Cara Overhaul Manual Transmission

Tools and Materials Needed

Before you begin, you will need to gather the following tools and materials:

• Floor jack
• Jack stands
• Transmission jack
• Socket wrench set
• Torx bit set
• Phillips head screwdriver
• Flat head screwdriver
• Pliers
• Hammer
• Punch
• Transmission fluid
• Transmission filter
• Gasket set
• Bearing set
• Seal set

Safety Precautions

Before you begin working, it is important to take the following safety precautions:

• Park the vehicle on a level surface.
• Engage the parking brake.
• Disconnect the negative battery terminal.
• Allow the engine to cool completely.
• Wear safety glasses and gloves.

Step-by-Step Instructions

Once you have gathered your tools and materials and taken the necessary safety precautions, you can begin the overhaul process.

1. Remove the Transmission

To remove the transmission, you will need to follow these steps:

1. Raise the vehicle using the floor jack and jack stands.
2. Place the transmission jack under the transmission.
3. Remove the bolts that connect the transmission to the engine.
4. Disconnect the electrical connectors from the transmission.
5. Disconnect the speedometer cable from the transmission.
6. Disconnect the driveshaft from the transmission.
7. Carefully lower the transmission from the vehicle.

2. Disassemble the Transmission

To disassemble the transmission, you will need to follow these steps:

1. Remove the bolts that hold the transmission case together.
2. Separate the transmission case halves.
3. Remove the input shaft assembly.
4. Remove the output shaft assembly.
5. Remove the gears and bearings from the transmission case.

3. Inspect the Parts

Once the transmission is disassembled, you will need to inspect the parts for wear and damage.

• Look for any cracks or damage to the gears.
• Check the bearings for any signs of wear or damage.
• Inspect the seals for any leaks.

4. Replace the Worn Parts

If you find any worn or damaged parts, you will need to replace them.

• To replace a gear, remove the old gear and install the new one.
• To replace a bearing, remove the old bearing and install the new one.
• To replace a seal, remove the old seal and install the new one.

5. Reassemble the Transmission

Once you have replaced the worn parts, you can reassemble the transmission.

1. Place the gears and bearings into the transmission case.
2. Install the input shaft assembly.
3. Install the output shaft assembly.
4. Place the transmission case halves together.
5. Install the bolts that hold the transmission case together.

6. Install the Transmission

To install the transmission, you will need to follow these steps:

1. Carefully lift the transmission into the vehicle.
2. Connect the driveshaft to the transmission.
3. Connect the speedometer cable to the transmission.
4. Connect the electrical connectors to the transmission.
5. Install the bolts that connect the transmission to the engine.
6. Lower the vehicle to the ground.

7. Add Transmission Fluid

Once the transmission is installed, you will need to add transmission fluid.

1. Locate the transmission fluid fill plug.
2. Remove the fill plug.
3. Add transmission fluid to the transmission until it begins to leak out of the fill hole.
4. Replace the fill plug.

8. Test the Transmission

Once you have added transmission fluid, you will need to test the transmission.

1. Start the vehicle.
2. Shift the transmission into all gears.
3. Listen for any unusual noises.
4. Check for any leaks.

If you experience any problems with the transmission, you will need to take it to a mechanic for further diagnosis.