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Here are the steps I used to rebuild a Non-World Class S10 T5 with a cable speedometer connection. New clips, bearings and seals will make this transmission run like new and ready for service.
Part #1. Building the Case
Part #2. Building the Main Shaft Gear Train
Step #3. Input Shaft and Bearings
Installing a Jeep T5 input shaft in place of the S10 shaft is a popular modification. The splines on the Jeep shaft are cut further along the length of the shaft. The 10 spline Jeep shaft is 1 + 1/8" in diameter and stronger than the 14 spline S10 factory shaft which is 1" in diameter. This shaft swap only works for an S10 T5 with 21 gear teeth.
Step #4. Installing the Main Shaft in the Case
Step #5. Install new seals in the front bearing retainer and tail housing. Install new shift fork pads.
Step #6 Install the reverse switch and drive gear.
Step #7. Prepare the lid and tail housing for installation.
** IMPORTANT** I suggest going through a test assembly of the lid and tail housing as a way to practice. Then do it all over again WITH the RTV for final assembly.
** IMPORTANT** I suggest going through a test assembly of the lid and tail housing as a way to practice. Then do it all over again WITH the RTV for final assembly.
Step #8 Let's practice bolting the tail housing to the case.
Step #9 We can now use RTV because you are familiar with the steps involved.
Step #10