Prodigy's How-to Rebuild Your Transmission (G15M-R)

[Prodigy]

Tools needed:
-new razor blade
-1-2 cans of brake cleaner
-safety goggles
-3/16” steel punch
-Red Locktite
-Ultra Gray RTV
-10mm, 12mm, 14mm, 32mm sockets
-inch lbs. torque wrench
-foot lbs. torque wrench

Remove ALL RTV with a razor
-Clean bellhousing and outer transfer case housing with brake cleaner (use safety goggles!)
-Allow time to let housings dry http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00453.jpg

http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00476.jpg

Replace differential http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00454.jpg

Replace steel ball, spring, “knuckle” edged piece (with the roll pin hole side up) http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00458.jpg

Align shift forks
Combine shift forks with gear sets (out of transmission) http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00459.jpg

Set the gear set assembly into position
Note : Do NOT break the plastic oil funnel!
-Wiggle the differential to allow the gears to slide into place.
-Insert steel punch into roll pin hole http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00460.jpg

Insert reverse gear, then reverse gear shaft
-Make sure that the arm is inside the grooved edge. http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00461.jpg

Insert reverse arm rod (dimpled side facing out)
-Check shift fork alignment
-Apply threadlock to bolts
-Torque bolt to ___ ft. lbs.
-Check reverse arm rod alignment http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00463.jpg

http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00464.jpg

Remove steel punch and insert roll pin into the “knuckle” edged piece
Check shift fork alignment http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00467.jpg

http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00470.jpg

Replace magnet http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00472.jpg

Make sure that the reverse gear shaft hole is facing outward http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00474.jpg

Replace oil channel on outer transfer case housing (10mm bolt - ___ ft. lbs.)
Apply RTV on the inside edge of all of the bolts (3/8” continuous bead) http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00480.jpg

Check shift fork alignment!
Replace outer transfer case housing
-Apply threadlock to bolts
-Finger tighten (15) 14mm bolts and let RTV cure (1 hour minimum)
-Torque the (15) 14mm bolts to __ ft. lbs. http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00482.jpg

Replace:
-Reverse gear shaft lock bolt
-Ball + spring (reverse gear tensioner)
-Shift fork shaft lock bolt
-Reverse gear sensor (if removed) http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00483.jpg

Slide main shaft collar onto the main shaft
-Replace fifth gear selector + fifth gear onto main and secondary shafts
-Insert roll pin into the fifth gear selector
-Apply threadlock to locking nuts
-Torque locking nuts to 90-140 ft. lbs.
-Using a punch, hammer the ring to lock the nuts onto the main and secondary shafts
-Take extreme care to NOT break the black plastic oil channel! http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00056.jpg

http://i459.photobucket.com/albums/qq314/prodigyprotege/transmission%20how-to/DSC00057.jpg

Apply RTV to case
-Replace fifth gear cover
-Finger tighten (9) 10mm bolts
-Torque to __ ft. lbs. after an hour
Press in new oil seals for the axles

[Prodigy]

Note : This how-to is incomplete.
I'll resize the pics and get the torque specs when I have time.

[sam1]

great pix. thanks!!!

[Sport23]

Very nice how to! Thanks for the write up.

[Prodigy]

Glad it could help... I still haven't had enough time to get around to getting the torque specs.

[bgibb68]

Glad it could help... I still haven't had enough time to get around to getting the torque specs.

your fired........(2thumbs)


dude....don't worry about the torque specs....people can get the manual and find that.....those pics alone are worth gold when doing it....let alone the non manual descriptions

[TheDirtyGoatee]

Question: How much time and money would this cost if you only have say, the tools (like actual tools not the locktite and crap)? Because I am sure that my transmission is going bad. I'll send ya a PM for some advice since the thread I started about it didn't gain any traction.

[Alamo1]

This is really good! I have been looking at what I can do to beef up my tranny and now I have the pics to understand what goes on inside when I do the job!

Great thread prodigy!