transmission rebuild

[beppomarx]

ok guys my transmission is about to get pulled apart today or tomorrow. im rebuilding it myself but im not ordering parts until i get it apart and see exactly what parts i need.

have any of you ever taken one of ours apart? what should i be aware or concerned of? i know it aint gonna be quick or easy but if there are common problems i can aviod then let me know.

btw its a 97 1.8 beta tranny. thanks!

[beppomarx]

wow this project is fun!!! lol :duh:

shes all apart. the only complication was one end retaining nut that is crimped on either side to lock it from spinning. i was punching out the crimps and broke the punch off in there so i had a fun time hacksawing around the broken punch/crimp abd i did scrape the threads a bit on the shaft but mostly its fine. the nut threads on ok but im ordering a new nut obviously with my parts.

so far im getting a new:

5th gear because 1 tooth is chipped

all new end roller bearings. the main problem was that one of the end bearings blew apart and the rollers themselves were lurking around aimlessly in my casing and a few of them are dented and bent.

new synchro spacers because 2 broke.

funny enough all my synchros are in great shape. since ive gotten this used one i have yet to grind it at all and it shows. all the teeth on the brass synchros are symmtrical and visually undamaged.

new input seal for the main shaft. where the clutc connects inside the bellhousing.

1 new shift fork. webtech only lists 3 forks in their description, and the one i need doesnt seem to be listed. so i got teh one thats used up until 05/99 i bvelieve and if its not the right one ill have to find a new one of see if teh one out of my old accent tranny will fit. im about 90% sure it will and hopefully its not worn like this one.

total so far $141. plus i fixed (or realized teh problem with) my leaky oil fill plug an the transmission so now no more leaks and im going to put amsoil in it i believe. or ill find some other fully synthetic gear oil to use.

ive never had a transmission apart before but my partner in crime marty has done 2 automatics before and even so this isnt THAT complicated. it was intimidating at first but with webtech diagrams and a little time i found out where all the parts go once i got it all apart and diagnosed.

ill have pics of this one after th weekend. i think i say that a lot but my computers working and so is the digi camera AND i have fresh batteries. my only excuse now will be harborfest cos thats this weekend too... but i have to get more work done before monday so ill try not to forget!!!! its pretty cool looking hehehe :rambo:

[MechaniX_034]

Since the tranny is now in pieces why not change the bearings as well? It would help the shifts[and not to mention the teeth]to limit the lateral throwout at this stage and would also eliminate the need for a rebuild sooner to do the job.

Also, please consider replacing the driveshaft oil seals and use a small amount of RTV on all the contact areas. Check if these areas are true also; it would be a PITA if things started leaking after the reinstall.

Nice to see you getting into it man, and all the best on the refit!:

[beppomarx]

as for the bearings, i am not going to take the gearsets themselves apart, so the roller bearings there will stay as is. i am however replacing all of the end bearings which are tapered roller bearings.

i replaced the axle seals just a few months ago and i have already ordered a new seal for the main shaft. are you saying use a little bit of RTV silicone to help the seal??? i wasnt planning on it but it does sound like a good precaution, thanks!

the only thing worrying me is that there is one shift fork not listed on webtech for some reason.... if you check all the diagrams you will see 3 forks listed but there is a 4th one where a shaft is pinned to it like the others but also has another hole in it so a seperate shaft can move and rotate freely. this one is not listed, or maybe im just missing it.

im going to disassemble my old accent tranny to see if that fork can be used if its in better condition. my new parts wont even be here till thursday anyway...

[Shadohh]

Yeah. I would replace.


Bearings and Syncros.

Order syncros for the new 03 tiburon tranny. They are much better deisgn.


Also... you coudl try using a fifth gear from a 5spd v6 sonata. should fit and be stronger then stocky.

Or look at a DSM 5fifth gear.

[iQfOreVa]

hey shad, the 03 gen snyncro's are a direct fit? that'll be cool, cuz im replacing all my syncro's. thanks man.

ill let u guys know if the 5sp v6 sonata's 5th gear fits or not.

[Edited by iQfOreVa on Jul 27, 2003 2:50 PM]

[beppomarx]

thanks shaddoh. i have the 1997 1.8 transmission. will these synchros still match up and work??? i assume so but i just need to clarify.

im also probably leaving the 5th gear as stock. just out of curiosity which gear would i need to replace due to weakness, is it 43230 or 43240 or both????

ok i am looking up part #'s for 03 synchros and have a question....

for synchros 43360A and 43380B they do not list the 3 synchro keys that are held and sprung by the 2 springs. im talking about the little metal keys that slip between the hub and sleeve. they all look the same, should i just order keys for the 97 or do the new ones not use these??? i am 90% sure those keys DO need to be there but nothing is listed in the parts column, and it says you only need 3 keys of 43373D.

also im having trouble determining which bearings are the shaft end bearings from the diagram. from what i can tell i have:

43222 BEARING-MNL T/A INPUT SHAFT FR
43223B BEARING-MNL T/A INPUT SHAFT RR
43220B BEARING-TAPER ROLLER
43220C BEARING-MNL T/A OUTPUT SHAFT R

if anyone can confirm those 4 bearings that would be great but im pretty sure on those as well.

edit

ok the synchros were about $70 apiece and i just couldnt swing it. so i got the 4 end bearings plus seals and hopefully the correct shift fork, as well as spacers 43217T and 43227T. also got 3 new syncro keys and 2 of 43216 end nuts.

shaddoh if i may ask, what makes the 03 synchros superior? is there less play in the brass ring itself,or are the teeth shaped differently??

[Edited by beppomarx on Jul 28, 2003 2:15 PM]