Hanlon Transmission Information Center

Transmission 101:

The drawing below shows how the gears in a T5 are positioned (other transmissions similar). This will give you a basic idea of how a transmission works. There are a couple of things to point out that are not shown. The reverse idler gear and 5th gear syncro are not shown. The 5th gear syncro is mounted on the end of the cluster gear toward the rear of the transmission.  In a T5, 5th gear is enclosed in the tail-shaft housing.

How it works:
When you engage first gear, #5 slides rearward. When you shift to second, #5 moves forward. For third gear, #5 centers and #2 moves rearward. For fourth gear, #2 moves forward to lock the input and output together. For fifth gear, #2 centers and the 5th gear syncro (not shown) slides forward. 

Click here to see drawings on how power goes through the different gears in the transmission.

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Disassembled Views

Tremec / Borg-Warner / TTC

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Transmission Diagnosis:

This chart list some possible troubles that may be encountered along with possible causes and remedies.

 

Problem	Possible Cause	Remedy
Will not shift (control lever moves)	Control lever assy. broken or damaged. Damaged offset lever, shift fork, selector plate or selector arm	Replace control lever and housing assy. Remove extension or adapter and case cover. Check for damaged parts. Replace damaged parts
Hard shift or control lever will not move into gear	Clutch not releasing Improper or low transmission lubricant Shifter shaft or shift rail binding Binding of sliding synchronizers or gears If reverse only, seized backup switch Worn or damaged flywheel pilot bushing Bell housing misaligned	Adjust or replace clutch Add or drain and replace with proper lubricant Remove extension or adapter and case cover. Check for damaged parts. Replace damaged parts Remove extension or adapter and case cover. Reach down into transmission and check that synchronizers and gears (parts with shifting grooves) slide freely on shafts. Remove and replace damaged parts Remove and check backup switch. Replace if seized Replace pilot bushing Align bell housing to within 0.010 inch TIR on face and in bore
Gears clash when shifting	Engine idle speed too high Clutch damaged or out of adjustment Pilot bearing between input shaft and Output shaft binding Damaged synchronizer Bell housing misaligned Damaged gear or gears Worn or damaged flywheel pilot bushing	Adjust idle speed to specifications Adjust or replace clutch Disassemble and check bearing rollers, input shaft ID and output shaft OD. Replace damaged parts Disassemble and check for damaged synchronizer parts. Replace damaged parts Align bell housing to within 0.010 inch TIR on face and in bore Disassemble and check for gear damage Replace damaged gears Replace pilot bushing
Transmission jumps out of gear	Loose transmission or flywheel housing bolts, improper alignment Synchronizer damaged or excessively worn Blocking ring damaged, worn index slots or friction surfaces worn or damaged Excessive countershaft endplay Shifting fork loose on shaft or rail; worn or damaged fork or inserts	Torque bolts to specifications. Realign if necessary Disassemble and check for worn or damaged synchronizer parts. Replace damaged parts Disassemble and check blocking ring for wear or damage Replace worn or damaged parts Disassemble and check. Replace worn or damaged parts. Re-shim if roller bearings used Disassemble and check for wear or damage. Replace worn or damaged parts
Transmission locked in one gear	Fork or offset lever loose on shaft or rail Worn or damaged forks, offset lever, shaft or rail Worn or damaged synchronizer Worn or damaged gears	Remove extension or adapter and case cover. Check for loose parts on shifter shaft or rail. Replace roll pin(s). If still loose, replace shaft or rail and/or attached parts as required Remove extension or adapter and case cover. Check for wear or damage Replace damaged parts Disassemble and check for worn or damaged synchronizer parts. Replace worn or damaged parts Disassemble and check for worn or damaged gears. Replace worn or damaged gears
Transmission noise NOTE: Make sure noise is coming from transmission and not clutch release bearing or other components.	Improper or low transmission lubricant Loose bolts or other attaching parts Improper flywheel housing to engine crankshaft alignment Noisy transmission bearings Noisy gears	Add or drain and replace with proper lubricant Make sure all attaching parts are torqued to specifications Check alignment and correct if neces­sary per vehicle service manual Disassemble and check bearings, bear­ing rollers and parts in and on which they operate for wear or damage. Replace worn or damaged parts Disassemble and check for worn or damaged gears (including speedometer gear). Replace worn or damaged gears
Transmission leakage	Leakage from other components Vent or breather clogged Too much or improper lubricant Loose bolts at sealing faces. Improperly applied sealant Worn or damaged oil seal	Verify transmission leakage. Thoroughly clean all exposed surfaces, then check for leaks. Remove vent or breather and clean or replace Remove fill plug to check for excess, or drain and replace Torque bolts to specifications Separate and thoroughly clean leaking surfaces. Reapply sealant. Replace parts and torque bolts to specifications Replace oil seal

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