Teardown #2, lots of pictures.

[135sohc]

The original trans from the car. 256,156 miles at the time of removal. Not to bad I think, its getting a full overhaul. New brass, all the bearings and maybe a couple NOS parts up my sleeve...


I was worried about needing new fork pads








This one just because I love this puller tool so much, turn the wrench a couple times and the bearing falls out.



Originally a 3.77 final drive. I have available a 3.50 final drive also. Leaning towards the 3.50 as I would like to lower the highway rpms but I'm also afraid it would make it to doggy around town. Opinions ?

[turbovanman²]

Impressed on those gear teeth, barely any wear,

[135sohc]

Impressed on those gear teeth, barely any wear,

Good driving pays off in the end

Little notchy in the colder temps. But damn this thing spoiled me, even at its worst it still shifted 100x better than this 568 I put in yesterday. Feels like I'm rowing in a bucket of oatmeal now

I think fresh brass on 3-4-5 (already have) and if I can find them new friction inserts and blocker rings for 1-2 should make it almost as good as new.

Debating if I want to just rebuild the stock differential with fresh parts ($100) or go all out and do the neon/T350 Quaife ($1,300). I'm certainly nowhere near the power level to grenade a stock diff but there are times when a LSD would be nice.

[jory]

The 3.50 final drive does not make it doggy at all. I love the fact that I cruise at 2000 rpm in 5th at 55 mph.

[135sohc]

According to the code scanner I was already turning over at about 2000rpms @ 55mph. Suprised me since the tachometer was indicating 2,250 but I know its also not very accurate.

[135sohc]

Timken KWK99106 repair sleeve for the input shaft seal surface. Its not scored or rough but it does have a polished down section from where the seal was contacting. Worth the effort or a waste of $ ?

[cordes]

I would go with the 3.50 in a Shadow all day.

If the shaft is just polished down, I would think that a new seal would be right as rain in there.

[135sohc]

What is the rpm difference between 3.50 & 3.77 ? I (think) I understand the math but I dont know how to apply it, not a strong area for me

[Vigo]

I like this one.

http://www.kabamus.com/garage/gears.html

Just input tire size, gear ratio, and diff ratio.

[135sohc]

That link makes my anti-virus alarm ping

[Juggy]

i woulda ran it another 200k !!!!!!!!!!! lolol

[cordes]

What is the rpm difference between 3.50 & 3.77 ? I (think) I understand the math but I dont know how to apply it, not a strong area for me

I'll try and crunch the numbers for you later today. Are you talking about sticking with the 3.77 gear set and running the 3.50FD, or did you want to know the RPM difference between each gear set with their native diffs?

[135sohc]

Stay with the 3.77 gearset but with the 3.50 final drive. The 3.77's are chunky gears, almost like a 555/568 but slightly more pitched to make them quieter.
I found franks gearing calculator but it doesnt allow for a side by side comparison.

[cordes]

Stay with the 3.77 gearset but with the 3.50 final drive. The 3.77's are chunky gears, almost like a 555/568 but slightly more pitched to make them quieter.
I found franks gearing calculator but it doesnt allow for a side by side comparison.

I'll run those numbers later this evening.

[cordes]

92' 523 stock.

Gear   Mph per 1000 RPM   Mph @2500 RPM   Mph @6800 RPM
--------------------------------------------------------
  1         5.89                15              40
  2         9.46                24              64
  3        14.33                36              97
  4        20.09                50             137
  5        27.44                69             187

 Mph             RPM (in Gears)
-------------------------------------------------
           1        2        3        4        5        
-------------------------------------------------
   5      849      529      349      249      182
  10     1699     1057      698      498      364
  15     2548     1586     1047      747      547
  20     3398     2115     1396      996      729
  25     4247     2643     1745     1245      911
  30     5097     3172     2094     1494     1093
  35     5946     3701     2443     1743     1275
  40     6796     4229     2792     1991     1458
  45              4758     3141     2240     1640
  50              5287     3490     2489     1822
  55              5815     3839     2738     2004
  60              6344     4188     2987     2186
  65                       4537     3236     2369
  70                       4886     3485     2551
  75                       5235     3734     2733
  80                       5584     3983     2915
  85                       5933     4232     3098
  90                       6282     4481     3280
  95                       6631     4730     3462
 100                                4979     3644
 105                                5228     3826
 110                                5476     4009
 115                                5725     4191
 120                                5974     4373
 125                                6223     4555
 130                                6472     4737
 135                                6721     4920
 140                                         5102
 145                                         5284
 150                                         5466
 155                                         5648
 160                                         5831
 165                                         6013
 170                                         6195
 175                                         6377
 180                                         6559
 185                                         6742

Gear Change  RPM drop (change @2500)  RPM drop (change @6800)
-------------------------------------------------------------
  1 -> 2         -944 (to 1556)          -2568 (to 4232)
  2 -> 3         -850 (to 1650)          -2311 (to 4489)
  3 -> 4         -717 (to 1783)          -1950 (to 4850)
  4 -> 5         -670 (to 1830)          -1823 (to 4977)

With 3.50 gears.

Gear   Mph per 1000 RPM   Mph @2500 RPM   Mph @6800 RPM
--------------------------------------------------------
  1         6.34                16              43
  2        10.19                25              69
  3        15.43                39             105
  4        21.64                54             147
  5        29.56                74             201

 Mph             RPM (in Gears)
-------------------------------------------------
           1        2        3        4        5        
-------------------------------------------------
   5      789      491      324      231      169
  10     1577      982      648      462      338
  15     2366     1472      972      693      507
  20     3154     1963     1296      924      677
  25     3943     2454     1620     1156      846
  30     4732     2945     1944     1387     1015
  35     5520     3436     2268     1618     1184
  40     6309     3926     2592     1849     1353
  45              4417     2916     2080     1522
  50              4908     3240     2311     1692
  55              5399     3564     2542     1861
  60              5890     3888     2773     2030
  65              6380     4212     3004     2199
  70                       4536     3235     2368
  75                       4860     3467     2537
  80                       5184     3698     2707
  85                       5508     3929     2876
  90                       5832     4160     3045
  95                       6156     4391     3214
 100                       6480     4622     3383
 105                                4853     3552
 110                                5084     3721
 115                                5315     3891
 120                                5546     4060
 125                                5778     4229
 130                                6009     4398
 135                                6240     4567
 140                                6471     4736
 145                                6702     4906
 150                                         5075
 155                                         5244
 160                                         5413
 165                                         5582
 170                                         5751
 175                                         5920
 180                                         6090
 185                                         6259
 190                                         6428
 195                                         6597
 200                                         6766

Gear Change  RPM drop (change @2500)  RPM drop (change @6800)
-------------------------------------------------------------
  1 -> 2         -944 (to 1556)          -2568 (to 4232)
  2 -> 3         -850 (to 1650)          -2311 (to 4489)
  3 -> 4         -717 (to 1783)          -1950 (to 4850)
  4 -> 5         -670 (to 1830)          -1823 (to 4977)

[Vigo]

That link makes my anti-virus alarm ping

I have used that site for many years with no ill effects. AVG, Spybot, Malwarebytes etc are not giving me any fuss about it..

[135sohc]

Is there such a thing as a teflon lined throwout bearing ? The retainer housing has a little wear from where the t/o bearing has moved fore-aft.

[135sohc]

Tonight I pulled everything back out to start detailing and cleaning everything up really well and. I may have found the source of the 'hard shifting' problem that I had with this particular transmission awhile back. On the 3-4, 5th and even starting on the reverse shift rail where there notched on the bellhousing end for the shift detents. The top the 'ramp' where the little spring loaded rollers ride is a bit burred and rounded over moreseo than it would have been when new. I'm going to see about trying to polish the area to remove some of the burring or inspect and possibly use a set of rails from another lower mileage transmission.
Upon cleaning up and doing a close inspection of the fork pads, comparing new vs these used ones. I'll be replacing the 3-4's and putting the others back in. There is almost zero wear on them aside from a few scratches.

[135sohc]

Is there such a thing as a teflon lined throwout bearing ? The retainer housing has a little wear from where the t/o bearing has moved fore-aft.

Nobody ?

[cordes]

I don't know the answer to your question. I'm also unclear as to which part of the TO bearing you are speaking of. Are you talking about the inside of it which rides back and forth on the input shaft housing deal?