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t5 rebuild advice 

 

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 Post subject: t5 rebuild advice
Posted: Sun Mar 02, 2008 11:29 pm 
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hey all

just did a manual conversion to my EL. turns out the box i got is a little worse for wear and crunches going into 4th. id like to either get it rebuilt or rebuild it myself. i've roughly gone over the instructions myself and even seen rebuilt kits on ebay for <$USD200. Has anyone on here attempted a T5 rebuild before, and have any advice to give?

Also if anyone knows of any reputable gearbox places in adelaide please let me know.

Thanks
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Posted: Mon Mar 03, 2008 12:00 am 
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They're pretty easy to rebuild, sure a bearing kit cant hurt, and in actual fact, may be lucky enough not to need any shimming.

replacement parts can cost a bit, syncro's and other wearing parts are still available, but parts are usually around 100+ each.

Most places will charge 600+ for a basic 'out of car' re-kit, plus parts obviously.

Once you punch that first roll-pin in on the gear lever, you've made it to the point of no return! you must dismantle to fetch it!.

They're easy!

 

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Posted: Mon Mar 03, 2008 12:40 am 
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are the syncros all the same, ie can u swap a good 3rd gear for a 2nd gear etc?

i would have thought that the syncros are the most expensive parts, apart from the gears which if theyre stuffedd you wouldnt bother fixing

 

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Posted: Mon Mar 03, 2008 9:40 am 
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thanks for the replies. From what I've seen you need a press, puller and some dial gauges which I don't have. Are these entirely necessary or are there ways to dismantle it with more common tools?
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Posted: Mon Mar 03, 2008 9:34 pm 
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You'll spend more on tools than the parts (as long as you get them from the states). Once you understand, it's pretty easy (like anything really lol). Do it right once the first time and make sure you measure everything up and triple check.

 

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Posted: Mon Mar 03, 2008 9:37 pm 
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You need to pull the rear bearing from the countergear to get it out, so having the right tools is handy - try borrowing/renting, etc.
To remove gears off the mainshaft, you'll need circlip pliers.

As Andrew has said, it's not that hard, you may just need to inspect bearings - burrs on synchros, gear teeth can be removed using a sharpening stone.
Parts like bearing shells that the case hardening has deteriorated, will need replacing, as normally it will quickly keep deteriorating.

 

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Posted: Mon Mar 03, 2008 9:44 pm 
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Krytox wrote:
They're pretty easy to rebuild.....


You sure? Heres what mine looked like during its rebuild, wasnt me who rebuilt it though...

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Posted: Mon Mar 03, 2008 9:49 pm 
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isnt it usually the synchros that die.....so replacing bearings aint gunna help with crunchy shifts

 

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Posted: Mon Mar 03, 2008 10:02 pm 
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gogetta wrote:
isnt it usually the synchros that die.....so replacing bearings aint gunna help with crunchy shifts


New bearings can do wonders for a gearbox.
In turn they can decrease endplay, tighten up the mainshaft. giving a more positive path for the syncro slider.

 

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Posted: Tue Mar 04, 2008 12:13 am 
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had a gearbox place look at it today. said that its odd only 4th is gone, and that it drives very well for a cheap s/h box otherwise, and there is no abnormal noise. they quoted $800 for a rebuild (thats parts+labour) off the car. said the crunching in 4th would be fixed with a new synchro cone for an extra $160 i think it was. they also said if i wanted they could just swap the cone and leave it but said it may not be the best idea.

at this stage i dont think i'll bother doing it myself... don't have the room or tools or time!
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Posted: Tue Mar 04, 2008 8:12 am 
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hey thats cheap...... here the "t5 guru" Mal Wood quotes 1500 for an exchange reco box. And that doesnt include fitting :shock:
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Posted: Tue Mar 04, 2008 12:37 pm 
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thats from a reputable place in adelaide... got quoted only $70 more at another place... i think the mal wood rebuilds are probably strengthened?
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Posted: Sat Mar 08, 2008 9:31 am 
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they would wanna be 1000hp strengthened for that...

 

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