How to rebuild your FWD 5 Speed Manual Transmission... (Guide)

Ok so I decided to create this guide to help you rebuild your FWD 5 Speed Manual Transmission. Now I know after looking at this you might say "well you didn’t take the gears off the shafts." You're right, I didn’t need to. But this will give you a place to start minus all the gears. Let's get started…
First off place your transmission on the front bell housing as displayed.
http://i21.photobucket.com/albums/b2...n/IMG00704.jpg
Then remove the seven 12mm bolds holding on the end piece. Under this you will see your 5th gear. You will need to remove the two 36mm nuts and the push pin holding it in place.
http://i21.photobucket.com/albums/b2...n/IMG00705.jpg
This is the pin you need to remove.
http://i21.photobucket.com/albums/b2...n/IMG00801.jpg
http://i21.photobucket.com/albums/b2...n/IMG00730.jpg
Next there is a 14mm bolt that you need to remove that is here, I didn’t have it in when I took this picture but you can't miss it.
http://i21.photobucket.com/albums/b2...IMG00792-1.jpg
After you remove that one 14mm bolt, proceed to remove the other thirteen 14mm bolts holding the mid-case on.
Once you take this off you might want to take this chance to clean the mid-case. as it will build up some nasty stuff.
http://i21.photobucket.com/albums/b2...n/IMG00710.jpg
Now you should see the gears exposed.
http://i21.photobucket.com/albums/b2...n/IMG00711.jpg
http://i21.photobucket.com/albums/b2...n/IMG00712.jpg
The differential should just pull right out as nothing holding it in place.
http://i21.photobucket.com/albums/b2...n/IMG00713.jpg

Now this is where you will want to remove the two 12mm bold holding the reverse gear mechanism in place and take out the two push pins
http://i21.photobucket.com/albums/b2...n/IMG00768.jpg
http://i21.photobucket.com/albums/b2...n/IMG00767.jpg
http://i21.photobucket.com/albums/b2...IMG00767-1.jpg
Once you get the pins out you will need to turn the shafts in order to remove the gears the one on the left goes to the left and the two on the right go to the right. It's kind of tricky as you will need to move the gear selector around to do this.
http://i21.photobucket.com/albums/b2...IMG00775-1.jpg
Once you get those moved you just lift the gears out. Now I kept mine together as I didn’t need to replace any of the gears on the shafts.
http://i21.photobucket.com/albums/b2...n/IMG00728.jpg
http://i21.photobucket.com/albums/b2...n/IMG00735.jpg
The small gear in the bottom right is the reverse gear.
http://i21.photobucket.com/albums/b2...n/IMG00729.jpg
And there you have your bell housing…
http://i21.photobucket.com/albums/b2...n/IMG00727.jpg

Now to put it back together you would just follow these same steps in reverse.
Make sure when putting the mid-case and the end piece back on to add some kind of seal, I used this. It's an industrial strength (overkill) but should do the job.
http://i21.photobucket.com/albums/b2...n/IMG00795.jpg
http://i21.photobucket.com/albums/b2...n/IMG00794.jpg
http://i21.photobucket.com/albums/b2...n/IMG00793.jpg
http://i21.photobucket.com/albums/b2...n/IMG00797.jpg
When you're all done, should look like this.
http://i21.photobucket.com/albums/b2...n/IMG00803.jpg
http://i21.photobucket.com/albums/b2...n/IMG00804.jpg
http://i21.photobucket.com/albums/b2...n/IMG00805.jpg
http://i21.photobucket.com/albums/b2...n/IMG00806.jpg
And if you have any extra bolt's and parts you know you did it right…
http://i21.photobucket.com/albums/b2...n/IMG00807.jpg

Nice. It's intimidating but anyone can do this stuff.

I need to open mine up and repress the speedo gear on my quaife, and also need to replace the reverse idler gear/shaft. My reverse has never worked right, always pops out and figured its a cheap part I can just replace and see if that fixed the problem.

Quote:

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Originally Posted by R/T93

Nice. It's intimidating but anyone can do this stuff.

I need to open mine up and repress the speedo gear on my quaife, and also need to replace the reverse idler gear/shaft. My reverse has never worked right, always pops out and figured its a cheap part I can just replace and see if that fixed the problem.

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You'll find that there are 4 metal balls that are spring loaded. These spring loaded balls are what hold your gears in the selected gear.
These 3 are for 1-5 and reverse and there is one more that hold revers in place as well.
http://i21.photobucket.com/albums/b2...n/IMG00802.jpg
Here is a break down of them with the location. I hope this helps. You may not need to take yours apart.
http://i21.photobucket.com/albums/b2...IMG00732-1.jpg
You should find a small spring and a metal ball in each one of these holes. Check them first.

Best write up I've seen in ages. Just saved the entire thing. Sensational.

How does this differ from an AWD?

Sent from my DROIDX using Tapatalk

Quote:

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Originally Posted by R/T93

Nice. It's intimidating but anyone can do this stuff.

I need to open mine up and repress the speedo gear on my quaife, and also need to replace the reverse idler gear/shaft. My reverse has never worked right, always pops out and figured its a cheap part I can just replace and see if that fixed the problem.

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I agree on the intimidation factor. I ripped into mine after blowing up my stock diff to replace the bearings and put and LSD in. When I first looked at it I had no idea what was going on. I just spent a few minutes looking at the manual and studying how everything works and it actually all makes sense.

Quote:

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Originally Posted by akotten

How does this differ from an AWD?

Sent from my DROIDX using Tapatalk

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AWD is the same basic idea but with a little more complication as you have the VCU/Planetary gears/output shaft. Same opinion of my above statement though, it might look complicated but it all makes sense after some studying.

Quote:

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Originally Posted by akotten

How does this differ from an AWD?

Sent from my DROIDX using Tapatalk

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The AWD trans is done in reverse. You remove the shifter assembly, bell housing, mid case... then all of the gears will be sitting straight up in the end case. There is a bolt that is behind the black plug in the end case. It's a 7mm or 12mm allen depending on what year your trans is.

Great write up.