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Old 10-26-2009, 05:31 PM   #1
rentfrow1
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Default Manual Transmission Overhaul

I just bought an MP3 manual transmission from the pick n pull yesterday to do an auto to manual swap in my '99 SL2 (114000mi). Other than cleaning the outside up with degreaser, is there anything I should do/look for to make sure I don't have any problems with it later? I am thinking I should replace some of the oil seals and peak inside to make sure there are teeth on the gears. Anything else?

For the clutch assembly, I will probably replace the clutch disk, pressure plate and throughout bearing, and I will get the flywheel refaced. I would appreciate any advice on where to source the parts and what to get. It is just a daily driver, so nothing fancy.

Time is not an issue, because I don't plan on putting the transmission in until this winter when I pull the engine to rering it (rings, bearings, gaskets, valve job). It burns 4-6 qts between oil changes (3000mi).

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Old 10-26-2009, 07:50 PM   #2
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Default Re: Manual Transmission Overhaul

If you plan on opening up the tranny have the differential pin welded in place. Wolfman has pictures of where to weld.

clutchcityonline.com is where you can get a LUK CLutch assembly for 159 shipped.

I doubt you need a resurfacing on the flywheel. But I can send you a link for a cheap light weight flywheel ($150 compared to the usual 300).

Read my debrief on my own engine rebuild.

Read Rebuilding My '95 SC2 for OldNuc's and my commentary on that rebuild also.

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Old 10-26-2009, 07:53 PM   #3
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Default Re: Manual Transmission Overhaul

get the diff pin welded, and clean off the magnet. when you take it apart DO NOT let the 5th gear synchro come off, its a pita to get back on since theres about 500 different combinations and only one works. And I know where you can get a stock replacement clutch for 95 + shipping, drop me a pm and I'll tell ya.

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Old 10-26-2009, 07:57 PM   #4
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Default Re: Manual Transmission Overhaul

I'd like the link for the flywheel. I've been toying with doing a lightweight flywheel when I'm in there. (clutch swap) Only holdback is cost, I don't see otherwise why a lightweight flywheel would not be a worthwhile upgrade!

Fidanza was one of my top items on my mod list.. $$$ though.

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Old 10-27-2009, 08:52 AM   #5
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Default Re: Manual Transmission Overhaul

I'd weigh the $40 or so a year of between-changes oil topping against the cost of having oil drainback holes drilled in the pistons.

With the re-ringing and new clutch/tran, sounds like you're into this car for the long haul...

At least you don't have to worry about the weak US dollar causing your oil prices to go up

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Old 10-31-2009, 10:35 AM   #6
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Default Re: Manual Transmission Overhaul

$40 or so a year? Try $120 to $150 /yr. I commute 70mi /day, and I add .5qt to 1qt every time I fill up with gas. I have probably already spent half of the repair cost in oil. Not to mention that I have to keep cleaning out the EGR valve and the throttle body. The engine is also developing leaks in the rear main seal and the cam cover gasket.

I am also doing the overhaul because I am an engineer, and I view this kind of thing as exciting and fun. I almost got an MP2 5th gear set from the junkyard yesterday, but I did not have the right size socket to get the input and output shaft nuts off. I think it is 30mm right?

On another note, no one answered my original question yet. Should I replace the seals in the junkyard transmission as insurance against future leaks, or do they typically last the life of the vehicle? Thank you for the responses.

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Old 10-31-2009, 10:50 AM   #7
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Default Re: Manual Transmission Overhaul

if you dig into the trans, check the bearings for play & replace any with any noticeable play.

You could also consider painting it. Here's what someone on sixthsphere did with theirs.


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Old 10-31-2009, 10:51 AM   #8
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Default Re: Manual Transmission Overhaul

if you're already replacing the rest of the stuff in the tranny you might was well replace the seals.

...
1994 SL2 HCE auto 113 hp 113 lbft (wheel) backup car
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For Sale: FlyWheel, Shifter assembly, Clutch Hydros, 1st gen 5 spd PCM. PM me for prices.

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Old 10-31-2009, 10:55 AM   #9
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Default Re: Manual Transmission Overhaul

and I know we're said it before but make sure you get the diff pin welded in place. I want to pimp slap the engineers that let the accountants make the decision to not put some way of holding the diff pin in.

...
1994 SL2 HCE auto 113 hp 113 lbft (wheel) backup car
2002 Chevy Cavalier SS
For Sale: FlyWheel, Shifter assembly, Clutch Hydros, 1st gen 5 spd PCM. PM me for prices.

WPI class of '12 ME

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Old 11-07-2009, 01:01 PM   #10
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Default Re: Manual Transmission Overhaul

I got the transmission apart and pulled the differential out to be welded. The differential bearings felt a little gritty, but that was probably just from cleaning the outside of the case. I will try to flush them out later. There were no obvious problems with the gear set. The magnet had some metal on it, but it wasn't too bad.

Anybody have a source for the tolerances I should check before I reassemble it?
Also, where would be good place to source the replacement seals?

Thanks for all the help. I will try to post some pics later.

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Old 11-07-2009, 01:45 PM   #11
1995sl1sohc
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Default Re: Manual Transmission Overhaul

Replace the differential bearings, chances are they grounded through bearings and toasted them. I know they did with mine BCA 208 is the part number. All stores should be able to cross it. NAPA # is 6208J.

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