Virginia Motor Sport Club Discussion Forums
January 19, 2018, 12:54:03 AM *
Welcome, Guest. Please login or register.

Login with username, password and session length
News:
 
   Home   Help Search Login Register  
Pages: [1]   Go Down
  Print  
Author Topic: Caprice trans rebuild  (Read 2008 times)
jloehlein
Administrator
Hero Member
*****
Offline Offline

Posts: 915


View Profile
« on: July 30, 2016, 08:15:48 AM »

So...I haven't been driving the Caprice much lately because the trans has been making some horrible noises.  Unfortunately, it's when I'm off the clutch, so I think it's the trans and not just a throwout bearing.  Not a big deal since I can tow with my truck...until I blew the head gasket on that.  The truck will sit until I can restore it (probably about a year).  So I decided to rebuild the trans on the wagon.  I had been putting it off for a while, but the other weekend one of the steel brake lines burst (rusty), so I decided to just dig into the car and take care of everything.

I don't have many pictures of the process, but I got the trans apart and found a few concerning things.

Here is the front cover - you can see the bearing race on the front of the countershaft has been spinning.  I believe this may be the noise I was hearing.  I'll get everything shimmed properly and then loctite it into place.



I also noticed that teeth that hold 5th/6th gear to the main shaft have a bunch of wear.  I ordered a new main shaft and 5th/6th driven gear.  Need to wait for that to get in this week before I can put everything back together.



Here are all the parts laid out.  I'm trying to keep them in order.



I also found a ton of play in the throwout bearing, cracks in the flywheel, and the pilot bearing had been wallowed out quite a bit (there's not supposed to be a lip there).  I guess this is what I get for taking the trans out of a 3500lb car, putting it in a 4500lb car, and then towing a 5-6k lb trailer.

Logged

2000 Honda Insight - Daily Driver (in the process of engine swapping now)
1995 Honda Civic CX - Street Mod/HPDE beater
1991 Mazda Miata (plus parts cars) - LeMons racecar
250whp, 1300lb Birkin S3 (track day car in the works)
jloehlein
Administrator
Hero Member
*****
Offline Offline

Posts: 915


View Profile
« Reply #1 on: August 14, 2016, 04:57:49 PM »

Man, progress has been slow over the past couple weekends, but I think it's finally done.  I got everything shimmed up last weekend and went to bolt the case back on, but snapped one of the guide bolts for the shift rails.  It's like a $2 part, but you can't find them anywhere.  So, I ordered them and waited until this weekend.  Yesterday, I finished putting the trans together, got it in the car and then realized the new rear seal had a split in it.  Got a new one this morning and threw the car back together with Jeff.  Started it and immediately knew something was wrong.

Turns out the clutch release fork was contacting the pressure plate before disengaging the clutch.  You can see where it wore the paint off and ground a portion of the pressure plate down.



Turns out this is a pretty common problem with LT1s and aftermarket clutches/flywheels.  They can be a bit thicker than factory and because the bellhousing is very shallow, tolerances are tight.  Jeff and I tore the exhaust and trans out one more time and I "milled" down the clutch pivot with the angle grinder and a file to move it away from the clutch.  We got it back together a couple hours later and fired it up.  Thankfully everything seems to clear now.

I had a small exhaust leak between the cats and x-pipe, so I used a bunch of copper RTV.  Haven't driven it since the RTV is drying, but it seems to shift more smoothly sitting still.  Keeping my fingers crossed!  At least everything is much cleaner than when I started.

Logged

2000 Honda Insight - Daily Driver (in the process of engine swapping now)
1995 Honda Civic CX - Street Mod/HPDE beater
1991 Mazda Miata (plus parts cars) - LeMons racecar
250whp, 1300lb Birkin S3 (track day car in the works)
Pages: [1]   Go Up
  Print  
 
Jump to:  

Copyright © 2018 Virginia Motor Sport Club