Tremec T-3650 Transmission Service Manual

TREMEC M.R. INDEX NOTES, CAUTIONS WARNINGS&

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNING that you should follow when you work on a vehicle. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle with the vehicle jacked up. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. It should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4”X4” or larger) to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away from the moving parts, when the engine is running, especially the fan and drive belts. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold tail pipe, catalytic converter and muffler. Do not smoke while working on the vehicle. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head. Keep hands and other objects clear of the radiator fan blades, Electric cooling fans can start to operate at any time by an increase in under hood temperatures, even though the ignition is in the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood. Disconnect the negative battery ground cable before using any electric welding equipment. Appropriate service methods and proper repair procedure are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts. NOTES, CAUTIONS & WARNINGS TREMEC M.R.

3 Introduction 4 Explosive view 5 Transmission Parts 6 Specifications 7 Lubrication 8 General Information 9 Torque Recomendations 10 Axial Clearances 12 Preventive Maintenance 12 Precautions 13 Inspection List 14 Turret Control Disassembly 15 Control Parts Group Disassembly 22 Primary Gear Parts Group Disassembly 24 Secondary Group Disassembly 30 Input Shaft Disassembly 31 Case Parts Group Input Shaft Disassembly 33 Extension Disassembly 36 Reassembly Reverse Gear 38 Troubleshooting Guide 57 Tools 60 CONTENTS

TR-3650 4 INTRODUCTION This manual is designed to provide detailed information necessary to service and repair the TREMEC 3650 transmission listed on the cover. As outlined in the Table of Contents, the manual is divided into 4 main sections: a) Technical Information and reference b) Disassembly and reassembly of the transmission c) Troubleshooting guide d) Tools required The format of the manual is designed to be followed in its entirety if complete disassembly and reassembly of the transmission is necessary. But if only one component of the transmission needs to be repaired, see the Table of Con- tents for the page numbers showing that component. For example, if you need to work on the Shifting Controls, you will find instructions for removal, disassembly, and reassembly on page into. Service manuals, Illustrated part list, drivers instructions, and other forms service information for theses and other TREMEC transmission are available upon request. On any repair or parts replacement, always use “original” TREMEC parts according to the corresponding “Service part Catalog”. The use “non original” parts may endanger the operation and performance of the transmission. TRANSMISIONES Y EQUIPOS MECANICOS, S.A. DE C.V. DOES NOT GUARANTEE service parts or failures resulted for a misuse or not being provided by an authorized TREMEC distributor. A product literature order from, service bulletins (detailing information on product improvements), repair procedures, and other service related subjects can be obtained by writing to the following address: PLANT AND GENERAL OFFICES: TRANSMISIONES Y EQUIPOS MECANICOS, S.A. DE C.V. Av. 5 de Febrero No. 2115 C.P. 76120, Querétaro, Qro. MEXICO TR-3650 TREMEC Design x10 Capacity nominal lbs-ft NOMENCLATURE: Letter designations Number designations Design Level Forward speeds

5 EXPLOSIVE VIEW 71 14 3 129 54 52 48 57 56 65 67 58 130 59 67 6 49 63 129 50 115 113 128 112 132 113 115 113 82 5 4 5 105 113 110 81 60 84 127 127 126 79 114 41 116 66 150 135 136 145 118 119 120 121 122 123 46 11 12 13 16 15 14 17 18 93 70 69 46 42 90 91 106 68 19 20 21 102 43 44 18 146 21 20 19 106 73 46 39 144 138 106 40 102 68 14 99 142 125 147 148 24 25 26 27 28 151 35 141 102 30 38 30 85 140 18 46 86 139 87 112 129 114 129 133 55 53 10 64 80 134 95 111 105 113 33 29 22 72 92 39 23 89 45 18 94 137 37 36 103 100 89 94 89 108 107 117 83 97 109 98 2 104 104 104 104 104 104 129 124 129 104 51 129 113 62 60 61 149 8 40 106 31 32 31 78 75 76 77 74 29 34 45 88 96 1 131 47 6 104 10 7 33 9 138 141 23

TR-3650 6 TRANSMISSION TR-3650 PARTS 1 1 MAGNET 2 1 ROLL PIN 3 8 ROLL PIN 4 1 SNAP RING SPEEDOMETER 5 1 TAG IDENTIFICATION 6 1 CENTER INTERLOCK PIN 7 2 SHIFTER INTERLOCK 8 1 BEARING ROLLER CUP * 9 2 ROLLER BEARING SELECTOR ARM 10 1 SPRING INHIBITOR 11 14 BOLT METRIC HEX WASHER HD 12 2 NYLON STOP 13 1 BEARING INPUT SHAFT POCKET 14 1 THRUST BEARING ASS’Y 15 1 THRUST WASHER SHAFT PILOTED 16 AR SNAP RING 2.30+/-0.05 MM AS REQU. 17 AR SNAP RING 2.40+/-0.05 MM AS REQU. 18 AR SNAP RING 2.50+/-0.05 MM AS REQU. 19 AR SNAP RING 2.60+/-0.05 MM AS REQU. 20 12 SPRING SYNCHRONIZER 21 2 1st. & 2nd. INNER RING 22 2 BLOCKER RING & LINING ASSY 1st. & nd. 23 2 1st. & 2nd. BLOCKER RING 24 1 SNAP RING HUB SYNCHRO 1st. & 2nd. 25 2 SNAP RING TOP INSERT 26 1 BEARING CONE & CUP ASS’Y MAIN SHAFT 27 1 BEARING CONE* 28 AR BEARING SHIM C.S. AS REQUIRED 29 AR BEARING SHIM C.S. AS REQUIRED 30 AR BEARING SHIM C.S. AS REQUIRED 31 AR BEARING SHIM C.S. AS REQUIRED 32 1 BEARING CONE & CUP ASS’Y C.S. 33 1 CUP BEARING * 34 2 ROLLER BEARING GEAR 5th. C.S. 35 2 ROLLER BEARING GEAR REV. IDLER 36 1 SPACER ROLLER BEARING GEAR REV. 37 2 O’RING INHIBITOR 38 1 CONE BEARING* 39 1 BEARING CONE & CUP ASS’Y REAR C.S. 40 1 CUP BEARING REAR C.S.* 41 1 CONE BEARING REAR C.S.* 42 1 SPACER ROLLER BEARING 5th. C.S. 43 1 REVERSE IDLER GEAR 44 2 1st. & 2nd. CLUTCH CONE 45 1 1st. GEAR SPEED ASS’Y M.S. 46 1 1st. GEAR SPEED M.S. * 47 2 BUSHING 3 rd GEAR & REV. 48 1 CLUTCH HOUSING ASS’Y 49 1 CLUTCH HOUSING * 50 1 TRANSMISSION CASE ASS’Y 51 1 TRANSMISSION CASE * 52 1 EXTENSION ASS’Y 53 1 EXTENSION * 54 1 MAIN SHAFT 55 1 SPEEDOMETER ROTOR GEAR 56 1 OIL SEAL EXTENSION 57 1 INPUT SHAFT 58 1 3 rd GEAR SPEED. M.S.* 59 1 2nd. GEAR SPEED. ASS’Y M.S. 60 1 2nd. GEAR SPEED. M.S. * 61 1 5th. GEAR SPEED. M.S. 62 1 SYNCHRONIZER ASS’Y 5th. GEAR C.S. 63 1 5th. GEAR C.S. * 64 2 5th: & REVERSE SLEEVE * 65 1 CLUSTER GEAR 66 4 BLOCKER RING 3 rd /4th./5th & REVERSE 67 1 1st. & 2nd. SHIFT RAIL 68 1 3 rd & 4 th. SHIFT RAIL 69 1 5th. & REV. SHIFT RAIL 70 1 5th. FORK SHIFT ASS’Y 71 1 5th. FORK SHIFT* 72 1 1st. & 2nd. GATE ASS’Y 73 1 1st. & 2nd. GATE * 74 1 1st. & 2nd. FORK SHIFT ASS’Y 75 1 1st. & 2nd. FORK SHIFT * 76 1 3th. & 4th. FORK SHIFT ASS’Y 77 1 3th. & 4th. FORK SHIFT * 78 1 SELECTOR RAIL 79 1 ARM SELECTOR INHIBITOR 80 1 SEAT SELECTOR GATE 81 4 DETENT PLUG 82 3 DETENT 83 3 ACTUATING SPRING 84 1 REVERSE FORK SHIFT ASS’Y 85 1 REVERSE FORK SHIFT * 86 1 3 rd & 4th. GATE 87 1 SHIFTER LEVER ASS’Y 88 2 SPACER FONT 89 2 THRUST WASHER 3 rd GEAR & REV. 90 1 3 rd & 4th. SYNCHRONIZER ASS’Y 91 1 3 rd & 4th. SLEEVE * 92 1 1st. & 2nd. SYNCHRONIZER ASS’Y 93 1 1st. & 2nd. SLEEVE* 94 1 SYNCHRONIZER ASS’Y REVERSE GEAR 95 1 REVERSE CLUTCH CONE 96 1 CLUTCH CONE 5th. SPEED. C.S. 97 1 SPRING BASE TURRET 98 1 RAIL REVERSE INHIBITOR 99 1 INHIBITOR REVERSE 100 1 PIN INHIBITOR RETAINER BAR 101 1 INTERLOCK SUPPORT 102 1 OIL SEAL BEARING RETAINER 103 1 WASHER SPRING RETENTION 104 1 GEAR REVERSE M.S. 105 1 THRUST WASHER 5th. GEAR C.S. 106 1 REVERSE SHAFT RAIL 107 1 BOLT M8X1.25X60 TORX BOTTON HEAD 108 1 REVERSE SUPPORT SHAFT 109 1 O’RING 110 12 INSERT SYNCHRONIZER 111 1 3 rd CLUTCH CONE * 112 1 3 rd GEAR SPEED ASS’Y M.S. 113 1 1st. & 2nd. HUB SYNCHRO * 114 1 3 rd & 4th. HUB SYNCHRO * 115 2 5th.. & REV. HUB SYNCHRO * 116 3 BALL 117 1 BALL SPEEDOMETER 118 2 DRAIN PLUG & FILLER PLUG 119 1 BREATHER 120 4 2nd. & 3 rd NEEDLE BEARING ASS’Y 121 1 BEARING TAPERED ROLLER CUP 122 1 BEARING TAPERED ROLLER CONE 123 1 CAP SCREW HEX HEAD SENSOR 124 1 SWITCH ASS’Y BACKUP LAMP 125 1 TUB RETAINER BEARING* 126 4 DOWEL PIN 127 1 BUSHING EXTENSION HOUSING 128 1 STUD CLUTCH RELEASE LEVER 129 1 SEAL OUTPUT SPLINE 130 AR BEARING SHIM 0.55 +/- 0.013 MM 131 AR BEARING SHIM 0.61 +/- 0.013 MM 132 AR BEARING SHIM 0.66 +/- 0.013 MM 133 AR BEARING SHIM 0.71 +/- 0.013 MM 134 AR BEARING SHIM 0.76 +/- 0.013 MM 135 AR BEARING SHIM 0.81 +/- 0.013 MM 136 AR BEARING SHIM 0.83 +/- 0.013 MM 137 1 SNAP RING 138 1 SPRING CENTERING SHIFT CONTROL 139 2 BOLT SHOULDER 140 14 BOLT METRIC HEX. WASHER HEAD 141 4 BOLT METRIC HEX. WASHER HEAD 142 9 PAD SHIFT FORK 143 1 SENSOR SPEEDOMETER * SOLD ONLY IN ASS’Y

7 Lengths measured from clutch housing face to cover rear (extension). Weights include shift bar housing, clutch housing, less shift lever assembly, and clutch parts. For more information on available application, see the transmission’s illustrated parts list. All weights are approximate. Oil capacities are approximate, depending on inclination of engine and transmission. Always fill transmission, with proper grade and type of lubricant, to level of filler opening. See LUBRICATION. SPECIFICATIONS IMPORTANT All TREMEC transmissions TR-3650 are identified by the model and serial number, and date. This information is stamped on the transmission identification tag and affixed to the case. The transmissions series TR-3650 have five forward speeds and one reverse, of advanced design that offers to you, the most efficent relation of capacity of partorsion-weight, that any other transmissions of 5 speeds within its rank. NOTES 1 2 3 TRANSMISSION MODEL ASSEMBLY DATE TRANSMISSION NUMBER SERIAL NUMBER MODEL GEAR RATIOS 1st. 2nd. 3rd. 4th. 5th. REV. OIL CAPACITY TR-3650-1/2 3.38 2.00 1.32 1.00 0.67 3.38 3800 C.C. TR-3650-3/4/5 3.38 2.00 1.32 1.00 0.62 3.38 3800 C.C.

TR-3650 8 Proper lubrication procedures are the key to a good all around maintenance program. If the oil is not doing its job, or if the oil level is ignored, all the maintenance procedures in the world are not going to keep the transmission running or assure long transmission life. TREMEC Transmissions are designed so that the internal parts operate in an oil circulating bath by the motion of the gears and shafts. CHANGE AND INSPECTION OF THE LUBRICANT Use oil ET-M99 specification. Additives and friction modifiers are not recommended for use in transmission TR-3650. PROPER OIL LEVEL Make sure oil is level with the filler opening. Because you can reach oil with your finger does not mean oil is at proper level. DRAINING OIL Drain transmission while oil is warm. To drain oil remove the drain plug at case bottom. Clean the drain plug before re-installing. OIL CHANGE AND REFILLING Clean case around filler plug and remove plug from case side. Fill the transmission to the level of the filler opening. The exact amount of oil depends on the transmission inclination and model. Do not over fill this causes oil to be forced out of the case and cause a deficients lubrication. when adding oil, types and brands of oil should not be mixed because of possible incompatibility. LUBRICATION Thus, all parts are amply lubricated if these procedures are closely followed: Maintain oil level. Inspect regularly. Change oil regularly. Use the correct grade and type of oil. Buy from a reputable dealer. OIL SPECIFICATIONS MODEL API SPECIFICATION TREMEC OIL TRANSMISSION SPECIFICATION CAPACITY TR-3650 Mobil 1 Synthetic ATF ET-M-99 3.8 Lts. Dexron III 1300-244-006 1 2 3 4 PROPER OIL LEVEL IMPROPER OIL LEVEL

9 GENERAL INFORMATION GENERAL INFORMATION GENERAL INFORMATION GENERAL INFORMATION GENERAL INFORMATION The TR-3650 transmissions have five forward speeds and one reverse, and are shifted as you would shift any synchronized transmission manual, following the simple 5 speed shift pattern. Follow the simple 5 speed shift pattern: The transmission must efficiently transfer the engine’s power, in terms of torque, to the vehicle’s rear wheels. Knowl-edge of what takes place in the transmission during torque tranfer is essential when troubleshooting and making repairs. Power ( torque ) from the engine is transferred to the input shaft and drive gear. Torque is transferred to the countershaft drive gear. POWER FLOW Torque is delivered along the countershaft to all countershaft gear. Torque is transferred to “engaged” mainshaft gear. The cross section illustrates 1st speed gear position. Engaged mainshaft gear internal clutching teeth transfers torque to mainshaft through synchronizer assembly. Mainshaft transfers torque directly to driveshaft t through rear yoke. 1 2 1 3 5 2 4 R NEUTRAL 3 4 5 6

TR-3650 10 Correct torque application is important to assure long transmission life. Over or under tightening of fasteners can result in a loose installation and, in many instances, can eventually cause demage to the transmission. Use a torque TORQUE RECOMENDATIONS wrench to obtain recommended torque ratings. Do not torque capscrews dry. Apply teflon to threads of all capscrews before in installing definitive. 2

Tremec T-3650 Transmission Service Manual

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