V8 Camaro non-world class T5 Transmission Rebuild
**Disclaimer** - These photos describe the method I used to rebuild my transmission. They are NOT intended to be an instructional guide. I studied professional literature and videos before rebuilding my T5 transmission. I recommend that you do the same.
Introduction
This is a non-world class V8 Camaro T5 rebuild. It was not difficult but I did a lot of preparation and watched an instructional video prior to beginning the rebuild.
I carefully disassembled a 1984 V8 Camaro T5 transmission. The gears were all in pretty decent shape. I cleaned all of the parts so they would be ready once the rebuild kit arrived.
The rebuild kit contained new bearings and races, slider springs and inserts, new seals, brass blocker rings, C-clips and a few washers.
Very Important Preliminary Steps
These preliminary steps will help avoid serious problems later.
It's important to install the correct type key inserts in your 3/4 slider assembly. Check your 3/4 slider hub to see if it is a world class or non-world class. My non-world class transmission actually has a world class style 3/4 slider hub. Therefore, I needed to use the world class style key inserts that have a flange. I'm not sure why it had a world class style hub. Perhaps the factory was in the midst of a design and production change, or perhaps a previous owner replaced a damaged 3/4 hub with a world class hub. I can't be sure. See photo below.
Not all slider rings are machined the same. The rings on the left have machining on all the splines. The rings on the right only have machining on 9 splines (3 sets of 3 splines).
Non-world Class V8 Camaro T5 Transmission Rebuild
Step 1: Assembly of the Countershaft and Thrust Washers
I started with a clean 1984 Camaro T5 case.
This front countershaft bearing needs to be pressed into the case.
Add plenty of transmission assembly lube. Install the thrust washer. It must fit around the bearing case. The bent tab goes towards the case and inside the hole. See yellow arrow.
Step 2: Assembly of the Main Shaft
Since I'm going to use an S10 tail housing on my T5, I will also use an S10 main shaft. That way the drive gear will be located in the right position.
Here's the 1/2 slider with new springs and key inserts.
Line up the slots on the 1/2 hub with the machined marks on the inside of the slider and install the 1/2 slider onto the main shaft. Use transmission lube and test to make sure it slides freely.
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Place the hook end of the spring into the back of one of the key inserts and install the spring in a clockwise fashion to hold the 3 key inserts in place. Flip it over and starting with the same key, install the second spring in a clockwise direction. The little hook end of each spring should be in the center of the same key.
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2nd gear is locked in place.
Study the next 4 photos carefully. The 3/4 slider MUST be assembled correctly.
Once 5th gear is properly seated against the bearing, install the medium sized C-clip to lock 5th gear into place. The main shaft assembly is complete for now.
Step 3: Reverse gear
Step 4: The Input Shaft Bearing
Step 5: Test fit the Reverse/5th Gear Shift Rod
Doing a test fit assembly now will make the final assembly go smoother.
Slip the reverse spring onto the rod. A: Hook the end of the spring onto the boss above the pilot hole before guiding the end of the rod into the pilot hole. B: Finish by hooking the other end of the spring to the reverse fork. The test fit is complete. Now disassemble in reverse order and set the pieces aside for now.
This is how it will look during the final assembly.
Step 6: New Seals
Step 7: Installing the Input and Main Shaft Into the Case
Next, you will install a new synchro ring onto the 3/4 slider. Use transmission gel and align the notches with the 3 keys inside the slider. See photo.
Apply lubricant to all bearings and contact surfaces, including the end of the main shaft. Study the photo on the left. Carefully align the cut out area of the input shaft with the countershaft as you install it onto the main shaft. Make sure none of the roller bearings inside the input shaft become dislodged or fall into the case during assembly.
Step 8: 5th Gear Slider Assembly
Lay the pieces on the table. The slanted edge and raised hub center should both be facing up. Lubricate both pieces and then insert the hub into the ring. Make sure the pieces slide freely.
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Position the key inserts and then install one of the springs in a clockwise direction. Place the hook end of the spring under the center of the key at the 12 o'clock position - see photo below.
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Test fit the smallest brass blocker inside the back of the slider assembly.
Step 9: Rear of the Case
Install new shifter fork pads on the 5th gear shifter fork.
Repeat the process outlined in Step 5 until it looks like the photo below. Put the 5th gear slider and brass blocker together. Hold the slider/blocker assembly in the fork. Two things now happen at once. You will guide the slider/fork assembly onto the countershaft splines and simultaneously guide the rod through the installation steps outlined in Step 5.
Here's another look at the Reverse/5th gear shift fork rod after installation.
This completes the 5th gear shift fork assembly.
Step 10: Reverse Shift Lever
Step 11: Reverse Switch and Filler/Drain Plugs
Step 12: Case Lid, Drive Gear and Tail Housing
I am building this Camaro T5 in a special way. It's something called an S10 conversion. Basically, it means I'm moving the shifter to the S10 position by using certain parts from an S10 T5. Namely, the S10 tail housing, main shaft and case cover are used. Not all S10 conversions incorporate the S10 main shaft, but mine does. Up to this point, everything has proceeded exactly as it would for a stock V8 Camaro non-world class T5 rebuild. Even if you are rebuilding a Camaro T5 without the S10 conversion, you will see that the following steps are very similar.
Before you apply fresh RTV and bolt the lid down - Did you remove all the dirt and old RTV from the bolts and from inside the holes? If not, do NOT bolt the lid down until you have done so.
Following the directions in the T5 Factory Service Manual, apply fresh RTV sealant to the mating surfaces of the case and case cover. With both forward gear sliders and the reverse lever in neutral, lower the lid making sure the forks engage with the 1/2 and 3/4 sliders. (These photos are from a different T5 but they show the process well.)
Following the directions in the T5 Factory Service Manual, apply fresh RTV sealant to the mating surfaces of the case and case cover. With both forward gear sliders and the reverse lever in neutral, lower the lid making sure the forks engage with the 1/2 and 3/4 sliders. (These photos are from a different T5 but they show the process well.)
Install the Drive Gear and clip onto the main shaft. It's important to choose the correct Drive Gear because it can't be changed unless you remove the tail housing.
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First the needle bearing, then the race, and finally the oil funnel in my hand will go onto the end of the countershaft. Use transmission lube to make them sticky so they stay in place.
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Following the directions in the T5 Factory Service Manual, apply RTV sealant to the mating surfaces of the case and tail housing.
I find this next step easier to do with the transmission tilted up in the air. Apply lubricant to the shift rod and corresponding hole in the tail housing. Carefully slide the tail housing over the main shaft. Take care to align the countershaft oil funnel with the recessed area in the tail housing. Never use the bolts to draw the tail housing up to the case. Review the next photo before you bolt the tail housing to the case.
I find this next step easier to do with the transmission tilted up in the air. Apply lubricant to the shift rod and corresponding hole in the tail housing. Carefully slide the tail housing over the main shaft. Take care to align the countershaft oil funnel with the recessed area in the tail housing. Never use the bolts to draw the tail housing up to the case. Review the next photo before you bolt the tail housing to the case.
As you move the tail housing closer to the case, you must correctly position the shifter pieces onto the end of the shifter rod. You must be absolutely certain the roll pin has been removed from inside the largest piece. Slide all the shifter box pieces into their final position at the same time the case and tail housing meet.
Properly tighten the case cover and tail housing bolts to the torque specified in the T5 Factory Service Manual before the RTV sealant cures.
Properly torque the fill and drain plugs, reverse lever bolt and reverse switch as specified in the T5 Factory Service Manual. YOU ARE NOT DONE YET!
Properly torque the fill and drain plugs, reverse lever bolt and reverse switch as specified in the T5 Factory Service Manual. YOU ARE NOT DONE YET!
Several keys steps remain before the rebuild is complete.
1. Install the proper amount of shims inside the input shaft bearing retainer so there is no endplay. The procedure is outlined in the T5 Factory Service Manual. Use RTV to seal the bearing retainer in place. Recheck the final endplay.
2. Install a fluid plug in the tail housing if you plan to add transmission fluid before you install the T5 on the vehicle. It will help avoid spills and fluid contamination.
3. Refer to the T5 Factory Service Manual and then add the correct amount and type of transmission fluid through the shifter box. Use RTV to seal the shifter base plate to the shifter box.
1. Install the proper amount of shims inside the input shaft bearing retainer so there is no endplay. The procedure is outlined in the T5 Factory Service Manual. Use RTV to seal the bearing retainer in place. Recheck the final endplay.
2. Install a fluid plug in the tail housing if you plan to add transmission fluid before you install the T5 on the vehicle. It will help avoid spills and fluid contamination.
3. Refer to the T5 Factory Service Manual and then add the correct amount and type of transmission fluid through the shifter box. Use RTV to seal the shifter base plate to the shifter box.