Rebuilding ZX 5 speed

[inline6]

Thanks for the compliments Steve. I've got a whole website in my head that I would love to get public, but I'm not an html person. A friend put together my website for me several years ago. I've got a lot of other stuff that I have learned along the way, as many Z owners have no doubt, but getting it public sure would save a lot of $, time and aggravation.

My 83 ZX transmission is nearly back together. I ran into a problem with the hog rings on the reverse idler gear. They are so thick and beefy, that even the toughest set of hog ring pliers I bought at Sears won't get them off. I damaged both of them getting them off and had to order new ones. So, I am waiting on parts.

I made a host of special tools (drifts of the right diameter and length, and another one that allows me to use a standard gear puller to reach one of the gears really far down on the mainshaft) that are like the ones in the ZX factory service manual. Since I have a second ZX tranny to rebuild for my 510, they will come in handy again some day.

Garrett

[Bambikiller240]

A friend put together my website for me several years ago. I've got a lot of other stuff that I have learned along the way, as many Z owners have no doubt, but getting it public sure would save a lot of $, time and aggravation.

Where is this website? I don't see a link anywhere (unless I'm missing something) I'd like to look at your site if I could find it.

[lordbiotree]

Hello Garrett,

Great job!

If you get a HTML editor they'll basically do all the work for you. Front page will make you a good text-picture site. Nothing fancy. Macromedia Dreamweaver is a good place to start.

Good luck.

[ChrisA]

Hey Carl, I think this is his site: http://members.tripod.com/Trueweb/Zcar/

Chris

[Bambikiller240]

Thank you, Chris. I appreciate the link. looks like an interesting site. i'll have to check it out in detail tonight.

Thanks again

[inline6]

I finished rebuilding and installing the transmission. Here is a fair amount of info that will help you and save you some of the trouble I had. Again, this was the 83 280ZX Nissan (not Borg Warner) box.

The most striking thing I learned: The synchros aren't what takes a beating when you crunch gears! Each gear has a part that is manufactured separately and then press fit to the gear itself. It has straight cut gears and is what the gear sleeve meshes with to secure the car in gear. The synchro helps the sleeve slide onto this part of each gear more easily. This piece, which takes the brunt of the wear is NOT REPLACEABLE. You have to buy new gears. (2nd was $214.00 from the dealer with 20% off) Given this, if your box is crunching gears horribly and it is not a problem outside of the gearbox, don't expect a cure all by rebuilding with new synchros.

Even with all new bearings and needle bearings, 3rd gear has a high pitched whine to it. I suspect that is a characteristic of the tranny. It is not loud, but present I think in all of them. Don't expect to get rid of it. The tranny, in general, is very quiet now however.

There are several regular bearings and some needle type bearings. I replaced them all, but the needle bearings were probably fine. There are some "bushings" (made of steel) that the needle bearings ride on. These look like wear items in the exploded view diagrams, but in fact don't seem to wear. Same with the washers next to the mainshaft nut and countershaft nut.

So here is what to replace in my opinion:

Countershaft bearings seemed to be worn most

Mainshaft bearings if you want to be thorough. My tranny easily had 150K+ miles but, I could not detect the difference between old and new when checking play

synchros as necessary. I replaced them all, but they showed little wear.

mainshaft and countershaft nuts

oil seals and front gasket

Special Tools:

Factory Shop Manual!

shop press

1 small 3 finger gear puller

1 large 3 finger gear puller

pipes of various diam. to use as drifts to install bearings:

(1) 7" long 1.5" min ID

(1) 7" long 1.0" min ID

(1) 16" long 1.063" min ID

(1) 8" long 1.375" min ID

pipe to use in making special tool to hold guts of tranny in shop press:

(2) 4" long .8" min ID (you need a welder to do some tack welds to make this tool)

several plates (.250" thick would be best) for making a "tool" to hold tranny guts in vise (shown in factory manual) and for the tool hold guts of tranny in shop press (also in manual)

bearing separater (used in press to get behind bearing when removing)

vise

Autozone has a tool rental program. Basically, you buy the tools (used) for list price and when you are done, return them and get a full refund.

Finally, there are two hog rings on the reverse idler gear that are beasts. I broke two sets of hog ring pliers and ended up mangling them and having to buy new ones. Get some serious hog ring pliers to do battle with these guys.

Summary:

Not hard at all with the right tools. Making the tools was the hard part. Second gear probably takes the most abuse in general. Examine that one closely compared to the others to gage amount of wear.

[Gav240z]

Thanks for that I think I might have a crack at rebuilding the 260z 2 seater box I aquired recently