Actually I skipped a bit ahead in that story.

First, we couldn't bleed the clutch. I was getting bubbles in the reservoir and my wife said "this feels like a brake pedal". So we screwed around for a while and decided the quick connect wasn't connected properly. Just enough for fluid to leak. So, we grabbed the old hose, cleaned it off and it snapped right in by hand. We decided we were going to have to pull the master cylinder and change the hose. We managed to pop it out of the firewall and lay it on a long prybar to drive the pin out, even got it back together in that position. We managed to do this without having to pull the reservoir off of the hose and totally remove it (though we had it out of the firewall and under the brake booster). Once that was done, it bled and the clutch started working properly.

So, DO NOT BUY THE DOORMAN REPLACEMENT CLUTCH LINE. I linked it in here earlier, it didn't fit. If you do buy one, test fit it into your slave cylinder BEFORE installing it into the master cylinder and installing it in the car.

While I'm on that subject. The RAM remote clutch bleeder kit didn't have the right fitting to connect to the RAM slave cylinder (just an overpriced stock slave from what I can tell, I removed the bleeder valves from both and they matched). So, the remote bleeder didn't fit either. I need to contact a couple companies about returning the things that didn't work (Tremec synchro, Doorman clutch master hose, RAM remote bleeder).

The trans will be apart again in a day or two and I'll sort out what to do with it all.

I have to thank Racerdad916 for the rebuild and help and Voodoo92 (he's not on here much) for being crazy enough to leave work and head down to have fun with transmissions when my wife sent him a text yesterday.

When we rebuilt the transmission, we did it with a series of gear pullers and an impact gun. That worked well and is how Racerdad has been doing them for years. When we did my trans, it was tight enough that one of the pullers bent. And using them takes time and I'm not getting any younger. So, yesterday I delivered my trans and a new 20 ton shop press to his garage so we can tear this apart again. I think it should go a bit faster this time. Besides, every kid wants a shop press! (Or am I the only weirdo?)

Now we just need time to get it apart.

My 20T press is one of my favorite tools. Use it for just about anything

Every garage needs a press, or a conglomeration of home made pullers... What ever works...

Kevin- were the defective synchros from Tremec or thegearbox.org? I'm going to be rebuilding mine this summer and I noticed they have two options for synchros. I was planning on going with the aftermarket REM polished option, as they are a good bit cheaper than the tremec parts and always seem to be in stock.

I had a press for 15 years and never used it. Got it for free; gave it away.

Agreed. Something tells me we will use them both...maybe at the same time. (IMG:http://www.frrax.com/rrforum/style_emoticons/default/wink.gif)



Mine were OEM Tremec synchros. Came from Tick Performance (not that it likely matters). I bought all Tremec parts for this project.

Edit:

The tight/bad synchro was a REM polished aftermarket synchro from Tick Performance. It wasn't a Tremec synchro.

The key is that if the assy is snug with the keys and springs, it will be really tight with the trans assembled. The sliders should move easily when moved without the fork on an assembled main shaft. I'll hit the inside of the slider with the bead blaster. That should remove enough of the coating to allow good movement....

I forgot to bring you the shifter with the trans. Once we get it back together, we'll know if it's right by putting the shifter on it. I'll try to remember it when we get time to get together and look at it.

I'm still puzzled. The Gearbox shows the aftermarket synchros as "REM polished". I ordered/paid for OEM Tremec Synchros (from Tick performance) and they showed up in boxes marked REM polished (with no Tremec decal). I'm not sure which synchros I got. So, I just ordered another snap ring kit (that I forgot) and another set of 1/2 and 3/4 synchros (OEM Tremec again) to go with the carbon fiber blocker ring kit. I'll sort out if I got OEM synchros or not once these arrive. Then I'll deal with it all, or I'll have lots of parts for sale. I have a this kit:

http://www.thegearbox.org/catalog/item/3838217/3503769.htm

that has 3 minutes of run time on it and was never on the "ground" (just run for a few seconds on jack stands). I guess it will be for sale soon since I'm changing over to the other parts. Anybody need some new parts at a discount?

At this point, I should have purchased a T56 Magnum, I think I'd be ahead. Oh well....

I'll get it on the sling and open it in the morning. If the parts show up, maybe we can get it done in short order..

I suspect I'll have parts on Friday. If we can work it out, I'll come help you. Or we can do it when we can get together.

All that makes me think I should just send mine to Tick and let them do it for me. I do not have a press but I can get creative with pullers. The cheap side of me says do it yourself. If I do hopefully I wont have these headaches. I was planning on the gear box for parts if I do it myself

I was going to get the stage 2 kit from the gearbox and it was in stock when I first looked. I didn't buy it right then and I didn't know they are hard to get. So, I wound up "building" my stage 2 kit from a few vendors. At this point I'm headed towards the worlds most expensive T56 overhaul. And honestly, the gearbox was fine (2nd might have been slightly notchy) and I was doing it as a "while I was in there" deal.

If you have a harbor freight nearby, I just used a 20% off coupon on a $169 press and walked out for $140-something (tax and all). For that price, we should have a press around to use.

Also, if you're going to do it, I may be able to offer you a deal on some parts. My 1/2 synchro was perfect (for the 3 minutes I tested it on jackstands). So I'll have a spare one once the other two arrive. I'm going to have to go back to Tick and see if they will take the 3/4 synchro back. If not, I may have to deal with my credit card. We'll know more once it's apart again.

I also have a full carbon fiber blocker ring kit coming. I really just want the 1st/2nd gear parts. I have brand new OEM parts (3 minutes of run time) that I might be able to combine with the rest of the new kit (all the other stuff I have is the carbon fiber blocker rings, I just wanted the carbon lined 1/2 parts...not sure it's really needed, the stock 2002 parts have been great in several cars for me now).

Anyway, I might be able to save you some money on some parts. Or I may just send the new parts back to Tick and use what I have with the new synchros. I need to quit before the transmission is worth more than I paid for the car. (IMG:http://www.frrax.com/rrforum/style_emoticons/default/wink.gif)

Also, the Gearbox builds their kits from parts (not a pre packaged kit) and I was missing the 5/6 blocker rings. I didn't know they came in the kit, but I noticed that they did. I emailed them and asked about them (and told them I had a 2nd day freight order that I placed that day) and they said they'd get them in the box and send them to me. Excellent customer service from them. I'm impressed. This is also a warning to check your parts list when it arrives and not 3 months later. (IMG:http://www.frrax.com/rrforum/style_emoticons/default/wink.gif)

Mine is grinding 3rd to 4th and 4th to 3rd. I was planning on the synchronizers for 1-2 and 3-4 and 5-6, the bronze shifter bushing, bronze fork pads, steel 3-4 fork, snap ring kit and the billet keys. Tear down and hope that is all I need/want. I am always interested in saving money lol. I may have to go get that press for that price. I always seem to need a press more than a puller. Let me know about your synchro when your replacements get there. I am interested.

Cool. I should have the second set of synchros tomorrow. The 1/2 that I have works flawlessly. I intend to return the 3/4 that I got. I ordered two more just to compare. If they match...cool. If they don't, I just wanted the option of swapping both.

Your rebuild plans are what my rebuild plans are/were. Mine just went a little sideways. Let me see what all I have extra and maybe I can help you out/save you some money....at least a little bit.

Just google harbor freight coupon and print the page off of the sale flyer. That's what I did.

IIRC, Most of our plans go atleast a little sideways. Sometimes it fun, and sometimes, it's stupid expensive....

That's what I paid for my press. Carried it home in my Miata and I've been making use of it ever since. Most important job I used it for was suspension bushings but I've also used it for wheel studs and other random things. Was huge for rebuilding the 10 bolt. Don't have a vice either so it fills in there too.

Yea, I really need to quit living up to my signature. I've tried, I swear I have. It's not going well. Maybe I need a 12 step program? Seems unlikely I'd walk that far..... (IMG:http://www.frrax.com/rrforum/style_emoticons/default/drink.gif)




In a Miata? You're more of a madman than I thought. I thought getting a 6' folding table in a 2002 Z28 coupe was a fun trick (with the hatch shut). A press in a Miata beats that by miles. Well done!

I have one of those presses. I bought it second hand from a friend who was relocating for work. I got to use it about two times, then it puked it's oil out, and I'm not sure it'll work any more at all. I need to replace the bottle jack so I have a working press again, but haven't had the need lately. I guess if I up the quality of the bottle jack, I'll have a better press in the shop.