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> Transmission rebuild, Manual gearbox
Pearl01stratcpe
post Oct 22 2012, 04:09 PM
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2012 Nissan Maxima
SV Sedan
VQ35DE / CVT
Pearl White



Decided to branch off from this topic- Clutch issue, or something internal? and turn it into a project log. Quick back story- transmission has made noise since August of 2009, and has gotten very bad despite proper maintenance. Gear oil was still like new when i emptied it to pull the transmission.

Trans is out, clutch is still in good condition, and the TOB is whooped, but wasnt loose, and definitely wasnt my noise.
I grabbed the input shaft and gave it a spin; sounds like a rock crusher. Pulled the little pan/plate off, and you can move the entire input shaft with gears back and forth a good 1/8", with some play up and down. I tried separating the clutch housing from the gear housing, and i get it 3/8" open and it wont open any farther. I need to find a trick to let them separate. Input shaft bearing measurements work out to be a standard 6307 bearing, so I can get one through work at 1/3 the cost.

I took the flywheel to a local machine shop and they did a great job making it like new. Clutch is all back together and on the car. Decided to buy a new one even though the original was still still working great since A: It has 139k on it and B: everything is open, might as well replace it now.
While removing the axles, I noticed my outer tie rod ends and lower ball joints were cracked open and leaking grease, so those are on their way as well.
Clutch kit- Pressure plate, clutch disc, and TOB - $120 on rockauto.com.
Flywheel resurface- $30
New ball joints and tie rod ends- $100 on rockauto.com
Gear oil ~$15
Input shaft bearing $20 Ended up being $92 for 2 bearings and 2 seals

Estimated at under $300 after its all done, doing it myself of course. $350 due to OE parts

Video 1 of noise, in neutral
Video 2 of noise, while driving
Video 3 of noise, with engine braking

(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-21154919.jpg)
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-21111105.jpg)
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-21111114.jpg)

Flywheel before
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-22115102.jpg)
Flywheel after
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-22165446.jpg)
Clutch together
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-22173722.jpg)

Ill update with pictures of the transmission internals when I finally get it opened.

This post has been edited by Pearl01stratcpe: Oct 23 2012, 01:16 PM
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dk89
post Oct 22 2012, 07:30 PM
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Dan I'm truly envious of your mechanical knowledge (IMG:style_emoticons/default/smile.gif) I wish I had not only the tools but the know-how. Would save me SOOO much money!
Glad to see you continuing to work on the car!
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wiseoracle
post Oct 23 2012, 08:54 AM
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QUOTE (dk89 @ Oct 22 2012, 09:30 PM) *
Dan I'm truly envious of your mechanical knowledge (IMG:style_emoticons/default/smile.gif) I wish I had not only the tools but the know-how. Would save me SOOO much money!
Glad to see you continuing to work on the car!


*cough* there are how to guides out there... *cough*

*cough* you can get a lot done with a basic 100+ piece tool kit *cough*

*cough* most autopart stores let you borrow tools for free *cough*

*cough* YOU HAVE YOUR OWN GARAGE!!! *cough*
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PhatKat
post Oct 23 2012, 09:40 AM
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2002 Dodge Stratus
R/T Coupe
3.0L / 5 speed
Black



QUOTE (wiseoracle @ Oct 23 2012, 11:54 AM) *
*cough* there are how to guides out there... *cough*

*cough* you can get a lot done with a basic 100+ piece tool kit *cough*

*cough* most autopart stores let you borrow tools for free *cough*

*cough* YOU HAVE YOUR OWN GARAGE!!! *cough*



Thine excuses hath been despatched!
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dk89
post Oct 23 2012, 11:32 AM
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:fawk: leave me along Long! (IMG:style_emoticons/default/laugh.gif)
It's probably down to my patience and time/schedule that really does away with these things. Convenience is also a huge factor in this equation...
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Pearl01stratcpe
post Oct 23 2012, 01:04 PM
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2012 Nissan Maxima
SV Sedan
VQ35DE / CVT
Pearl White



Having the factory service manual is very handy for finding hidden bolts, and is the main reason why I didnt fear opening the gearbox.The little things like pulling the brake calipers, unhooking the tie rod ends, popping out an axle, removing a steering knuckle all add time to the job. If you dont have a big socket to fit the axle nut, if a tapered ball joint doesnt want to pop free can make you have to run to the autoparts store adding more time. Luckily I have helped friends work on their stuff, so I knew exactly what I was getting into, and was able to have the trans out in a few hours.

After I browsed the service manual (which is worth its weight in gold) I realized I needed to remove the reverse idler gear. One bolt and it separated with ease.

I unbolted the bearing retainer, and lifted the input and output shafts together. The bearing wasnt destroyed, and I could have driven a little bit longer on it, but it was only a matter of time until a ball broke and either jammed the bearing and ruined the shaft, or a piece broke off and got in between gears.
Magnet in gearbox made to collect shavings. I thought the filler plug and drain plug were supposed to be magnets, but they arent.
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23101426.jpg)
All clean
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23121950.jpg)

In housing
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23072349.jpg)
On table
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23074206.jpg)

Differential and all gears
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23075554.jpg)
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23075606.jpg)

Bad bearing removed
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23101223.jpg)

Housing before
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23074214.jpg)
After pressure wash and good dry
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23121741.jpg)

The bad bearing
(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-23122211.jpg)


I decided that since I was replacing the one inboard ball bearing on the input shaft, that I might as well replace the inboard roller bearing on the output shaft as well. Both shafts have sealed ball bearings on the opposing sides, and felt like new, so Im not going to mess with them. New Input shaft seal and case seal have been ordered as well.

The bearing dimensions on the rock auto website for the input shaft bearing are not correct. They measure out to be a 6307 bearing, but the bearing in the housing is OE specific; only the manufacturer has it. It is part number 2526A0001 to Mitsubishi, and on the bearing its an NGK B25-157. My work deals with bearings daily, and none of our bearing suppliers could get it. Dodge Dealer wanted $64 for it, Mitsubishi wanted $33.

For anyone in the future needing this info:
2526A0001- Bearing, M/T Input shaft (interchanges with MD700207)
MD741818- Oil Seal, M/T Input shaft
MD746157- Cap, M/T Case seal - (stupid design requires this to be destroyed to split the gearbox open)
MD747707- Bearing, M/T output shaft

Parts should be here Thursday; in the mean time Ill probably paint the case either silver or black, and hopefully have ball joints and tie rod ends the same day.



This post has been edited by Pearl01stratcpe: Oct 24 2012, 11:35 AM
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Pearl01stratcpe
post Oct 24 2012, 11:44 AM
Post #7


2g Pimps
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From: Knoxville, TN
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2012 Nissan Maxima
SV Sedan
VQ35DE / CVT
Pearl White



I pulled the roller bearing inner race off the output shaft, and the outer race with rollers out of the housing today, what a PITA. ended up having to break the cage, pull the rollers out and weld a bead in the race to have it retract in. Finally got it out, and painted the transmission case flat black, so now itll look as good on the outside as it does on the inside (IMG:style_emoticons/default/biggrin.gif)

(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-24091347.jpg)

(IMG:http://i86.photobucket.com/albums/k100/Bekistan20/Transmission%20rebuild%20October%202012/2012-10-24130711.jpg)

Unfortunately. rockauto had my ball joints and tie rods ends shipped from separate locations, so Ill have tie rod ends here tomorrow, and the ball joints Monday, so i cant drive it until Monday night (IMG:style_emoticons/default/dry.gif)
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