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T56 Service Manual

T56 Service Manual

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Published by shortbus_scribd
T56 Transmission Service Manual
T56 Transmission Service Manual

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Published by: shortbus_scribd on Jul 08, 2009
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08/14/2011

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IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of allmotor vehicles as well as the personal safety of the individual doing the work. This Manual provides generaldirections for accomplishing service and repair work with tested, effective techniques. Following them will helpassure reliability. There are numerous variations in procedures, techniques, tools and parts for servicing vehicles,as well as in the skill of the individual doing the work. This Manual cannot possibly anticipate all such variationsand provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided inthis Manual must first establish that he compromises neither his personal safety nor the vehicle integrity by hischoice of methods, tools or parts.
NOTES, CAUTIONS, AND WARNINGS
§
 
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each oneis there for a specific purpose. NOTES give you added information that will help you to complete a particularprocedure. CAUTIONS are given lo prevent you from making an error that could damage the vehicle.WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury.The following list contains some general WARNINGS that you should follow when you work on a vehicle.
§
 
Always wear safety glasses for eye protection.
§
 
Use safety stands whenever a procedure requires you to be under the vehicle with the vehicle jacked up.
§
 
Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.
§
 
Set the parking brake when working on the vehicle. lf you have an automatic transmission, set it in PARKunless instructed otherwise for a specific operation. lf you have a manual transmission, it should be inREVERSE (engine OFF) or NEUTRAL (engine ON
)
unless instructed otherwise for a specific operation.Place wood blocks (4" x 4" or larger) to the front and rear surfaces of the tires to provide further restraintfrom inadvertent vehicle movement.
§
 
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
§
 
Keep yourself and your clothing away from the moving parts, when the engine is running, especially the fanand drive belts.
§
 
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold
,
tail pipe,catalytic converter and muffler.
§
 
Do not smoke while working on the vehicle.
§
 
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning towork on a vehicle. Tie long hair securely behind the head.
§
 
Keep hands and other objects clear of the radiator fan blades, Electric cooling fans can start to operate at anytime by an increase in underhood temperatures, even though the ignition is in the OFF position. Therefore,care should be taken to ensure that the electric cooling fan is completely disconnected when working underthe hood.
§
 
Disconnect the negative battery ground cable before using any electric welding equipment.
 
CONTENTS
SECTIONPAGE
1
T56 On-Vehicle Service and Troubleshooting
1-1Maintenance ………………………………...……………………...……………………...1-2Troubleshooting ……………………………………………………...…………………….1-3Transmission Removal ………………………………………………...………………….1-4Transmission Installation ...……………………………………………...………………..1-11-11-41-5
2
T56 Transmission Disassembly Procedures
2-1 Shifter………………………………………………………………………..……………...2-2 Extension Housing…………………………………………………………...…………….2-3 Speedometer Gear/Rotor …………………………………………………..…………….2-4Reverse Speed Gear………………………………………………………..…………….2-5Reverse Shift Fork ………………...…………………………………………..………….2-65th/6th Driven Gear……………………………………………………………...……….2-7Countershaft Extension Assembly………………………………………………...……..2-8Transmission Case ...………………………………………………………………...…2-9Guide Plate ……………………………………………………………………………..….2-10 Shift Rail Assemblies and Gear Clusters ………………………….…………...…….2-12-12-52-52-62-62-72-72-82-8
3
T56 Subassembly Cleaning, Inspection, Repair or Replacement
3-1Cleaning ………………………………………………………………………………..…...3-2Inspection …………...…………………………………………………………………...…3-3Repair or Replacement ………………...…………………………………………..….….3-4Input Shaft……………………………………………………………………………...…...3-5Mainshaft……………………………………………………………………....……..…….3-6Countershaft ………………...…………………………………………………..………...3-7Countershaft Extension Assembly………………………………………………...……..3-8Synchronizers………………………………………………………………………...…….3-9Shift Rail and Fork Assemblies……………………………………………………...……3-10 Transmission Front Adapter…………………………………………………………...….3-11 Transmission Case ……………………………...…………………………………..……3-12 Extension Housing………………………………………………………………...……….3-13-13-53-63-73-93-103-123-143-163-173-18
4
T56 Transmission Assembly Procedures
4-1Shift Rail Assemblies and Gear Clusters………………………………………………...4-2Transmission Case ………………………………………………………………………..4-3Countershaft Extension Assembly ……………………………………………………….4-45th/6th Driven Gear ………………………..……………………………………………..4-5Reverse Shift Fork ………………...………………………………………………..……4-6Reverse Speed Gear ……………………………………………………………..……...4-7Speedometer Gear/Rotor …………………………………………………………..……4-8Extension Housing …………………………………………………………………….....4-9Shifter …………………………………………………………………………………..….4-14-24-34-34-34-34-44-44-5
5
Shimmin Procedures
5-1Input Shaft, Mainshaft and Countershaft …………………………………...…………..5-2Cuntershaft Extension ……………………………………………………..……..……...5-15-1
6
Specification
6-1 Fastener Tightening Specification………………………………………………………...6-2Shiming Specifications ………………………………………………………..………….6-3Lubricant Specifications …………………………………………………………..……..6-4Endplay Tool Specifications ………………………………………………………...…...6-16-16-16-2
 
SECTION 1T56 ON-VEHICLE SERVICE ANDTROUBLESHOOTING
1-1MAINTENANCE1-1-1. GENERAL.
 
The only periodic maintenancerequired for the TREMEC T56 Transmission is to maintainproper lubrication
.
1-1-2. LUBRICATION SCHEDULE.
 
Refer to theVehicle Owner’s Manual or Service Manual
.
CAUTION
Excessive temperatures may break down thetransmission lubricant (refer to vehicle servicemanual for maximum allowable temperature).If thereis reason to believe that the transmission has beensubjected to temperatures exceeding 275° F, changethe lubricant immediately.
1-1-3. APPROVED LUBRICANT
.
Most T56transmission models use Dexron
®
II automatictransmission fluid. Refer to the vehicle owner’s manual orservice manual for lubricant specifications.
CAUTION
Do not mix different brands or types of transmissionlubricant. DO NOT USE GEAR OIL IN THE T56TRANSMISSION SINCE THIS MAY DAMAGE THEBLOCKING RING MATERIAL.
1-1-4. CHECKING LUBRICANT LEVEL
.
Proceed asfollows:
NOTE
To check or drain the lubricant, the transmissionshould be warm. This is best done shortly afterengine shutdown.
a. Wipe fill plug (2) and surrounding area clean.b. Remove fill plug (2).c. When transmission is full, lubricant will just drip out fillplug opening.d. Add approved lubricant if required.e. Install fill plug (2) and torque to 20 lb. ft (27 N.m.)
1-1-5. CHANGING LUBRICANT.
Proceed as follows:
a. Wipe drain and fill plugs (1 and 2) and surroundingareas cleanb. Place suitable container under transmissionc. Remove drain plug (1).d. Remove fill plug (2).e. Allow all lubricant to drain.f. Install drain plug (1) and torque to 20 lb. ft. (27 N.m).g. Add lubricant through fill plug opening until lubricant just begins to drip back out of opening.
 
NOTE
 
The amount of lubricant required varies from modelto model. Refer to the vehicle service manual fortransmission capacity.
 
h. Install fill and torque to 20 lb. ft (27 N.m).
1-2. TROUBLESHOOTING1-2-1. GENERAL.
In the event of operating difficulty,it is recommended that the transmission (engine) beshut down. In most cases, to accurately pinpoint thesource of trouble, it may be necessary to removeand disassemble, or partially disassemble, thetransmission. Specific inspection procedures fordetail parts of the transmission are provided inSection 3.
WARNINGTowing:
Drive shaft MUST be disconnected vehicle is to betowed. Failure to do so WILL result in internaltransmission damage.
1-2-2. TROUBLESHOOTING CHART
.
Table 1-1 liststroubles which may be encountered along with possiblecauses and remedies.
1-1

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