91rs1022

iTrader: (3)

I'm looking at rebuilding my t5. Is there any special tools I'll need? Any advice?

midias

A way to press on and off bearings, dial indicator, snap ring pliers and a way to measure check preload like a torque watch.

Get the rebuild DVD from these guys

http://www.hanlonmotorsports.com/

http://www.flatheadv8.org/T5Rebuild.pdf

Required tools:
(well, maybe not all required; some merely desired...)
Metric combination wrench set (at least 10mm, 13mm, 15mm)
Metric sockets and ratchet (same sizes as above...)
7/8” open-end wrench (reverse light/neutral switch)
3/16” diameter punch (shift block, reverse idler shaft, shift forks)
External snap ring pliers
Retaining ring pliers
6” or 8” calipers
1” travel dial indicator
Magnetic base and stand for dial indicator
4” C-clamp
Two- or three-jaw puller
Scribe
File (no, fingernail file won’t work!)
Parts washer or many cans of carb cleaner!
Air compressor and air nozzle
Regular screwdrivers (large and small)
Valco Tube-Grip (RTV sealant dispenser; the best $15 I ever spent!)
3/8” or 1/2” diameter punch (I use Chevrolet fuel pump pushrod)
Bushing driver, 1.625” O.D. x 1.500” I.D.
Foot-pound torque wrench
Dremel w/ cut-off wheel (for marking synchro hubs/rings)
4” C-clamp (or Quick-grip)
3lb sledge
Cold chisel
T40 Torx bit
1-7/8” O.D. x 1–1/4”(1-1/4” pipe) to 1-3/8” I.D. x 5-1/2” long pipe (for cluster bearings)
3” diameter slug of material, approximately 1-1/2” thick or so...
Bearing separator, or harmonic balancer puller and threaded rods
Shop press (optional, but makes life much easier)
Required chemicals:
RTV (I prefer Permatex UltraBlack, but any oil resistant RTV will work.)
Loc-tite 242 (blue, removable)
Non-hardening thread sealer (Pli-A-Seal, Grey Bolt Prep, etc.)
Vaseline (for holding loose parts in place)
Three quarts of your favorite trans fluid
Loc-tite 271 (red, permanent)

91rs1022

iTrader: (3)

Awesome, thanks

InfinityShade

http://www.5speeds.com/t5.htm

I suggest buying and installing one of these as well. This site has rebuild kits and books as well as videos.

Abubaca

iTrader: (3)

I rebuilt mine, never having seen the inside of the manual transmission. I bought the Hanlon Video, linked above, and the rebuild kit from them as well. Watched it once all the way through to figure out what tools I'd need. Bought the shop press from Harbor freight, as well as a few sets of snap ring pliers, a dial indicator and a magnetic base. Had everything else. All in all, it cost me about $350 if I remember correctly, not counting the purchase of the worn out T5 and pedals.

knightfire

These videos deal with the ford version of the T5, but they will give you mega info about what you want to do. I watched these and found them very interesting.....

Manual Transmissions, How they work:

History of the T5:

Rebuild Part 1:

Rebuild Part 2:

Followup: