M5R1 Rebuild Kit Identification

[Jim_Philly]

Anxiously waiting so I don't have to be the guinea pig! I already have the bearing kit so I'd probably cobble together the synchro rings from eBay.

FYI Cobra quoted me $920 for their -BWS kit. Ha.

 

[Shran]

Dang. Why would you even bother rebuilding your own if the kit costs that much...a reman trans is only a few bucks more.

 

[crazyramen]

Gonna have to push it back further....

There's a big snowstorm coming in this weekend and I don't have a garage to work in lol. It's gonna be a b* trying to get all this stuff out in a storage unit even if it isn't freezing cold out, let alone if it's a high temp of <55*f next week...

 

[crazyramen]

GOOD NEWS (for me not for you )... I got it apart today and it's not the multi syncro design. Someone else is going to have to be the guinea pig xD. I've got the 30 tooth reverse design.

As far as my rebuild goes, I'm going to replace all the bearings and syncros along with the reverse gear. The engage teeth (IDK the name - the teeth on the gear that engage the syncro collar) on the reverse are totally chowdered - probably from my (and the previous owner) beating it into gear after the syncro wore out. Along with that, it also wore out the reverse syncro collar (again, making up terms)
Bad syncro collar (Reverse):

Good (5th):

I've also got some wear that I'm not familiar with, if someone knows a bit more about this kind of stuff and could give me some info about it I'd appreciate it.

I have some on where bearings sit in the case. I can feel some pitting/striations, but they don't feel as deep as some wear that I've felt on a chainsaw cylinder that went bad (but that totally lost compression from them - don't cold rev your saw!!):

There's some strange discoloration (is it wear?) on some of the spots that bearings sit on the input and output shafts.
Input:

Output:

Also I just thought this was cool/weird but here's the 3rd/4th syncro hub. This is the side that faces the back of the thrust bearing. I definitely have to replace it. These striations are mad deep:

Good luck to whoever's gonna be the one to try cobbling together their own kit for the multi piece design!!

 

[Shran]

Right on... I thought it was 2nd gear that was in question? Not 5th/reverse? The 30 tooth 5th/R variation started in the early 90's... '88 up to some point had 36t 5th/R.

Dunno if I'd worry much about that discoloration on the input and main shafts. That's just where your bearings sit... if they're not loose after you press them on, I'd run it.

I also would not worry too much about the places where your bearing races ride in the case. Every one I've torn down has looked about like that and it's hard for them not to when you're sliding parts through them at an angle during assembly, often several times. I would for sure check the rear bearing retainer and replace it if there is ANY sign of wear where the races sit... I had issues with that on one of mine.

 

[crazyramen]

Right on... I thought it was 2nd gear that was in question? Not 5th/reverse? The 30 tooth 5th/R variation started in the early 90's... '88 up to some point had 36t 5th/R.

Dunno if I'd worry much about that discoloration on the input and main shafts. That's just where your bearings sit... if they're not loose after you press them on, I'd run it.

I also would not worry too much about the places where your bearing races ride in the case. Every one I've torn down has looked about like that and it's hard for them not to when you're sliding parts through them at an angle during assembly, often several times. I would for sure check the rear bearing retainer and replace it if there is ANY sign of wear where the races sit... I had issues with that on one of mine.

Yeah it's second, but the teeth on reverse seems to be how sellers identify the kits. Sorry for the confusing text.

I didn't think any of that was a huge deal, I'm glad you agree! Thanks for the piece of mind

 

[Jim_Philly]

I certainly will! I'll probably have it apart next weekend and will update then.

Hey there! How did this project go? My truck is still sitting and I'm finally getting ready to actually do the rebuild, haha.

 

[Charles1991]

It will not be kit #1, that is for early trucks...88, 89 and only applicable for a couple years.

My guess is that it'll be kit #3, I believe the 2nd gear synchro changed in 2000 or so... I have used kit #2 several times for early 90's transmissions.

Where did you source the 2nd rebuild kit. I found one for my 30 tooth but it's listed for RWD. I know the housings are a different but would the kit work for 4x4.

 

[scotts90ranger]

The only difference between 4x2 and 4x4 as far as a rebuild kit goes is the output shaft seal, most of the kits online have the parts for both at least the last one I got did... The only physical metal parts different between 4x4 and 4x2 are the output shaft and rear housing...

holy cow, the kits have gone up $125 in the last year and a half... I paid $150ish now it's up to $275, but either of the ones on Amazon or Ebay look the same and will work. The only issue will be the 5/R stuff since that was a break on tooth count, I had to replace something when I rebuilt mine the first time...

 

[Shran]

Where did you source the 2nd rebuild kit. I found one for my 30 tooth but it's listed for RWD. I know the housings are a different but would the kit work for 4x4.

Probably eBay or RockAuto. gear5th, allstate gear and spark surplus are usually the eBay sellers I buy from. As Scott said the main difference is the output seal, everything else is the same so the RWD kit should work for you.