IMPORTANT SAFETY NOTICE - Tremec

1 IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedure are essential for the safe, reliable operation of all motor vehicles as well as the personal SAFETY of the individual doing the work. This Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal SAFETY nor the vehicle integrity by his choice of methods, tools or parts. NOTES, CAUTIONS, AND WARNINGS As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS.

2 Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNING that you should follow when you work on a vehicle. Always wear SAFETY glasses for eye protection. Use SAFETY stands whenever a procedure requires you to be under the vehicle with the vehicle jacked up. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. It should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4 X4 or larger) to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement.

3 Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away from the moving parts, when the engine is running, especially the fan and drive belts. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold tail pipe, catalytic converter and muffler. Do not smoke while working on the vehicle. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head. Keep hands and other objects clear of the radiator fan blades, Electric cooling fans can start to operate at any time by an increase in under hood temperatures, even though the ignition is in the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood. Disconnect the negative battery ground cable before using any electric welding equipment.

4 ContentsSectionPage1 INTRODUCTION AND DESCRIPTION1-1. Introduction ..1-10. T5 WC & STD ON-VEHICLE SERVICE AND TROUBLESHOOTING2-1. Transmission ..2-21. Transmission Installation ..2-12-12-42-73 T5 WC DISASSEMBLY3-1. General Information ..3-6. T5 HD Transmission disassembly Procedures ..3-13-14T5 STD DISASSEMBLY4-1. General Information ..4-6. T5 STD Transmission disassembly Procedures ..4-14-15 T5 WC & STD CLEANING, INSPECTION, REPAIR OR REPLACEMENT5-1. Cleaning ..5-5. Inspection ..5-10. Repair or Replacement ..5-15-85-166 T5 WC ASSEMBLY6-1.

5 General Information ..6-4. T5 HD Transmission assembly Procedures ..6-16-17T5 STD ASSEMBLY7-1 General Information ..7-4. T5 STD Transmission assembly Procedures ..7-17-1 Section 1 Introduction and Description1-1. INTRODUCTION1-2. PURPOSE. This manual containsmaintenance, service and parts information for theT5 Five-Speed Manual Transmission manufacturedby Tremec (TRANSMISIONES Y EQUIPOSMECANICOS DE ) Av. 5 de febrero , Quer taro,Qro. M SCOPE. As you will see in the Table ofContents, this manual provides information formaintenance, troubleshooting, disassembly ,cleaning, inspection, repair or replacement, andassembly of the T5 TRANSMISSION CLASSES. Twobasic T5 transmission classes are covered in thismanual: WC (world class) and STD (standard).Separate disassembly (Section 3 and 4) andassembly (Sections 6 and 7) instructions areprovided for each of these classes.

6 In other sectionof the manual, variations within the classes arenoted in the instructions and parts shown in the illustrations in the serviceinstructions are typical for those used in a particularclass of transmission (WC or STD). Some parts maybe encountered in service that are different inappearance than those illustrated. These different parts perform the same function as those T5 TRANSMISSION CLASSIDENTIFICATION. The T5 transmission can beidentified as WC or STD by the last three digits ofthe transmission part number (see Table 3-1 or 4-1in the disassembly sections). In this manual, figuretitles, lists, tables and main paragraph headings arein the proper section for the transmission PART IDENTIFICATION. Each detail partshown in the exploded views in this manual for aparticular transmission class (WC or STD) isassigned an index number.

7 This same indexnumber is used to identify the part throughout thismanual. For example, WC index number 116 (inparenthesis in the text) refers to the countershaftgear in all applicable sections. The same is true forSTD index number The exploded view illustration in Section 5 (figure5-1 or 5-2) make it possible to view the completetransmission assembly in addition to the illustrationsin the Sections 3,4,6 and 7 relating to a specificdisassembly or assembly PART NUMBERS. The purpose of the indexnumbers in the illustrations in this manual is to identifyparts. Part numbers are not used. Once a part isidentified, refer to the Tremec T5 TransmissionParts Catalog for the correct part ABBREVIATIONS. Abbreviations, other thanthose in common use, found in this manual areidentified in Table DESCRIPTION1-11. TRANSMISSION DESCRIPTION. TheTREMEC Automotive T5 is a five speed,countershaft, helical gear transmission.

8 It is fullysynchronized for ease of shifting. Gear ratios varyfrom model to model (refer to vehicle service manualfor specifications.) The input and output ends of theinput and output shafts are supported by taperedroller bearings. A pilot roller bearing is used betweenthe input and output shafts. The countershaft gear issupported in tapered roller bearings for WC modelsand straight roller beatings for STD models. Theseand other basic differences in the two classes areshown in Table APPLICATION. The T5 transmission is used onsports cars, small to medium sedans and coupes,compact trucks and vans, utility vehicles and similar2-wheel and 4-wheel drive 1-1. AbbreviationsAR As RequiredAssy AssemblyID Inside DiameterNP Not ProcurableOD Outside DiameterPN Part NumberQTY QuantityTIR Total Indicator ReadingTable 1-2.

9 Basic Differences Between T5 WC and STD ClassesFEATUREDESCRIPTIONWC STDB earings under gearsBlocking ringsCountershaft bearingsNeedle bearingsFiber synchronizersTapered roller bearingsJournalsBrass synchronizersStraight roller bearings1-1 Section 2T5 WC & STD On- Vehicle Service and Troubleshooting2-1. MAINTENANCE2-2 GENERAL. The only periodic maintenancerequired for the Tremec T5 transmission is tomaintain proper LUBRICATION SCHEDULE.

10 Refer to theVehicle Owner s Manual or Service temperatures may bread down thetransmission lubricant (refer to vehicle servicemanual for maximum allowable temperature). If thereis reason to believe that the transmission has beensubjected to temperatures exceeding 275 F, changethe lubricant APPROVED LUBRICANT. Most T5transmission models use Dexron II automatictransmission fluid. Refer the vehicle owner s manualor service manual for lubricant not mix different bands or types of transmissionlubricant. DO NOT USE GEAR OIL IN THE T5 TRANSMISSION SINCE THIS MAY DAMAGE THEBLOCKING RING CHECKING LUBRICANT LEVEL. Proceed asfollows (see figure 2-2):NOTETo check or drain the lubricant, the transmissionshould be warm. This is best done shortly afterengine Wipe fill plug (2) and surrounding area Remove fill plug (2).