Rebuilding your transmission: Advice, Parts Sources, other resources.

[OldSixBolt]

I have a few spare gearboxes lying around with fragged synchros that I would like to dive into and replace. One is a 90 AWD DSM, another from a 91.

I'm more than confident in putting it back together, however I'm not sure where is the best place to source the parts. Assuming I'm just doing a basic freshening up (re using gearsets, rails, forks ect, and just replacing bearings, hub/synchro assemblys), where is the best/cheapest place to source these parts? Is there anything else I should keep in mind before tearing this thing down?

Thanks in advance.

[hal]

Lay your hands on a copy of the OEM rebuild manual for these units.

[spoulson]

I tried my hand at rebuilding my transmission. Let's just say I got it right on the 3rd try. It's not that difficult once you've done it, but you'll need to invest in time to find all the special tools you might not already have and not rush any of the steps. (e.g. large sockets, metal chisel/punches, lock ring pliers, hydraulic press, etc.).

Do what Hal says and get the FSM (same as the rebuild manual?), but you will really need some practical experience that the manual doesn't provide.

[DSSA]

I have a few spare gearboxes lying around with fragged synchros that I would like to dive into and replace. One is a 90 AWD DSM, another from a 91.


Check the intermediate shaft diameter for 2nd gear on the 90 to see if it's even worthwhile. I don't know how many times I've gotten 90 transmissions dropped off and they don't want to build it (especially FWDs) after they find out the price of a new, late 1990+ intermediate shaft.

As far as sourcing parts, feel free to give me a call or drop me an e-mail.