C56 dismantle/syncro replacement guide?

[touge_ae101]

Has anyone got/know of an online source that tells you what you need to take apart to replace the syncros? i'm guna head home from uni now and start taking gearbox apart and wouldn't mind a rough guide of some sort...

thanks in advance

Rhys

[gasman]

the greogrys car manual that i got for a ae92 has a gearbox teardown for a c52. i used it to rebuild my e58 and it had all the basic steps in there

[Bazda]

I can pull one apart in my sleep lol.
I duno if thats a good thing or bad... :S

[touge_ae101]

haha yeah not sure if that is healthy bazda!

so what is the basic structure of getting them apart? obviously need to split the casing...has there got a circlip inside the bellhousing the holds that bearing in?

how do the selector(s) come out?

any special tricks/tool i need to know of??

just want to get it apart now to inspect it and see how many of the syncros i need to replace.

[Bazda]

ok a quick run down, i'll try my best...

remove the side bolt which holds the reverse gear shaft in place (hard to explain but its a bolt all by it self on the side of the casing)
Remove all the ball/springs (allen head things, should be 4 of them but you only need to remove 3)
remove the top casing over 5th gear
remove 5th gear selector fork (bolt int he side of it to the shaft), lift off the hub and syncro.
remove circlip off the top of 5th gear.
Now you need a puller thinghy to pull the hub off 5th gear
remove all circlips on the shafts you can see
another puller to pull off the opposing gear
remove more circlips etc
get out a gas torch and apply small amount of heat to the botls holding on the big cover, usually they have loctite and you will just strip the heads if u dont melt the loctite a little, after this they will come out like a dream
thats should be everything up in that department done now.
remove all the bolts holding the bell housing
remove gear selector fork (remove reverse sensor and holder bolt)
there are 3 bolts on the inside of the bell housing (clutch side), need to remove those.
you should be able to split the casing now (soft hammer might be needed)

From there the next bit is too hard to explain lol. there is a sequence I use to get the rest out which works really well for me but I def coulnd not explain it in a few sentences....it requires removing the selector hubs & shafts in a certain sequence.

You need the manual lol

I've seen Stu had one written up somewhere but it removes the case with the gears attached still. Not ideal in your case but might be good when changing just a diff, still putting it back together would be a pain this way.

[touge_ae101]

haha cheers bazda that gives me an idea of where to start. i really just want to get it apart to see what i need to do to get it back to being fully functioning and not crunching.

[allencr]

This C52 site looks nice & complete compared to any thing you'll find in any manual, don't know the differences between it & your C56, or who to thank.


http://www.ae92gts.com/ae92gts_trans_rb_1.html

[whynot]

I have a complete c52 and e51 service section for the gearboxes if you want to have a look through them at some point

[Mr Revhead]

A while ago someone on toymods was translating the C series manual....

[touge_ae101]

A while ago someone on toymods was translating the C series manual....

haha so they're probably still trying to do it?!?

awesome that website will teach me what i need to learn for now and might get that c52 manual off you when i'm back from holiday mark.

[85AW20v]

The writeup Stu did for the diff replacement was on Starlet Central....