It's a left hand thread. A 1/2" impact wrench works good to remove the nut.

 

Thank you Jim



Thank you! I did this today at lunchtime (with the impact wrench), and began dis-assembly of the countershaft. Got the second gear synchro modified, and will read the directions in the FSM again to prepare for assembly tomorrow. I checked the manual again, and did not see anything about the threads. Was thinking I just overlooked it. Oh well, it's only been 35 years since I took a manual transmission apart .

Take care,
Tim Glover

 

It is REVERSE THREAD!!!, 30mm is the correct nut size.

Make sure you line up the 1-2 syncro seals properly and use the proper re-torque sequence after: 80 - 0 - 80 ft. lbs.

 

Is second the only synchro that gets modified?



Thank you Jeff on the tip for lining up the 1-2 synchro seals. I have the pdf on my jump drive now, and the exploded CS diagram from page 100.

Is second the only synchronizer ring that you modify? It was a bit scary grinding off the tabs, but it is now done. At the moment, first gear is still on the CS assembly, along with what I believe is the first gear synchronizer, the 1-2 synchro hub and reverse gear.

Take care,
Tim Glover

 

I need to do this mod as well, please post results and any tips when you're done, if you don't mind.

 

I have done this modification to about 20 transmissions and it works great. I do the modification to both the first and second gear syncros just to guarantee there's not an issue later. First grinds also, although its less common.

 

Thank you again Jeff. I am almost there, so I will go ahead and modify first gear synchro as well.

Tim


P.S. Other than the Input Shaft Bearing, do you replace any other bearings in the transmission? The other ones look good, no galling or pitting. The ISB was surprisingly intact for all the racket it was causing, but definitely was bad. I've seen lots worse pictures on this forum. All the balls and retainers were still in their original locations on mine.

 

Jeff, How much do you charge to do this modification to the tranny? My 2nd gear downshift grind just started a few months ago and I am coping with it, but I would just like to see if it is worth my time to take off my tranny and send it to you. Or buy a spare tranny....

 

Could someone explain to me exactly how I modify the first and second gear synchronizers. I have the drawings but i'm not sure exactly what "tabs" i need to grind off. thanks.

 

The info can be found here:
http://hybridautomotive.com/insight/

OR HERE:
http://www.insightcentral.net/forums/problems-troubleshooting/25031-manual-transmission.html
PLEASE include your location in your profile.

Thank You
Willie

 

Found it, the key was searching for "clocking tabs"
http://www.insightcentral.net/forum...problems-troubleshooting/25196-new-owner-2001-gen1-transmission-problems-2.html

 

fly75

Your "Transmission Gru" is only 135miles away.

WIllie