6MT Slipping Out of 5th Gear

[ermax]

The transmission is one of those things you simply have to put you hands on to fully understand. Holding the stacks in your hand and sliding the sleeves and watching what they do and being able to rotate the shafts really helps with the understanding. The first time I pulled the tranny in my Integra I had it pulled apart in the house for a few weeks. Mostly waiting for parts. I had a backup car so I really wasn’t in a rush. I had a backup tranny which also needed some work but I had confidence that between the two I would eventually have the car back on the road. I’m not sure what your tool box is like but you will probably need some snap ring pliers and possibly a hydraulic press. Again, I’ve never been in this specific tranny so I can’t tell you with any authority what tools you would need.

[ermax]

Originally Posted by takethecake

Guys, thank you again so much for your help - definitely feel like I'm making some progress here. And yes, I did buy the car new so anything wrong is my own doing haha.



Seems like the parts would be pretty cheap - about $50 per gear shift fork, about $40 for a shift fork shaft. So I might just try to tackle this on my own - would be a great way for me to learn about working on transmissions, and worst case if I bungle something too bad it looks like I could probably get a used transmission for $500 or so.



So just need to figure out exactly what to order - I'd prefer to err on the side of ordering anything I might need, since I should be able to return anything unused. I'm looking at these diagrams and it's making my head hurt a little - I tried color-coding the same parts across each diagram but it'd be nice to get confirmation that I'm looking at everything the right way.



The first pic below is snapped from this pretty helpful youtube video I found:

From this page, I think I want:

-PN# 32810C - Gear Shift Fork #3

-PN# 32809C*A - Shift Fork Rod #3

-PN# 32847A*C - Gear Shift Head (pretty sure this one is #3)



Any ideas on whether I should also get:

-PN# BRSN01 - Snap Ring

-PN# BRBL04 - Bolts (that appear to lock the shift fork to the shaft)

-PN# BRPI07 - "Pin" ?



(Are there any consumables required - gaskets, crush washers, etc - to remove and replace the transmission other than the fill & drain plug washers?)



What is the difference between the gear shift head and the gear shift fork - how do they interact with each other? It seems they both have the shaft passing entirely through them?



Also, any significance to the fact that the 5th gear is the same speed as the engine (input shaft gets locked to output shaft)?



And last, what does shift fork #4 control? The 6th gear hub sleeve? I'm confused why the "reverse & 5th" shift head I circled in green on my previous post is named that - I'm pretty sure it's mated with shift fork #4



Here's another good diagram taken from that youtube video:









Thanks and sorry for all the questions - hopefully this helps someone else out too!

I should be able to answer most of these questions but not from my iPhone. Too much typing. But I will at least answer the simple one. 5th locks directly to the output shaft because 5th is 1:1. That is also why you don’t get any gear whine in 5th.

[takethecake]

Originally Posted by Ultramaroon

If you daily the car, I suggest installing a spare transmission before digging into yours. Depending on your luck, you can find them between $500-$800.

I say that because, based on your questions, you have a long way to go. Just being direct.

Haha I honestly appreciate the directness; it really does help to know what you don't know - and that does sound like good advice about having a backup transmission before tearing mine apart. Fortunately I have another vehicle available so I'm okay with the BRZ sitting for a month or two if necessary.

Originally Posted by ermax

I’m not sure what your tool box is like but you will probably need some snap ring pliers and possibly a hydraulic press.

I do have a pretty decent set of tools but I would need to pick up some snap ring pliers, sounds like a pin punch set would be a good investment too. The manual talks about using some SST's (special service tools?) to mostly perform diagnostic measurements, but also, for instance, to "remove the No. 4 transmission clutch hub, No.4 transmission hub sleeve, No. 4 gear shift fork and No. 5 gear shift fork shaft all together." I assume the repair manual disassembly page is what you'd do for a full diagnostic teardown - I don't think I'd need to do everything in there but hard to say until I can take a look inside and move things around.

The only place it calls for a press is to "(re)-install the No. 4 transmission clutch hub, No. 4 transmission hub sleeve and No. 4 gear shift fork as a unit, using SST and a press." I don't have a press but if that's a step I find I need to do, I bet I could find a local shop to do that part for me.

So I guess my main concern is the SST's mentioned, do people working on their own transmissions usually buy these, borrow them, go to a shop to borrow them, use a similar tool instead? Don't see much when I google the various SST #s - like where to buy them, how much they cost, etc.

I can't thank you guys enough - I don't know where else I could get this kind of information

[humfrz]

Originally Posted by takethecake

........................So I guess my main concern is the SST's mentioned, do people working on their own transmissions usually buy these, borrow them, go to a shop to borrow them, use a similar tool instead? Don't see much when I google the various SST #s - like where to buy them, how much they cost, etc........

I have found that it all depends on what the SST is going to do. Many times one can "work around" the need by being innovative or modifying an existing tool.

For example, I have in my tool box, an 1/2" opened ended wrench, cut in half. I used it to adjust the side draft carburetors on my 1970 MGB.

Why do I still have it? Hell, I don't know, why do I still have a 8 track tape player out of a 1979 Lincoln Mark V, that I used to have .....??


humfrz

[takethecake]

Haha gotcha, yeah I tend to hang onto those kinds of things too - at least I recently finally got rid of the stock head unit to my old acura rsx I totaled 6 years ago..

I'll definitely spend some time really digesting the repair manual and all the steps before I dive into this - at least I have a much better understanding of what I'm dealing with here. If/when I start this project I'll be sure to take a ton of pictures so I can share, and more importantly remember what everything's supposed to look like when I attempt to put it back together..

[takethecake]

Want to add this link for anyone else who might be going down this road - I don't think there could be a better resource:

Originally Posted by VerusEric

DIY manual is now up on our website (and linked HERE).

(from this post)