Tremec T5 WC STD transmission gearbox workshop service repair manual

IMPORTANT SAFETY NOTICE 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, AND 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.

Contents Section Page 1 INTRODUCTION AND DESCRIPTION 1-1. Introduction ………………………………………………………………………. 1-10. Description……………………………………………………………………… 1-1 1-1 2 T5 WC & STD ON-VEHICLE SERVICE AND TROUBLESHOOTING 2-1. Maintenance……………..……………………………………………………….. 2-7. Troubleshooting………………………………………………………………….. 2-10. Transmission Removal… ……………………………………………………… 2-21. Transmission Installation ……………………………………………………….. 2-1 2-1 2-4 2-7 3 T5 WC DISASSEMBLY 3-1. General Information ……………………………………………………………... 3-6. T5 HD Transmission Disassembly Procedures ……………………………… 3-1 3-1 4 T5 STD DISASSEMBLY 4-1. General Information ……………………………………………………………... 4-6. T5 STD Transmission Disassembly Procedures …………………………….. 4-1 4-1 5 T5 WC & STD CLEANING, INSPECTION, REPAIR OR REPLACEMENT 5-1. Cleaning ………………………………………………………………………….. 5-5. Inspection ………………………………………………………………………… 5-10. Repair or Replacement …………………………………………………………. 5-1 5-8 5-16 6 T5 WC ASSEMBLY 6-1. General Information ……………………………………………………………... 6-4. T5 HD Transmission Assembly Procedures ………………………………….. 6-1 6-1 7 T5 STD ASSEMBLY 7-1 General Information ……………………………………………………………... 7-4. T5 STD Transmission Assembly Procedures ………………………………... 7-1 7-1

Section 1 Introduction and Description 1-1. INTRODUCTION 1-2. PURPOSE. This manual contains maintenance, service and parts information for the T5 Five-Speed Manual Transmission manufactured by TREMEC (TRANSMISIONES Y EQUIPOS MECANICOS S.A DE C.V.) Av. 5 de febrero No. 2115, Querétaro,Qro. México. 1-3. SCOPE. As you will see in the Table of Contents, this manual provides information for maintenance, troubleshooting, disassembly, cleaning, inspection, repair or replacement, and assembly of the transmission. 1-4. T5 TRANSMISSION CLASSES. Two basic T5 transmission classes are covered in this manual: WC (world class) and STD (standard). Separate disassembly (Section 3 and 4) and assembly (Sections 6 and 7) instructions are provided for each of these classes. In other section of the manual, variations within the classes are noted in the instructions and illustrations. NOTE The parts shown in the illustrations in the service instructions are typical for those used in a particular class of transmission (WC or STD). Some parts may be encountered in service that are different in appearance than those illustrated. These “different” parts perform the same function as those illustrated. 1-5. T5 TRANSMISSION CLASS IDENTIFICATION. The T5 transmission can be identified as WC or STD by the last three digits of the transmission part number (see Table 3-1 or 4-1 in the disassembly sections). In this manual, figure titles, lists, tables and main paragraph headings are in the proper section for the transmission being serviced. 1-6. PART IDENTIFICATION. Each detail part shown in the exploded views in this manual for a particular transmission class (WC or STD) is assigned an index number. This same index number is used to identify the part throughout this manual. For example, WC index number 116 (in parenthesis in the text) refers to the countershaft gear in all applicable sections. The same is true for STD index number 105. 1-7. The exploded view illustration in Section 5 (figure 5-1 or 5-2) make it possible to view the complete transmission assembly in addition to the illustrations in the Sections 3,4,6 and 7 relating to a specific disassembly or assembly procedure. 1-8. PART NUMBERS. The purpose of the index numbers in the illustrations in this manual is to identify parts. Part numbers are not used. Once a part is identified, refer to the TREMEC T5 Transmission Parts Catalog for the correct part number. 1-9. ABBREVIATIONS. Abbreviations, other than those in common use, found in this manual are identified in Table 1-1. 1-10. DESCRIPTION 1-11. TRANSMISSION DESCRIPTION. The TREMEC Automotive T5 is a five speed, countershaft, helical gear transmission . It is fully synchronized for ease of shifting. Gear ratios vary from model to model (refer to vehicle service manual for specifications.) The input and output ends of the input and output shafts are supported by tapered roller bearings. A pilot roller bearing is used between the input and output shafts. The countershaft gear is supported in tapered roller bearings for WC models and straight roller beatings for STD models. These and other basic differences in the two classes are shown in Table 1-2. 1-12. APPLICATION. The T5 transmission is used on sports cars, small to medium sedans and coupes, compact trucks and vans, utility vehicles and similar 2-wheel and 4-wheel drive vehicles. Table 1-1. Abbreviations AR As Required Assy Assembly ID Inside Diameter NP Not Procurable OD Outside Diameter PN Part Number QTY Quantity TIR Total Indicator Reading Table 1-2. Basic Differences Between T5 WC and STD Classes FEATURE DESCRIPTION WC STD Bearings under gears Blocking rings Countershaft bearings Needle bearings Fiber synchronizers Tapered roller bearings Journals Brass synchronizers Straight roller bearings 1-1

Section 2 T5 WC & STD On- Vehicle Service and Troubleshooting 2-1. MAINTENANCE 2-2 GENERAL. The only periodic maintenance required for the TREMEC T5 transmission is to maintain proper lubrication. 2-3. LUBRICATION SCHEDULE. Refer to the Vehicle Owner’s Manual or Service Manual. CAUTION Excessive temperatures may bread down the transmission lubricant (refer to vehicle service manual for maximum allowable temperature). If there is reason to believe that the transmission has been subjected to temperatures exceeding 275° F, change the lubricant immediately. 2-4. APPROVED LUBRICANT. Most T5 transmission models use Dexron II automatic transmission fluid. Refer the vehicle owner’s manual or service manual for lubricant specifications. CAUTION Do not mix different bands or types of transmission lubricant. DO NOT USE GEAR OIL IN THE T5 TRANSMISSION SINCE THIS MAY DAMAGE THE BLOCKING RING MATERIAL. 2-5. CHECKING LUBRICANT LEVEL. Proceed as follows (see figure 2-2): NOTE To check or drain the lubricant, the transmission should be warm. This is best done shortly after engine shutdown. a. Wipe fill plug (2) and surrounding area clean. b. Remove fill plug (2). c. When transmission is full, lubricant will just drip out fill plug opening. d. Add approved lubricant if required. e. Install fill plug (2) and torque to 20 lb-ft (27 Nm). 2-6. CHANGING LUBRICANT. Proceed as follows (see figure 2-2): a. Wipe drain and fill plugs (1 and 2) and surrounding areas clean. b. Place suitable container under transmission. c. Remove drain plug (1). d. Remove fill plug (2). e. Allow all lubricant to drain. f. Install drain plug (1) and torque to 20 lb-ft (27 Nm). g. Add lubricant Through fill plug opening until lubricant just begins to drip back out of opening. NOTE The amount of lubricant required varies from model to model. Refer to the vehicle service manual for transmission capacity. h. Install fill plug and torque to 20 lb-ft (27 Nm). 2-7. TROUBLESHOOTING 2-8. GENERAL. In the event of operating difficulty, it is recommended that the transmission (engine) be shut down. In most cases, to accurately pinpoint the source of trouble, it may be necessary to remove and disassemble, or partially disassemble, the transmission. Specific inspection procedures for detail parts of the transmission are provided in Section 5. 2-9. TROUBLESHOOTING CHART. Table 2-1 lists troubles which may be encountered along with possible causes and remedies. 2-1

Table 2-1. Troubleshooting Chart PROBLEM POSSIBLE CAUSE REMEDY Will not shift (control lever moves) Control lever assy broken or damaged Damaged offset lever, shift fork, selector Plate or selector arm Replace control lever and housing assy Remove extension or adapter and case Cover. Check for damaged parts. Replace Damaged parts Hard shift or control lever will not move into gear Clutch not releasing Improper or low transmission lubricant Shifter shaft or shift rail binding Binding of sliding synchronizers or gears If reverse only, seized backup switch Worn or damaged flywheel pilot bushing Bell housing misaligned Adjust or replace clutch Add or drain and replace with proper Lubricant (refer to paragraph 2-4 Remove extension or adapter and case Cover. Check for damaged parts. Replace Damaged parts Remove extension or adapter and case cover. Reach down into transmission and Check that synchronizers and gears (parts With shifting grooves) slide freely on shafts. Remove and replace damaged parts. Remove and check backup switch. Replace if seized Replace pilot bushing Align bell housing to within 0.010 inch TIR on face and in bore. Gears clash when Shifting Engine idle speed too high Clutch damaged or out of adjustment Pilot bearing between input shaft and Output shaft binding Damaged synchronizer Bell housing misaligned Damaged gear or gears Worn or damaged flywheel pilot bushing Adjust idle speed to specifications Adjust or replace clutch Disassemble and check bearing rollers, Input shaft ID and output shaft OD. Replace damaged parts Disassemble and check for damaged Synchronizer parts. Replace damaged parts Align bell housing to within 0.010 inch TIR on face and in bore Disassemble and check for gear damage. Replace damaged gears Replace pilot bushing Transmission jumps out of gear Loose transmission or flywheel housing Bolts, improper alignment Synchronizer damaged or excessively worn Blocking ring damaged, worn index slots Or friction surfaces worn or damaged Excessive countershaft end play Shifting fork loose on shaft or rail; worn Or damaged fork or inserts Torque bolts to specifications. Realign if Necessary Disassemble and check for worn or Damaged synchronizer parts. Replace Damaged parts Disassemble and check blocking ring for Damaged parts Disassemble and check. Replace worn or damaged parts. Reshim if roller bearings Used. Disassemble and check for wear or Damage. 2-2

Table 2-1. Troubleshooting Chart (Cont) PROBLEM POSSIBLE CAUSE REMEDY Transmission locked in one gear Fork or offset lever loose on shaft or rail Worn or damaged forks, offset lever, Shaft or rail Worn or damaged synchronizer Worn or damaged gears Remove extension or adapter and case Cover. Check for loose parts on shifter shaft or rail. Replace roll pin(s). If still loose, replace shaft or rail and/or attached parts as required Remove extension or adapter and case Cover. Check for wear or damage, Replace damaged parts Disassemble and check for worn or damaged synchronizer parts. Replace worn or damaged parts Disassemble and check for worn or damaged gears. Replace worn or damaged gears Transmission noise. NOTE: Make sure noise is coming from transmission and not clutch release bearing or other components. Improper or low transmission lubricant Loose bolts or other attaching parts Improper flywheel housing to engine crankshaft alignment Noisy transmission bearings Noisy gears Add or drain and replace with proper lubricant (refer to paragraph 2-4) Make sure al attaching parts are torqued to specifications Check alignment and correct if necessary per vehicle service manual Disassemble and check bearing, bearing rollers and parts in and on which they operate for wear or damage. Replace worn or damaged parts Disassemble and check for worn or damaged gears (including speedometer gear). Replace worn or damaged gears Transmission leakage Leakage from other components Vent or breather clogged Too much or improper lubricant Loose bolts at sealing faces Improperly applied sealant Worn or damaged oil seal Verify transmission leakage. Thoroughly clean all exposed surfaces, then check for leaks Remove vent or breather and clean or replace Remove fill plug to check for excess, or drain and replace Torque bolts to specifications Separate and thoroughly clean leaking surfaces. Reapply sealant. Replace parts and torque bolts to specifications Replace oil seal 2-3

2-10. TRANSMISSION REMOVAL 2-11. GENERAL. The following paragraphs provide procedures for removing the T5 transmission. For 4-wheel drive vehicles, instructions are also given for removing the transfer case. If the vehicle is not equipped with 4-wheel drive, disregard paragraph 2-18 and references to the transfer case in the other paragraphs 2-12. OTHER COMPONENTS. Before or during transmission removal, it may be necessary to remove or disconnect other components. This is required to provide access to or clearance for the transmission ( and transfer case, if used ). Since these components vary widely from vehicle to vehicle, specific instruction are not provided in this manual. Refer to the vehicle service manual. Such components may include: a. Console or similar cover. b. Parking brake lever and controls. c. Wiring and/or vacuum harness. d. Exhaust system components. e. Clutch components. f. A skid plate or protective covers on the underside of the vehicle. 1.13 SUPPORTING TRANSMISSION ( OR TRANSFER CASE, IF USED) Before removing any parts which attach or support the transmission(and transfer case, if used), support the transmission on a suitable jack or stand. The jack or stand must be capable of supporting and holding the transmission independently. Also the jack or stand shall be capable or lowering, raising and moving the transmission laterally. 2-14. PROCEDURES WITH VEHICLE ON FLOOR. Before raising the vehicle, proceed as follows: a. Position vehicle over suitable hoist. WARNING When using a drive-on lift, be sure to properly chock the wheels to prevent the vehicle from rolling off. b. Disconnect negative battery terminal. c. Shift vehicle into neutral and release parking brake. On 4-wheel drive vehicles, shift into 4HI. d. Remove shift lever (see figure 2-1): 1. Detach bottom of boot (1) so that it can be raised to provide access to lower end of shift lever. Boot attachment methods may vary from that shown. 2. If shift lever is threaded on, loosen lock nut (2), then remove shift lever (4) using wrench on flats (5) provided. 3. If shift lever is attached with screws (3), then remove screws (3) and shift lever (4). 2-15. LIFTING VEHICLE. Lift vehicle on suitable hoist, allowing clearance for removal of transmission (and transfer case, if used), and related components such as propeller shaft (or shafts), cross members and supports. If unsure, refer to vehicle service manual for approved lift points. NOTE On some vehicles, it may be necessary to remove or disconnect other components (refer to paragraph 2-12) Figure 2-1. shift Lever 2-16. DRAINING LUBRICANT. Drain lubricant from transmission (and transfer case, if used) (refer to paragraph 2-6, steps a through e). Reinstall fill and drain plugs. 2-17. REMOVING REAR PROPELLER SHAFT. The rear propeller shaft (3, figure 2-2) is splined to the transmission (or transfer case, if used) output shaft. It will be necessary to disconnect the rear end of the propeller shaft first, then move the shaft rearward to disengage the splines. Support the propeller shaft to prevent it from dropping. Bend universal joints just enough to permit shaft removal. Otherwise damage may result. Refer to the vehicle service manual for specific procedures. 2-4

Figure 2-2. Transmission 2-5

2-18. REMOVING TRANSFER CASE (4-WHEEL DRIVE VEHICLES ONLY). On 4-wheel vehicles, proceed as follows to remove transfer case (see figure 2-3 and 2-4 and refer to WARNING following paragraph 2-14, step a): a. Remove front propeller shaft (17, figure 2-3) by removing bolts (15) and retainers (16). Observe same precautions in handling front propeller shaft as for rear propeller shaft (refer to paragraph 2-17). b. Remove shift lever linkage and bracket attached to transfer case and transmission. c. Support transfer case on suitable jack or stand (refer to paragraph 2-13). CAUTION Make sure transfer case is completely supported by jack or stand before removing bolts (18,figure 2-4) attaching transfer case to transmission. Do not allow transfer case to “hang” from transmission by splined shaft since this may damage input bearings. d. Remove bolts (18) attaching transfer case (19) to transmission (10). e. Move transfer case (19) straight back toward rear of vehicle to completely disengage splines from transmission (10). Remove gasket (20). f. Carefully lower transfer case on jack or stand. 2-19. REMOVING TRANSMISSION SUPPORT BRACES. The main transmission attachment points are at the clutch housing (4, figure 2-2) and at the transmission mount (5) on the cross member (6). Supplemental support braces may or may not be used, depending on the vehicle. If used, remove supplemental support braces and any other components necessary to provide for transmission clearance. Figure 2-3. Front Propeller Shaft 2-20. REMOVING TRANSMISSION. Proceed as follows (see figure 2-2 and refer to warning following paragraph 2-14, step a): a. Support transmission on suitable jack or stand (refer to paragraph 2-13). b. Remove back-up switch electrical connection (7). Also, if used, remove neutral switch electrical connector or any others that may be used. c. Remove speed sensor electrical harness or speedometer cable (location may vary). d. Remove bolts (8) and lockwashers (9) attaching transmission (10) to transmission mount (5). e. Remove cross member (6). CAUTION Make sure transmission is completely supported by jack or stand before removing bolts (11) attaching transmission (10) to clutch housing (4). Do not allow transmission to “hang” from clutch by splined shaft since this may damage input bearings. f. Remove bolts (11) attaching transmission (10) to clutch housing (4). g. Using care not to dislodge clutch parts, move transmission (10) straight back toward rear of vehicle to completely disengage splines from clutch. h. Carefully lower transmission (10) on jack or stand. Figure 2-4. Transfer Case 2-6

2-21. TRANSMISSION INSTALLATION 2-22. GENERAL. Install Transmission (and transfer case, if used) in vehicle from which it was removed as described in the following paragraphs. Note the following: CAUTION T5 transmissions are not necessarily interchangeable from vehicle to vehicle. Installation of the transmission in a vehicle other than that from which it was removed may result in premature failure. a. The following paragraphs provide procedures for installing the T5 transmission. For 4-wheel drive vehicles, instructions are also given for installing the transfer case. If the vehicle is not equipped with 4- wheel drive, disregard paragraph 2-24 and references to the transfer case in the other paragraphs. b. Before or during removal of the transmission, parts not specifically related to the transmission may have been removed to provide access or clearance. Be sure to reinstall these components exactly as they were prior to removal (refer to paragraph 2-12). c. The transmission (and transfer case, if used) must be supported on a suitable jack or stand capable of raising it the transmission into position, aligning and moving it to engage the drive splines. 2-23. INSTALLING TRANSMISSION. Proceed as follows (see figure 2-2): a. Apply thin coat of high temperature grease to input shaft spline on transmission (10). b. Shift transmission (10) into high gear and raise on jack or stand. Align transmission with clutch housing(4). CAUTION Make sure transmission is in exact alignment with clutch before engaging splines. Do not force transmission input shaft into clutch. Otherwise damage may result. If necessary, turn transmission output shaft to align input shaft spline with that in clutch. c. Carefully move transmission (10) forward, engaging splines in clutch, until transmission mounting flange contacts clutch housing (4). CAUTION Keep transmission completely supported by jack or stand until bolts (11) attaching transmission (10) to clutch housing (4) are installed and torqued. Do not allow transmission to “hang” from clutch by splined shaft since this may damage input bearings. d. Make sure mounting holes in transmission (10) and clutch housing (4) are aligned and install bolts (11). Torque bolts to 55 lb-ft (75 Nm). Do not remove jack or stand at this time. e. Install cross member (6). Install bolts (8) and lockwashers (9) attaching transmission (10) to transmission mount (5). Torque bolts to 35lb-ft (59 Nm). d. Remove jack or stand supporting transmission . e. Install speed sensor electrical harness or speedometer cable (location may vary). f. Install back-up switch electrical connection (7) and any other electrical connectors that were removed. g. Install any supplemental supports or braces that were removed during transmission removal. WARNING Be sure to fill transmission with proper fluid (refer to paragraph 2-4). Otherwise transmission will be damaged when engine is started. If vehicle is driven, transmission could lock up causing personal injury. 2-24. INSTALLING TRANSFER CASE (4-WHEEL DRIVE VEHICLES ONLY). On 4-wheel drive vehicles, proceed as follows to install transfer case (see figure 2-3 and 2-4): a. Apply thin coat of high temperature grease to output shaft spline on transmission (10, figure 2- 4). b. Install new gasket (20) on transfer case (19) mounting face. c. Raise transfer case (19) on jack or stand. Align transfer case with transmission (10). CAUTION Make sure transfer case is in exact alignment with transmission before engaging splines. Do not force transfer case onto transmission. Otherwise damage may result. If necessary, turn transfer case output shaft to align input shaft spline with that on transmission. d. Carefully move transfer case (19) forward, engaging splines on transmission, until transfer case mounting flange contacts transmission (10). CAUTION Keep transfer case completely supported by jack or stand until bolts (18) attaching transfer case (19) to transmission (10) are installed and torqued. Do not allow transmission to “hang” from clutch by splines shaft since this may damage input bearings. e. Make sure mounting holes in transmission (10) and transfer case (19) are aligned and install bolts (18). Torque bolts to 23 lb-ft (31 Nm). Remove jack or stand. f. Attach shift lever bracket and linkage removed at transfer case removal. g. Make sure front propeller shaft (17, figure 2-3) is properly lubricated and install. Attach to transfer case (19) with retainer (16) and bolts (15). Torque bolts to 15 lb-ft (29Nm). WARNING Be sure to fill transfer case with proper fluid (refer to vehicle service manual). Otherwise transfer case will be damaged when engine is started. If vehicle is driven, transfer case could lock up causing personal injury. 2-7

You're Reading a Preview

Tremec T5 WC STD transmission gearbox workshop service repair manual

Description

Reviews

Q&A

Recently Viewed