t5 gearbox rebuild help

[imbhvn]

Hey peoples, can anyone shed some light on whats involved in rebuilding a t5 gearbox? how hard is it? are the bearings pressed into place ectc etc. Thanks in advance.

[mongrelEF]

Not hard, but you need a good mechanical understanding. Gregorys' books actually have a half-decent walkthrough.
Special tools - Circlip pliers, a 3mm punch, and feeler gauges. You may need to buy some shims for the gears but usually the old ones provide the correct clearances once there are some new bearings under the gears. Doing the AU t5 is much easier than the earlier units as they have a cage bearing on the front of the mainshaft rather than loose needles. This also means you shouldn't need to get the mainshaft resleeved as they rarely wear away anymore.

[imbhvn]

Cheers for the heads up, thankfuly the gearbox is covered by warranty, hopefully the box they give me this time doesn't fail me. probably wont hurt to do a rebuild anyway.

[mongrelEF]

Haha hopefully! Looking at about $380 for the bearing kit, and $30 -$60 each for the synchros depending on what you need to replace. Usually first and 5th. The boxes usually go 2-300 000 km if looked after but don't like towing heavy loads in 5th on a regular basis.

[imbhvn]

well got a phone call yesterday, the bearings are fine the gears sheared off! told me its not covered by warranty and tried saying i had been doing some heavy towing (which i hadnt) and that it will cost over 1000 to get it repaired. so now im left with a ****** box! ill upload a pic of the gears when i get home

[Chewy]

Threaten to call the ombudsman...

[mongrelEF]

yup, if the car's still under warranty then stripped gears bloody well should be covered! In any case, towing won't kill the gear, it kills the bearing and in extreme cases, the gearbox casing. Not the gear! That has to be a casting fault. As above, speak to the ombudsman about it....

[blueoval]

imbhvn - where are you located mate?