Thread: Transmission case + 5th gear fix

Ok I see it over and over again we break the infoumous trans case or deal with 5th gear pop out . I'm showing you how to do it yourself and save some $$$ !This is for b13/b14 lsd and non lsd tranny's . Now dont be afraid this is fairly easy to do the hard part is taking out the transmission . First off if you have a broken case due to wheel hop or bad motor mounts dont go and spend 300-600 for a used trans when you can fix it in about 2-3 hrs and spend around $100-$150.
Ok so say you have a trans with cracked case look for someone selling a trans with bad 5th gear as you only need the case . These can be had for roughly 100-150 with a bad 5th gear . Or you have a bad 5th gear and need a cracked trans with a good working 5th gear . This lsd transmission belongs to member "viprdude" aka Kyle .This was in his 95 se-r and he cracked the case due to wheel hop. So I'm replacing the case and welding the new one for extra reinforcement . Both lsd and non lsd transmission's are the same except for the outer case . so if you have a lsd trans you need to get a lsd trans and same for non lsd trans . You can interchange the bellhousing side of the cases . Also b13/b14 are same with the exception of the crank sensor on the b14's . So if you want to use a b14 trans for parts on a b13 that will be fine. I will soon have a thread on b15 tranny's as they are simalar but internaly different .So lets get started...........

Tools needed
-10mm socket -
-12mm socket
-rubber hammer or peice of wood and standard hammer
-pry bar/screw driver
-good silicon sealer
-good work bench or good flat spot on the driveway

Here is the link from benfenner on the actual 5th gear break down a replacement and the difference between the new style 5th gear and the old popout one ....Good stuff !
http://www.sr20-forum.com/general-maintenance/18390-how-recognise-repair-5th-gear-pop-out-b13-b14-transmission.html

STEP 1
remove old trans and drain it ! LOL
Lay the trans on its bell housing side so the driver side is straight up and make sure it is in nuetral .

Now remove the small circle cover on the end of the driver side part of trans case (6) 10mm bolts .And under that you will see a bearing and (2) snap rings . You will need to take only the outer and lager snap ring off leaving the small one on there .Its tricky to get out and hidden down in there but should come out with a snapring tool (see picture below)or two small flathead screw drivers . Also try not to loose the o-ring on that round cover .


What the ring looks like ...


STEP 2
Romove the (12) 12mm bolts around the case



STEP 3
Seperating the case. Hit it on both sides with a rubber hammer or a peice of wood and standard hammer until it splits loose you may have to use a prybar or screw driver to help gently pry as it may be stuck on the 2 dowel pins .


STEP 4
twist the half of the case counter clock wise and pull it sratight up and off


STEP 5
romove this platic looking sheild cover its lifts right off . This is a very important peice that keeps the gears lubed !! As the diff ring gear spins it throws gear oil up onto the plastic cover and allows it to run down the channels draining on the gear stacks keeping them lubed. DONT FORGET TO PUT IT BACK IN !!.

Now this is what you should have looking at you at this point


STEP 6
removing the gear stacks . Start by taking out the (3) 10mm bolts the hold the shift fingers/arms inplace


And this hidden one ...


STEP 7
remove the reverse gear and shaft. The shaft pulls right out and the gear slides out . If you ever wonder why your trans makes "WRRRRR noise in reverse going over 5mph ! its because the gear is straight cut and not anggled like the others ! The "PAR" gear set has all straight cut gears and allways make a whiney noise like that .


set it aside like this and try not to loose the washer that on top .


STEP 8
remove the (3) 12mm bolts holding the main shaft/gear stack


STEP 9
remove the gear stacks .Be careful not to drop some of the parts
use two hands and wiggle it out as one unit all together and lay it on its side .



STEP 10
remove the diff unit it will pull right up and out .Be carefull not to damage to plastic gear ring on the bottom that is for your speed sensor !


Now that the case is empty of the gears stacks and diff now would be a good time to inspect the gears and shift forks for signs of wear and tear . Dont worry about the shift rod linkage and other parts in the old bellhousing case as you will be using the new ones in the new case . Should look like this so far.......


Be sure the new case still has these check ball springs and did'nt fall out.


This is the infamous "5th gear " pop out problem shift fork .


At the end of the fork is a notch and should look like this but if it dont then time to replace . The arm/finger tab should sit nice and snug in this notch on the fork but on 5th gear pop out tranny's the notch over time gets worn from the bad 5th gear and the notch gets larger and lager then you have no 5th gear .


This is the arm/finger tab that sits inside of that shift fork notch and has a steel cap on the end of it. You should take the steel cap and make sure it fits nice in the notch on the fork. Dont worry if there is tinny bit of wiggle room its ok .




Start by inspecting the diff bearing race on the new case for any "divits or dents" by running your finger along the race .
Next inspect the shaft bearings also for dings or dents


Here you can see the small hair line crake in the case im point at it with a screw driver its hard to see .....


Now would be a good time to replace all the seals in the tranny and clean the case or take a wire brush to clean it . DO NOT use a sanding disc on the mating surface of the two halfs to clean the silicon off you will end up with sealing issues . I would use a razor blade or a dygrinder with a rubber disc pad .

Again this should take you no more than 2-3hrs start to finish with the exception of a break for a sandwich or cold beer !
If you have the abillity to pull the transmission out then you sure as heck can rebuild it .

Now reverse the steps to put the new tranny back togather . I will update the thread tomarow with the resembly process. If you have any questions feel free to send me a pm .My name is Keith

Nice write up very detailed,i think it should be stickied.

This is awesome. Thank you, Keith.

I cannot wait until you update this some more. I am glad my dirty, cracked transmission did one last good thing before its rebirth.

Tomorow I will show how the take the gear stack apart and replace the good old 5th gear .And in the next week or two get some pics of me welding up the case . I hope to have a b15 trans to work on and document that as well . I already rebuilt fubar102's b15 trans and should of took pics of that after a mainshaft bearing let go in it . B15 trannys are designed so much stronger than a b13/b14 .

I need to replace my diff.

I think that dude should just sell me his damn car...

Lol i don't think i want to yet.Sometimes i do,then sometimes i don't.

Just do it, I will love it and keep it forever.

The sooner the better so I can get my original, first SE-R fixed up correctly (rust repair needed in the major way).

Keith, thank you so much for doing this. That trans has not been used since 2006 and it looks pretty good form the pics you have up here.

Awww so nice of you.But not ready to part away from it yet.I know you'll treat her right.

Manny I have 2 working lsd's sitting in my shop drop off your trans.

Kyle I'll weld up the trans thats in your car when you put this one in .
Allways good to have a spare trans