K20 Transmission tear down DIY
This is a k20 transmission tear down diy to basically show you what to do to crack open the case and remove the gear set/diff.
That being said this will start off with you already having the trans out of the car.
1) take a 14mm Allen head socket and remove this cap/cover
http://img.tapatalk.com/d/14/02/28/2ezysaba.jpg
You'll see the countershaft bearing and it's held in by a clip (don't touch the clip just yet)
http://img.tapatalk.com/d/14/02/28/ubytyvy7.jpg
Now take an 8mm amen head socket and remove this bolt. It locks the shift selector into place.
http://img.tapatalk.com/d/14/02/28/tupera5u.jpg
Then remove these 3 bolts
http://img.tapatalk.com/d/14/02/28/e2azebe9.jpg
BUT Careful!!! They're small Springs and balls inside. These are to help the shift forks rest in place in any particular position.
http://img.tapatalk.com/d/14/02/28/yrehy5ut.jpghttp://img.tapatalk.com/d/14/02/28/upy2edug.jpghttp://img.tapatalk.com/d/14/02/28/ubaqeju7.jpg
After removing those with a magnetic till or whatever fashion you see fit it's time to pull the shift selector out of the trans.
You do so by removing the 4 screws on top of it and a tip while removing it is to make sure the trans is in neutral. This lines up all the tabs on your shift fork like such
http://img.tapatalk.com/d/14/02/28/y8ure2yv.jpg
http://img.tapatalk.com/d/14/02/28/y3ypepem.jpg
If it's in a gear you will see one shifted like this abs that makes removing the selector difficult for no reason.
http://img.tapatalk.com/d/14/02/28/ybavyvup.jpg
Now use a 14mm socket to pull the reverse idler bolt
http://img.tapatalk.com/d/14/02/28/qy8yvemy.jpg
And a 10mm to remove your speed sensor depending on the year of your car.
The 5 speed and 6 speed both use the same sensor but you'll need a spacer to go between the sensor and trans casing if your swapping to a 5 speed gear set like I am.
I used a Fender washer. It was the perfect thickness.
http://img.tapatalk.com/d/14/02/28/y9a4ary6.jpg
Now take and remove all of the 12mm bolts holding the two case halves together. Take note where the long ones go as well as brackets. It will be easy to see why you need a line bolt in a given spot due to the thickness of the case.
The spot I used to pry is right under the speed sensor
Once all those books are removed grab a pair of snap ring pliers and a flat head screw driver or small pry bar.
Search for an area easy to use to separate the casing. Open the C-clip on top of the countershaft like so.
http://img.tapatalk.com/d/14/02/28/aqymyzap.jpg
While holding that open use your flat has to pay apart the casing. You'll see one you've lifted the case enough you no longer have to keep hold of that C-clip.
Then bang!!!!! You've now exposed the gears diff and bearings.
http://img.tapatalk.com/d/14/02/28/u9equ7a5.jpg
No its time to pull the. Shafts out along with the gears.
Take and simply slide up the reverse gear and the shaft it rides on. (take note of the shafts hole direction. It's important for when your assembling the transmission back together. If it's not like up correctly you will not be able to put that 14mm bolt back in place.
Now remove the 2 10mm bolts from the revered arm and pull that off to the side
http://img.tapatalk.com/d/14/02/28/yzadutag.jpg
No take hold of the shift forks and both shafts and pull up and wiggle the gears should remove quite easily.
https://www.dropbox.com/s/c9wfq7pata...221_200549.mp4
Take not if the washers that are on the end of the mainshaft. One is a sorting washer and needs to be kept in correct orientation.
http://img.tapatalk.com/d/14/02/28/naduqaby.jpg
Next the diff will pull out. You may have to wiggle a bit. I didn't take a picture of this.
Now your left with a case full of bearings, and if your like me, a bunch of metal in the case and magnet. And I have too many pictures of carnage lol
Take your time do it right and you'll get it done without a fight! That rhymes!
s4 IG-petefromthestreets
Cage plus radio member #1
