Drivetrain T5 Teardown Question

Glliw

Member
Oct 21, 2019
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Sheboygan, WI
Hey everyone,

So the '90 LX 5.0 that I recently picked up had a whole hose of transmission issues with the T5 so I took it apart and have a few new questions. The symptoms were grinding going into every gear, with 1-2 being the worst and had to be perfectly rev-matched to let it into the gear and 5th gear being non-existent. Also, the speedometer did not work at the dash.

Last night I got the transmission out of the car and popped off the top cover and tail assembly to get a better look at the gear train. With the tail off, the two smaller ring halves in the picture on the table fell out. Pulling off the bearing retainer, I found that it's 4 screws were barely installed, and one of them was entirely stripped out of the casing. Certainly not helping the issue!

The 5th gear looks to have taken a few hits as well as the teeth are pretty marred on the outer surface.

When I pulled the gear-train that is not pressed in, I could see a bunch of junk in the bottom of the case. The following was down there:

  • 2 spring clip halves
  • what looks to be a couple of grenaded synchronizer keys
  • the speedometer gear retaining clip
  • a LOT of metal shavings

There was also some damage to the sidewall of the case, though superficial in nature.

There's a few pictures attached.

I believe the larger ring is the 1-2 or 3-4 syncro spring but haven't dug in deep enough to confirm. This is my first transmission teardown, so learning as I go here.

Can anyone confirm which parts are the actual failed parts or what else I should be looking at due to those failed parts? Would you consider this still a good candidate for a rebuild?


Thanks,
Will
 

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Mustang5L5

This is a big reason why I pulled it out
Mod Dude
Feb 18, 2001
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Synchronizer clips and keys. Your synchro won’t work without that. Inspect the synchro hard parts for damage and replace if showing wear from grinding.

Still a rebuildabke trans. Just might need some hard parts.

I also spy the clip for the speedo gear on the mainshaft
 

Glliw

Member
Oct 21, 2019
15
1
13
29
Sheboygan, WI
Thanks man. I'll take a closer look at the hard parts later this week. From looking around, clips and keys are pretty darn cheap, at least from what I see at allstategear.com. This is going to be one of those projects where I spend more on tools than I do on parts, lol.

Yeah, somehow that speedo gear clip got into the main case which was a little surprising to me as that little yellow plastic gear rides along out at the output shaft.
 

Glliw

Member
Oct 21, 2019
15
1
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29
Sheboygan, WI
I got a few minutes this evening to take a closer look at the referenced video above (actually is a different one by the same guy than what I had previously watched) and spent some time staring at my assembly. Definitely learning a lot here as I've never had to dig this deep into a transmission before.

From what I can tell, the synchro rings look to be in good shape though the synchro ring between what I think is 1st and reverse is entirely loose on the shaft. That's probably where the broken big ring came from.

First gear on the main shaft looks to be a bit higher than desired on the contact patch area.
 

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JMGlasgow

Advanced Member
Feb 19, 2017
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While you're in there you should upgrade the front bearing retainer and rear cluster support plate.
 

Mustang5L5

This is a big reason why I pulled it out
Mod Dude
Feb 18, 2001
31,676
7,896
224
Massachusetts
The inside dog teeth on the 1-2 synchro slider (3rd pic) are bashed up. That part needs to be replaced.


Cant get a good view of the other gears to comment
 
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nickyb

Active Member
Apr 3, 2009
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I've just rebuilt a spare t5 I had.got a lot from Paul c. At fivespeeds.com,same guy Eric is in video with. I would get the complete kit with bearing retainer.
 

Glliw

Member
Oct 21, 2019
15
1
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29
Sheboygan, WI
Thanks everyone. I just ordered the complete kit from LMR as well as the front bearing retainer. Harbor Freight's running a deal for Thanksgiving on their 20 ton press, so I'll pick that up Friday AM and hopefully get the rebuild done over the weekend.
 

JMGlasgow

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Feb 19, 2017
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Make sure you shim the front bearing. The 5speeds.com peel shim kit is really nice.
 

Glliw

Member
Oct 21, 2019
15
1
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29
Sheboygan, WI
Make sure you shim the front bearing. The 5speeds.com peel shim kit is really nice.

Yep, I will be, and am following along with all of his videos. I won't be using his peel shim though. The LMR kit comes with a handful of different input shims it looks like anyways.
 

JMGlasgow

Advanced Member
Feb 19, 2017
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Hopefully you find a combo that works. Did you get the billet main cluster support plate to replace the stamped steel junk one?
 

Glliw

Member
Oct 21, 2019
15
1
13
29
Sheboygan, WI
Fingers crossed. If not, I'll just wait for the $16 peel one from 5speeds.com since I'm in no particular rush. The car will be sitting until the snow melts anyways.

Yeah, I got the upgraded piece through LMR for the bearing retainer.

 

JMGlasgow

Advanced Member
Feb 19, 2017
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While you're in there you really should. They stretch and cause all kinds of problems.