings, bearing puller, impact puller, punch set, linear dial indicator, and possibly a hydraulic press. In addition, a large, sturdy workbench with a vise or transmission stand is required.

4. As you disassemble the transmission, take careful notes about how each part is removed, where it is placed in relation to other parts, and how it is held in place (see fig. 9.4, a-g).










5. Before removing a transmission for repair, it's a good idea to have some considerations. Where is the fault in the transmission? Some problems may be associated with certain transmission components, which makes it easier to check and replace parts. Information about possible causes of failures is given in the section "troubleshooting" at the end of this book.