infernosg's S5 N/A Build

[infernosg]

Got the transmission disassembled as far as I care to go.

Started by removing the gear selector rods and clutch forks.



This was the best method of organization I could come up with - taping parts onto cardboard and scribbling the disassembly number from the FSM on the tape. In the end I have two of these cardboard pieces completely filled.



The modified puller from FC Fach to get those hard-to-reach bearings and clutches:



After that I basically forgot to take pictures because I started having difficulty. The mainshaft lock nut didn't cooperate for the longest time. I ended up completely disassembling the 5th/reverse clutch to remove it. The biggest PITA was the main countershaft bearing. The mainshaft popped right out of it's bearing but the countershaft didn't want to cooperate. For reference the FSM states to "tap the end of the countershaft lightly with a brass hammer." Yeah, that didn't work. I ended up having to pull the bearing out of the bearing support plate. Shortly after removing counter shaft bearing:



You can see the giant-ass socket FC Zach made for the mainshaft lock nut in the background. Quick shot of the countershaft, maintshaft, and bearing plate.



You can see the bearing still on the countershaft and the mainshaft bearing still in the support plate. Both have been removed since that picture was taken. All that work just to get to this:



The "input shaft" and second gear pinion. The input shaft needs to be cut down a bit to fit the RX-7. Once that's done I get to clean all the individual pieces and reassemble. Synchros all look good so no plans to replace them now. I spent the better part of Sunday cleaning 24 years of demon sludge (road grime + engine oil + transmission fluid) off/out of the transmission cases in preparation for paint.