IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation ofall motor vehicles as well as the personal safety of the individual doing the work. This Manual provides general directions. for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability ‘There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools. or parts. NOTES, CAUTIONS, AND WARNINGS ‘As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle, WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle. + Always wear safety glasses for eye protection + Use safety stands whenever a procedure requires you to be under the vehicle with the vehicle jacked up. ‘+ Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. + Setthe parking brake when working on the vehicle. It yu have an automatic transmission, setitin PARK unless instructed otherwise for a specitic operation. If you have a manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4" x 4” or larger) tothe front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. * Operate the engine only in @ well-ventilated area to avoid the danger of carbon monoxide. + Kesp yourself and your clothing away from the moving parts, when the engine is running, especially the fan and drive belts. ‘+ To prevent serious bums, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and mutfler. + Do not smoke while working on the vehicle. ‘+ Toavoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head. + Keep hands and other objects clear ofthe radiator fan blades. Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition isin the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood. * Disconnect the negative battery ground cable before using any electric welding equipment.TREMEC TR-3550 AND TKO TRANSMISSIONS TABLE OF CONTENTS Important Notice — Before You Begin Service... Identity Your Type of Tremec TA-3550 of Tremec TKO Transmis Shifter Location Conversion Kits... Disassembled View Legend — Late Disassembled View... . Dissassembled View Legend .. ToReplace T-5 Transmission with Tremec T3550 or TKO High Perimance Transmissions Transmission Removal. so Transmission Installation Disassembly — Transmission. Disassembly and Assembly—Subassemblies Input Shaft Bearing ....0nnmn Countershaft (Cluster Gear) — Early One-Piece Design Countershaft (Cluster Gear) — Late Three-Piece Design Fifth Gear Synchronizer Assemb\ Reverse Idler Assembly — Eatly and Late Design: Quiput Stat and Gear Assembly — Early and Late Designs. ‘Synchronizer Case Cover and Shitting Mechanism Shifting Lugs Extension Housing Reverse Inhibitor Assembly Extension Housing Rear Seal ‘Assembly — Transmission ‘Transmission Diagnosis Inspection Transmission Cleaning... Specifications Metrics Introduction Nomenclature for Bolts Bolt Strength Identification Hex Nut Strength Identification . Other Types of Parts. English/Metric Conversi Decimal and Metric Equivalents .. Torque Conversion1 TREMEC TR-3550 AND TKO TRANSMISSIONS 1 IMPORTANT NOTICE—BEFORE YOU BEGIN SERVICE IDENTIFY YOUR TYPE OF TREMEC TR-3550 OR TREMEC TKO TRANSMISSION This service manual covers the TR-3550 (#2600682) and TKO (#2600708) model Tremec Transmissions, ‘The part number is located on an identification tag on the right side of the transmission, The following chart brietly describes differences in the TR-3550 and the TKO, as well as design changes that have been made since the Wenemissions were niroduced Dsassombled views of hese say and ata design pats ae located on pages 2-3. B ‘COMPONENT EARLY/LATE DESIGN ‘APPLICATION TR-3550 | TKO Input Shaft = 10 Splines | 26 Splines Main Output Shalt = 28 Splines _| 31 Splines E Extension Housing - seal/bushing = Standard Dia_| Larger Da. ‘Shitt Lever (Short Throw) = Optional ‘Standard ‘Gountershatt (Cluster Gears) Early design is one-piece, Late design's Yee Yes three-piece. Reverse Idler Gear Assembly Tate design—2* set of roller bearings Yes Yes Eek | oo ‘ae daigr— Shi alam anges Vee | Veo Ye enn St Sadr Ral Eni day Sol saan ae Tea Ya Raeerl asaya da eaarean alone copa em nEean ay degr-Speman manana ear bearing cages. Late design— Retained with snap rings. SHIFTER LOCATION CONVERSION KITS Part Number Shifter Kit Application —_Gimension 1Mu2671196 Front Shit Conversion Kit TR-OS50TKO ——178.20mm Mu2671127 Mig-Shitt Conversion Kit TR3S50TKO ——_-322,00mm Two Shift Conversion Kits are available from Tremec to customize the shitter location for your vehicle, The standard dimension is 495.80mm {rom the front of the transmission to the centerline of the shifter for both Tremec TR-3550 and TKO models as shown in the illustration. im) et BTREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLED VIEW LEGEND — LATE DESIGN AND TKO t of SLNINOdNOO 12G0W OL ANDINA xvawassy ‘ONLLAIHS ‘Nv uaA0o 1:00 r0-y oP SLNZNOdWOD NDISAG 3LV1TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLED VIEW “S-) SADVd NO LSI SLuVd 33S — LUVd ANDINN S43SN T3GO0W OWL & SALNBNOdNQD NDISSG-ALV1 HO4 Z 3OVd 33S +4 TREMEC TR-3550 AND TKO TRANSMISSIONS SS DISASSEMBLED VIEW LEGEND PARTNO. DESCRIPTION NO. PARTNO. DESCRIPTION 2605866 Shift Fork inspecton Cover 4A 2606415 TKO modelExtension Housing 2604902 Bolts (4 Req'd) ‘Assy (Without bushing) 2604899 Star Washer (4 Req'd) 48 2605892 Reverse Inhibitor Spring 2605811 Shift Rail Guides (3 Red's) 48 2606283 —_Reveise Inhibitor 2605812 Shit Rail Guide O-Ring 2603887 Rlevarse Inhibitor Roll Pin (9 Req'd) 2606248 Lug Extension Cover 2605804 Early—First-Second Shit Ral 2804902 Bolt (4 Rea’) TOBR-0004 Late—First- Second Shift Rall 2604899 Star Washer (4 Req'd) 2604895 Shift interlock Pin (2 Req'd) 2671061 Shift Turret Assy 2605817 E-Clip Snap Ring (2 Req'd) 2605884 Lateral Support Pivot (2 Req'd) 2604154 Shift Lug Roll Pin 2 Red's) 2128715 Breather 4101900008 Ball Bearing 2605949 Lateral Support Pivot Looking Tab 2806264 Transversal Spring ‘Washer (2 Req'd) 2606212 _‘First-Second/Fith-Reverse Shit 2606237 3550 mode!—Shitt Lever Assy Lug ( Redit) (Standard Throw) 2606263 Piston Spring (2 Req'd) 2670945 3550 mode!—Shit Lever Assy 44/1822 Shift Lug Roll Pin {Ghort Throw) 2605815 Piston (2 Req'd) 2608240 —_Turrat Dust Cover 2606293 Third and Fourth Shit Lug 2604025 Turret Dust Cover Retaining Bolt 2606265 ‘First Second/Fitth-Reverse Shit (4 Req'd) Lug Assy 2603968 Turret Assy Retaining Bolt 2605806 __Early—Fith-Reverse Shift Rall 2606247 Early—Shift Link TOBR.0003 Late—Fith-Reeverso Shit Pal, 2606464 _Late—Shif Link 2605805. Early—Third-Fourth Sift Rail 2606247 _Early-—Shift Lever Socket TOBR-0002 —Late—Fitt-Raverse Shit Rall 2606463 _Lato—Shift Lever Socket 2604154 Shi Fork Roll Pin (2 Reid) 2606246 Shift Lever Socket Bushing 2606214 —_*Fifth-Reverse Shit Lever 2601227 Early—Shilf Lever Socket Assy Allen 2605808 _First-Second Shit Fork Screw 2605986 —Third-Foutth Shit Fork 1451822 Late—Shift Lover Socket Assy Allen 2605902 Shift Fork Nyion Inserts Screw 2605829 _interlock Bracket Bolt (2 Req'6) 2601227 _Early—Shilt Select Finger Allen 2605810 interlock Spring Bracket Screw 2601082 interlock Spring (8 Req'd) 141622 LateShift Select Finger Allon 10J000012 Ball Bearing (3 Redd) Screw 2605809 Case Cover w/o Guide Pins 2605855 Shift Select Finger 2605802 Case Cover w/ Guide Pins 2603979 3850 ModelExtension Housing Oil Late—Case Cover/Shiting Assembly Seal Case Cover Bot (10 Fed’a) 2606416 TKO Model--Extension Housing Ol Interlock Plug Allan Screw bre Genter interlock Pin 2606244 Neutral Safety Switch Transmission Case Assy veri Speedometst Driven Gear (also includes #36 & #37) 99796-0616 Speadometer Cable Retaining 13F000008 Drain Pug Screw 413F000008 Filler Plug 2606216 averse Shift Fork Assy 2603099 Magnet Retainer Lock 2605823 ‘Filth and Reverse Shit Ral {not serviced separately) 2904342 Reverse and Overdrive Actuating 2602631 Case Magnet Pin Roll Pin (Not Sersiead Separataly) 2604154 Filth Gear Shit Fark Roll Pin 2604636 Extension Housing-To-Case 2606111 ‘Fifth Gear Shift Fork Assy ‘Alignment. Dowel Pin 2603965 Wave Type “E” Clip 39 2605082 Backup Lamp Switch Gasket 2608948 Reverse and Overdrive Lever 402606249 «Backup Lamp Switch 2605824 Reverse and Overdrive Actuating 41 2604720 ‘Reverse Balancing Pivot Pin = 42 2606098. Reverse Inhibitor Shaft Reverse Shat 42 6501095 Reverse Inhibitor Shaft Allen Screw 1432524 Reverse Shaft Locking Pin 44 2606228 3550 model—Extension Housing 2603695 Reverse Ider Assy Thrust Washer Assy (2 Req'd) 44& 260614 TKO modetExtension, Housing Assy (Includes bushing)5 TREMEC TR-3550 AND TKO TRANSMISSIONS 5 ————S DISASSEMBLED VIEW LEGEND (CONTINUED) NO. PARTNO. DESCRIPTION NO. PARTNO, — DESCRIPTION 80 2605799 EarlyRollor Bearing End Spacer 1162670799 _‘Frst-Second Synchronizer Assy and (@Reqe) Reverse Gear 80A 2608465 Late—Roller Gearing End Spacer 1172606110 _Early--Spacer (First Gear) (@ Reqs) 117A 2602650 _Late—Snap Ring (Fist Gear 81 2605797 __EarlyRoverse Gear Roller Baaring Bearing) (44 Reqs) 118 2606109 aller Bearing Assy 81 2605797 Late—Fleverse Gear Roller Bearing 119 2606070 Fist Gear (22 Req'd) 120 2605708 Spit Ring Thrust Washer Retainer 81A 2602661 Late—Fleverse Gear Roller Bearing 121 2605707 Spit Ring Thrust Washer (44 Req'd) 122 2605706 Output Shaft-To-Case Bearing 82 2606094 Reverse Goar 123 2605701 Bearing Race 83 2608795 Thrust Washer 124 2605700 Output Shaft-To-Case Bearing Assy 84 2605798 —_EarlyRollr Bearing Spacer 125 2606242 9550 Model-—Output Shaft (28, 848 2606466 _Late—Roller Bearing Spacer Splines) 85 2605800 Reverse Selector Sleeve 125A 2606413 TKO ModelOutput Shatt (31 88 2606093 Reverse Idle Gear Splines) 87 2603698 Front Bearing Retainer Bolts 126 10400006 all Bearing (4 Reqs) 127 104000008 Ball Bearing 88 2606243 Front Bearing Retainer 128 2601215 Speedometer Drive Ge 83 2603865 Input Shaft Seal 129 2604502 Snap Ring 90 2606066-069 input Shatt-To-Case Bearing 130 2606258 O-Ring Seal Selective Shim 131 2608289 © Case Plug 81 2605689 input Shaf-To-Case Bearing Cup 1322605787 _Gountershaft Bearing Race (2 Req'd) 92 2606065 input Shaft-To-Case Taper Roller 139 2605788 _Countershaft Bearing (2 Reqd) Bearing 134 2605786 Countershatt Bearing Assy 93 2606064 input Shaft-To-Case Taper Roller 135 2608281 _Early—Countersha (One Piece) Bearing Assy 435A 2606225 Late—Countarshatt With Integral 84 2608241 3550 Model—Input Shaft (10 First and Sacond Gears, Splines) 1358 2606232 —_Late—Countershaft - Fourth Gear 84 2606412 TKO Mode!Input Shaft (26 135C 2606293. Late—Countershatt- Third Gear Splines) 1350 5J001008 —_Late—Countershaft - Woodrut Keys 95 2601210 Input Shaft Pocket Bearings (2 Rea) (17 Req'd) 135E 2602645 Late—Countershatt- Snap Ring 96 2605768 Fourth Gear Clutch Cone 136 2606087 _Gountershait-To-Case Bearing Assy 97 2608124 Synchronizer Blocker Ring 137 2606118 Thrust Washer 88 2705765 Thrust Washer 438 2606089 Synchronizer Hub-Fith Gear 99 235982 Thrust Bearing 439 2605780 Synchronizer Collar 100 2905767 Thrust Washer 140 2606088 Fifth Gear Synchronizer Assy 11 2605764 Synchronizer Collar 441 2602561 Roller Bearings (86 Roa'd) 102 2604372 Synchronizer Insert (9 Req’) 142 2606092 Roller Bearing Spacer 103 2605117 Synchronizer Spring (2 Req'd) 149° 2606091 ith Gear Clutch Cone Yo 2606083 Synchronizer Hub 144 2605789-792 Countershatt Rear Gearing 105 2606082 ‘Thira-Fourth Synchronizer Assy _-«148-*1C00072B- Extension Housing-To-Case Bolt 108 2606262 Third Gear Assy (6 Reqs) 107 2606081 ‘Earty—Spacer (Third Gear) 146 5000007 ‘Star Washer (6 Req'd) 107A 2606339 Late—Snap Ring (Thitd Gear 147 2603891 9550 Model—Extension Housing Bearing Cage) Bushing 408 2506075 _—Rolor Beary Assy 147A 260617 TKO Model—Eitension Housing 109 2606077 Split Ring Thvust Washer Retainer Bushing 110 2606076 Split Ring Thrust Washer 111 2606074 Second Gear 112 2602660 Snap Ring 113 2606073 Synchronizer Collar 114 2602648 ‘Synchronizer Inserts (3 Req'd) 418 2606072 Synchronizer HubTREMEC TR-3550 AND TKO TRANSMISSIONS TO REPLACE T-5 TRANSMISSION WITH TREMEC TR-3550 OR TKO HIGH PERFORMANCE TRANSMISSIONS Parts Required: Three quarts GM Synchromesh transmission fluid (GM part no. 12345348) ar optional automatic transmission fluid (Dextron 1 Four 7/16 - 14 x 1 1/2 grade 8 bolts and lock washers (Ford part no. 57661-S2). Bell housing (Ford part no. D9ZC-6392-C) Crossmember (Ford part no, E62Z-6A023-A) Procedure Out! Remove T-5 transmission as outlined in transmission removal procedure. Remove existing bell housing and clutch linkage. Install new bell housing and align to crankshatt Reinstall clutch linkage. Break crossmember bushing-1o- ccrossmember tack weld with hand grinder ‘and reposition crossmember to its most rearward position Install TREMEC TA-S550 transmission as outlined in installation procedure using new bolts and lock washers. Tack weld (in two places) the crossmember bushings to the crossmember before lowering the vehicle. TRANSMISSION REMOVAL Remove shift knob. Remove shift boot by unsnapping plastic plate which retains the shift boot, Remove two bolts securing the shift handle to the shift tower. Raise the vehicle on a hoist. NN Remove oil drain plug and drain transmission. Properly dispose of ol Remove four nuts retaining exhaust pipes to exhaust manifold. Remove four nuts retaining exhaust pipes to mufflers. Remove exhaust system pipes by siiding out ot retainer bracket. Mark the driveshaft U-joints at the rear companion flange (yoke) so that it may be installed in the same position. Disconnect the driveshaft from the rear U-joint flange. Slide the driveshaft off the transmission output shaft Remove the two nuts retaining the rear transmission support to the crossmember. Remove bolts. ‘Support the engine and transmission with transmission jack and raise slightly. Remove the two nuts from the cross member bolts, Remove bolts and remove cross- member. Disconnect the wiring hamess from the backup lamp switch. On 5.0L engines, disconnect neutral sensing switch, Remove the bolt from the speedometer cable ‘etainer and remove speedometer driven gear from the transmission. Remove the four bolts retaining transmission to the flywheel housing. CAUTION: Care should be taken to ensure that lowering the transmission will not cause damage to engine components. Lower the engine enough to obtain clearance for transmission removal. Move the transmission and jack rearward until the transmission input shaft clears the fy-wheel housing. CAUTION: Do not depress the clutch pedal while the transmission is removed. Remove existing bell housing and clutch linkage as suggested in the manufacturer's service manual.TREMEC TR-3550 AND TKO TRANSMISSIONS TRANSMISSION INSTALLATION CAUTION: Bell housing should be aligned to have a runout of no more than .005 inch to the crankshaft. Damage to the transmission may occur if improperly aligned. Install bell housing and clutch linkage. Make sure that the mounting surtaces of the ‘transmission and flywheel housing are free of dirt, paint and burrs. Raise the transmission and move forward on the guide pins until the input shaft splines enter the Clutch hub splines and the case is positioned against the fiy-wheel housing. Guide pins can be installed in the two lower mounting bolt holes to ease installation. Install two new 7/16 inch — 14x 1 1/2 grade 8 bolts snug, and remove the guide pins. Install the two lower retaining bolts. Tighten all retaining bolts to 61-89.4 Nem (48-86 Ib-f). Connect the speedometer cable to the extension housing. Install the speedometer driven gear and secure. Tighten the retaining screw 4-6 Nem (3-5 Ib-f). Using a transmission jack, raise the rear of the transmission and install the transmission support. Install and tighten retaining bolts to 48.8-67.7 Nem (96-50 lb-ft). With the cross member firmly held on the workbench, break the bushing-to- ccrossmember tack welds with a hand grinder. NOTE: The bushing must slide freely in the cross member. Position crossmember in the side brackets and install crossmember bolts. install the two nuts and tighten to 34-48 Nem (25-35 lb-ft), \With the transmission extension housing resting onthe engine rear suppor, side tho trosamember to ts most rearward postion and install the transmission extension housing retaining bolts. Tighten the bolts to 3449 Nem (25-05 It) ‘Tack weld, in two places, the crossmember bushing to the cross member. Connect the backup lamp switch wiring hamess. On 5.0L engines, connect neutral ‘sensing switch to the wiring hamess. Reinstall exhaust system pipes and torque nuts to 27-41 Nem (20-30 lb-ft). Slide the forward end of the driveshaft over the transmission output shaft. Ensure drive- shaft index marks align. Connect the driveshaft to the rear U-joint flange. Tighten U-bolt nuts to 56.9-77.2 Nem (42-57 Ib-f), Fill the transmission to the proper level with approximately three quarts of GM ‘Synchromesh transmission fluid (GM part no. 12345349). Lower vehicle. Install shifting handle to shifting tower by stalling and tightening the two retaining bolts and tighten to 29.8-43.3 Nem (22-32 lb-ft), Snap plastic plate into console. Reinstall shift knob. Check the shift and crossover motion for full shift engagement and smooth crossover operation,8 TREMEC TR-3550 AND TKO TRANSMISSIONS 8 DISASSEMBLY—TRANSMISSION Drain transmission fuid NOTE: Perform Steps 4 through 13 only if the shift lever is loose. Ifthe shift lever is not Remove transmission from vehicle as loose, go to Step 14, outined. 4. Remove four shift turret dust cover bolts. Properly mount transmission in bench ‘mounted holding fixture. SHIET TURRET Dust COVER Remove dust cover. SHIT uzven SNe Inspect shit lever for looseness. PNGT BO NOTE: Shiter should be loose without excessive movement. Excessive lateral Z SHETLEVER movement or end play may indicate worn or damaged components. Straighten locking tabs holding shit lever pivot bots. Remove two shift lever pivot bolts.9 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY—TRANSMISSION (CONTINUED) 9. Remove shift lever assembly. SHIFT LevER ASS SHIFT TURRET Inspect ball on end of shift lever for wear {excessive}. Remove six shift turret housing bolts. . Remove shift turret, Inspect shifter ball socket bushing for wear. Replace if worn. SWETING LUG iSPECTH iNgpectiON ‘SHIFT TURRET CoveR EXTENSION SHIFTER BALL HOUSING” SOCKET BUSHING 14. Remove four shifting lug inspection cover bolts and star washers, 15. Remove shitting lug inspection cover. THIRD AND FOURTH SHIFTING LUG FIRST AND SECOND SHIFTING LOG IETH AND REVERSE SHIFTING LU ——§1005.0 NOTE: Insert @ magnet into area under shifting lugs to catch roll pins when pushed tree. MAGNET SETH AND REVERSE. SHIFTING LUG10 TREMEC TR-3550 AND TKO TRANSMISSIONS 10 LS DISASSEMBLY — TRANSMISSION (CONTINUED) Using a pin punch, remove roll pin securing the fith and reverse shifting lug to the fith and reverse shift ral. Remove fifth and reverse shifting lug and roll pin. EIETH AND REVERSE SHIFT RAIL FIFTH AND REVERSE SHIFTING LUG. . Using a pin punch, remove the first and second shifting lug roll pin. |. Remove first and second shitting lug. ‘THIRD AND FOURTH SHIFT RAIL ‘THIRD AND FOURTH SHIFTING LUG . Rotate shiting selector rail moving selector finger away from the third and fourth shifting lug. |. Using a pin punch, remove the third and fourth shifting lug rol pin Remove third and fourth shifting lug. EIBST AND FIRST AND SECOND. D SHITRAL SHIFTING LUG Remove six extension housing-to- transmission case retaining bots. NOTE: Mark placement of transmission identification tag. Remove extension housing. EXTENSION HOUSING ‘TRANSMISSION CASE" TREMEC TR-3550 AND TKO TRANSMISSIONS 1 ———_—— DISASSEMBLY—TRANSMISSION (CONTINUED) 25. Remove four transmission case inspection ‘cover bolts and star washers, 26. Remove transmission case inspection cover. ‘TRANSMISSION CASE INSPECTION COVER ‘TRANSMISSION CASE ASSY S101 Remove 10 transmission case cover-to-case bolts. NOTE: Mark location of wiring hamess strap. Remove case cover and shifting mechanism. “TRANSMISSION CASE COVER AND SHIFTING MEGHANISM Y- ‘COUNTERSHAFT END BEARING soa Using pin punch, remove fith gear shifting fark rol pin. Remove fith gear synchronizer assembly and shift fork together. ne BTHGeaR pera Gean Seere* SMT ROAR SyNcMRONIZER ASS 1019.4 NOTE: Be careful to remove the fifth gear synchronizer thrust washer withthe fith gear ‘synchronizer assembly to prevent possible loss of the roller bearings Jocated inside the fith gear synchronizer assembly FIFTH GEAR SYNCHRONIZER, THRUST WASHER FIFTH GEAR, SYNCHRONIZER FOLGER BEARINGS NOTE: Be careful not to lose the thrust washer locking-and-bearing retaining ball when fifth gear synchronizer assembly is removed. Remove ball from countershaft with a magnet,12 TREMEC TR-3550 AND TKO TRANSMISSIONS 12 DISASSEMBLY — TRANSMISSION (CONTINUED) Using universal dial indicator, measure firs, 33. Remove four front bearing retaining bolts. second and third gear end play. (0.000- 0.016 inch, maximum of 0.018 inch). Record for reference. Gear rattle or clunking noise indicates Possible excessive backlash. DIAL INDICATOR (OUTPUT SHAFT ASSY SIOISA Using universal dial indicator, measure gear backlash on frst, second and third gears (0.000 - 0.018 inch). Record for reference. NOTE: Insert a screwdriver between countershaft drive gear on transmission case to prevent movement of the countershaft assembly. ‘SCREWDRIVER DIAL INDICATOR, FIRST GEAR FRONT BEARING RETAINING BOLTS, FRONT BEARING RETAINER CASE ASSY Remove front bearing retainer. NOTE: Be carefut not to lose the front bearing shims that are positioned in the bearing retainer. INPUT SHAFT. TO-CASE BEARING RETAINER FRONT nee ‘TRANSMISSION a CASE ASSY S10113 TREMEC TR-3550 AND TKO TRANSMISSIONS 13 ———— DISASSEMBLY — TRANSMISSION (CONTINUED} 38, Remove input shaft and bearing assembly. 38. Using a pin punch, remove roll pin retaining the selector link pin to the fith and reverse shift rail INPUT SHAFT. INBUT SHAFT: TO.CABE TocAs BEARING RACE BEARING EIETH AND REVERSE. SHIFT RAIL SF sion NOTE: Be careful not to lose the 17 roller bearings inside the shaft assembly between the input shaft and output shaft 39. Rotate fith and reverse shit ral counterclockwise disengaging selector link Pin from selector ink. 40. Remove selector link pin from fh and reverse shift rail, 96. Remove output shaft-to-case bearing race. 97. Remove output shaft assembly. SELECTOR UNCP FIFTH AND REVERSE SHIFT RAIL REVERSE SHIFT FORK14 TREMEC TR-3550 AND TKO TRANSMISSIONS 14 DISASSEMBLY — TRANSMISSION (CONTINUED) Remove fifth and reverse shitting rail REVERSE SHIFT FORK 42, Remove reverse shift fork. AEVERSE SHIFT FORK’ REVERSE IDLER GEAR ASSY 510208 43. Remove selector link retaining clip (E-clip) and selector link, ‘SELECTOR UNK bivor REVERSE IDLER ASSY FIETH AND REVERSE ‘SELECTOR UNK Remove reverse idler gearshaft. NOTE: Do not remove roll pin trom shaft unless shaft is to be replaced. REVERSE IDLER GEARSHAFT15 TREMEC TR-3550 AND TKO TRANSMISSIONS 15 DISASSEMBLY — TRANSMISSION (CONTINUED) Remove reverse idler gear assembly as a a, complete assembly. NOTE: Be careful not to lose the 44 needle bearings. 48, 46. Slide reverse idler gearshaft through assembly to maintain integrity of assembly. REVERSE IDLER REVERSE GEAR GEAR SLEEVE AEVERSE SHAFT COoKING PIN FRONT REVERSE IDLER GEAR REAR REVERSE THRUST WASHER IDLER GEARSHAFT REVERSE IDLER GeAaR THRUST WASHER, Remove cluster shaft intermediate roller bearing. CLUSTER SHAFT INTERMEDIATE ROLLER BEARING CLUSTER GEARSHAFT Remove cluster gear assembly. ‘TRANSMISSION CASE ,16 TREMEC TR-3550 AND TKO TRANSMISSIONS 16 — DISASSEMBLY AND ASSEMBLY—SUBASSEMBLIES Input Shaft Bearing Countershatft (Cluster Gear) — Disassembly and Assembly Early One-Piece Design Disassembly and Assembly Mount input shaft assembly in hydraulic press. Mount countershatt assembly in hydraulic Press of input shalt front bearing, press with universal press plate C-clamp Positioned under the tapered roller bearing. Press off the countershaft tapered roller NIvensa bearing, PRESS PLATE 0 INPUT SHAFT BEARING To assemble, mount shaft in hydraulic press. Press new bearing onto input shaft. To assemble, mount the countershaft in hydraulic press and press on the bearing. CAPPEDw7 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY—SUBASSEMBLIES (CONTINUED) 7 Countershatt (Cluster Gear) — Late Three-Piece Design ITEM NO. PART NUMBER DESCRIPTION 1 2605786 Tapered Roller Bearing 2 2602645 Snap Ring 3 2506232 Cluster — Head (Fourth) Gear 4 2606283, ‘Cluster — Third Gear 5 2606225 (Chustor — Shatt and FirsSetond Gears 6 54005008 Woodrul Key (2 Req'd) UNIVERSAL, Disassembly PRESS PLATE 1, Mount countershaft assembly in hydraulic press with universal press plate C-clamp ostioned under the tapered roller bearing (cee illustration on page 16) w Press off the countershatt tapered roller bearing, 3. Remove the snap ring 4. Position universal press plate C-clamp under the head (fourth) gear. Press off head gear, and remove the Woodruff key. 5. Position universal press plate C-clamp under the thrid gear. Press off the third gear, and remove the Woodruff key.18 TREMEC TR-3550 AND TKO TRANSMISSIONS 18 DISASSEMBLY AND ASSEMBLY—SUBASSEMBLIES (CONTINUED) 4. Carefully press on the third gear. CAUTION: The slot in the head gear and the third gear, and the matching Woodruff keys on the countershaft must be accurately aligned (see illustration) prior to pressing on the gears to avoid damage during installation. Mount countershaft in a hydraulic press with universal press plate C-clamp positioned under the second gear. Install the third gear Woodruff key in the slot on the countershaft, withthe top of the Woodruff key parallel to the countershatt. ‘TOP OF WOODRUFF THIRD GEAR KEY PARALLELTO WOODRUFF = COUNTERSHAFT KEY Install the head gear Woodruff key in the slot fon the countershaff, with the top of the Woodruff key parallel to the countershaft. Accurately align the slot in the third gear with ‘THIRD GEAR the Woodruff key. HEAD GEAR WOODRUFF KEY : ‘Accurately align the slot in the head gear with the Woodruff key. Carefully press on the head gear. Install the snap ring. Press on the tapered roller bearing,19 TREMEC TR-3550 AND TKO TRANSMISSIONS 19 DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES Fifth Gear Synchronizer Assembly Disassembly 1. Remove fith gear shift fork. 2. Remove fith gear and synchronizer ring assembly, Remove 43 roller bearings. Remove roller bearing spacer. Remove 43 roller bearings. Remove fith gear blocker ring. Remove fifth gear clutch cone. ‘Assembly 1. Load 43 roller bearings around the fitth gear clutch cone. Use ET-M11 grease to hold bearings in place. 2. Install roller bearing spacer. 3. Load remaining 43 roller bearings around the fifth gear clutch cone. Use ET-M11 (grease to hold bearings in place. 4, Slide blocker ring into position. 5. Install ith gear and synchronizer ring assembly. 6. Install fifth gear shift fork. ITEM NO. PART NO. DESCRIPTION 1 2606118 Thrust Washer 2 2606089 Fifth Gear and Synchronizer Hub Assy 3 2605117 ‘Synchronizer Spring (2 Req'd) 4 2604372 ‘Synchronizer insert (3 Req'd) 5 2605780 ‘Synchronizer Collar 6 2602661 Roller Bearings (86 Req'd) 7 (2606082 Roller Bearing Spacer 8 2605124 ‘Synchronizer Blocker Ring 8 2606091 Fih Gear Clutch Cone20 TREMEC TR-3550 AND TKO TRANSMISSIONS 20 DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Reverse Idler Assembly — Early and Late Designs Disassembly Remove front thrust washer. REVERSE REVERSE IDLER GEAR GEAR SLEEVE AEVERSE SHAFT LOCKING PIN FRONT AEVERSE IDLER GEAR, REAR REVERSE THRUST WASHER IDLER GEARSHAFT REVERSE IDLER GEAR THRUST WASHER ‘Assembly Remove bearing end spacer. Remove reverse gear. NOTE: 22 roller bearings are inside the reverse gear of early and late designs. Remove center thrust washer. Remove roller spacer. Remove reverse sleeve. Remove reverse idler gear. NOTE: Early Design — 22 roller bearings inside. ign — 44 roller bearings inside. (Two rows of 22 roller bearings, separated by a spacer.) Remove roller bearing end spacer. Remove rear thrust washer. NOTE: During assembly, use ET-M11 grease to hold bearings in place. 1. Install roller bearing end spacer. 2. Early Desion — Load 22 roller bearings into reverse idler gear. — Load 22 roller bearings into reverse idler gear. Install roller bearing spacer, then load a Second row of 22 roller bearings (total of 44). Install center roller spacer. Install reverse idler gear selector sleeve. Install thrust washer. Install reverse idler gear. Load 22 roller bearings into reverse gear. Install end spacer. Install thrust washer.21 TREMEC TR-3550 AND TKO TRANSMISSIONS 21 DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) O® Early Design — Reverse I _ oo 1052.4 ITEM NO. PART NO. DESCRIPTION Early Design Late Design 7 72503695 (2 Reqd) | 2603695 (2 Reqd) Thrust Washer 2 2605799 (2 Req'd) NA Roller Bearing End Spacer 2A NA 2606465 (3 Req'd) Roller Bearing End Spacer 3 | 2605797 (44 Reqd) | 2605797 (22 Read) Roller Bearing 3A NA 2602661 (44 Req'd) Roller Bearing 4 2606004 260894 Reverse Gear 5 2605795 2808795 ‘Thrust Washer 8 2605798 NA. Roller Spacer 6A NA. 260466 Roller Spacer 7 2605800 2605800 Reverse Selector Sieeve 8 2606093 2608093, Reverse Idler Gear 9 1472524 142524 Reverse Idler Gearshaft Locking Pin 10 2605793 260579, Reverse Idler Gearshaft (0 Late Design — Reverse idier Assembly22 TREMEC TR-3550 AND TKO TRANSMISSIONS 22 —L————— DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Output Shaft and Gear Assembly — Early and Late Designs isassembly and Assembly 1. Remove input shaft thrust bearing outer race. 2, Remove input shaft thrust bearing. ‘ourpur: ASSY NOTE: Early design output shafts incorporate spacers to retain first and third gear bearing cages. Late design output shafts use snap rings. Output shafts with snap ring grooves can be used with spacers. 6. Remove third gear synchronizer blocker THIRD GEAR BEARING SNAP RING. THIRD GEAR, ROLLER BEARING in — Output Shaft Remove input shaft thrust bearing inner race. Remove fourth gear synchronizer blocker ring and clutching cone. Remove third and fourth gear synchronizer assembly. i SHAFT “THIRD AND FOURTH, GEAR SYNCHRONIZER THIRD GEAR. SYNCHRONIZER BIOSKER RING EQURTH GEAR SYNCHRONIZER BLOGKER RING FOURTH GEAR CLUTCHING CONE 1088-8 8. Remove third gear. Late Design — Remove third gear bearing snap ring. 9. Remove third gear roller bearing, (UTPUT SHAFT ASS’ Hl ROLLER BEARING GEAR Early Design — Output Shaft23 TREMEC TR-3550 AND TKO TRANSMISSIONS 23 ——$——$——$————_ DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Remove split collar thrust washer retaining fing. Remove split collar thrust washer. Remove locking ball with a magnet. CAUTION: Do not lose ball. Remove second gear. Remove second gear roller bearing. Remove second gear synchronizer blocker ring, ‘OUTPUT SHAFT RSSY 16. Remove snap ring. 17. Remove reverse gear and second gear and first gear synchronizer assembly. ‘outpuT SHAFT ASSY ‘THIRD GEAR BEARING ‘SNAP RING GROOVE, Late Design — Output Shaft ‘SECOND SEAR ROLLER BEARING SECOND GEAR SYNCHRONIZER SECOND BLOCKERRING GEAR 18. Remove first gear synchronizer blocker ring. O.GEAR REVERSE GEAR, FIRST ‘ND SECON SYNCHRONIZER ASSY BLOCKER FING Early Design — Output Shaft24 TREMEC TR-3550 AND TKO TRANSMISSIONS 24 DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) 49, Remove first gear. FIRST GEAR Late Design — Output Shaft Early Design — Output Shaft Early Design — Remove first gear bearing Remove split collar thrust washer retaining spacer. ring, — Remove first gear bearing Remove split collar thrust washer. ‘snap ring. Remove locking ball with a magnet. 21. Remove first gear roller bearing. CAUTION: Do not lose ball. SPUT COLLAR THRUST WASHER ‘SPUT COLLAR RETAINING FING FIRST GEAR ‘ROLLER BEARING RST GEAR BEARING SNAP FING Late Design — Output Shaft Early Design — Output Shaft25 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) 25, Remove output shatt rear bearing. ‘QuTpUT SHAFT ASSY (OUTPUT SHAFT Late Design — Output Shaft Early Design — Output Shaft |. Remove speedometer gear snap ring. 29. To assemble, reverse Disassembly procedure. Flemove speedometer gear. Remove speedometer gear locking ball bearing, ‘SPEEDOMETER GEAR SNAP RING spe A Seggpoweres ourpur ‘SHAFT Late Design — Output Shaft Early Design — Output Shaft26 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) ‘Synchronizer Disassembly Remove synchronizer insert retaining springs. Slide synchronizer sleeve off synchronizer hub. Remove three synchronizer inserts. ‘Assembly NOTE: All synchronizer sleeves and hubs are marked for select fit Align select fit marks on synchronizer sleeve ‘and hub and assemble sleeve on hub. Install three inserts into synchronizer assembly. {Install insert retaining springs. NOTE: Make sure that tabs on end of springs are installed in opposite directions. INsEATS SLEEVE RETAINING SPRINGS Case Cover and Shifting Mechanism Disassembly Remove shifting fork roll pins. NOTE: Rotate third and fourth shifting fork to gain access to roll pin. Remove spring interlock bracket bolts, NOTE: Bracket retains tension on shift interlock springs and ball bearings. REVERSE AND FIFTH CEVER ROLL PIN FIRST AND SECOND ‘SHIFT FORK ROLL ‘THIRD AND FOURTH sua SHIFT FORK ROLL PIN SPRING INTERLOCK BRACKET 1040-4 Remove shift interlock springs and ball from case cover. Remove Allon-head screw plug from case cover. ALLEN HEAD ‘SCREW PLUG.27 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Rotate fifth and reverse shift rail 90-degrees. Remove fifth and reverse shift lever while ing fith and reverse shift ral from transmission case cover. Remove fifth and reverse shift rail by pulling ‘out through rear end of case cover. Remove three shift interlock pins from shifting rails of transmission case cover using a magnet. FIRST AND SECOND SHIFT FORK FIFTH AND REVERSE: SHIFT LEVER FIFTH AND REVERSE: SHIFT RAL RST AND Second SHE RAL ‘ao ano FOURTH TRANSMISSION CASE ‘SHIFT RAIL ‘our EERE? THIRD AND FOURTH SHIFT FORK, Remove third and fourth shift rail and shift fork. Remove first and second shift rail and shift fork. Remove three shift rail guides. ‘CASE COVER ‘Assembly NOTE: Inspect and replace O-ring seals on shift rail guides as necessary Install first and second shift rail and shift fork. Install first and second shift fork roll pin. Install third and fourth shift rail and shift fork. Install third and fourth shift fork roll pin. With cover on side, so the three shift interlock pins will be in the vertical position, install a large pin, the smaller center pin, and finally the second large pin. Install fith and reverse shift rail, Install fifth and reverse shift lever and roll pin.28 TREMEC TR-3550 AND TKO TRANSMISSIONS 28 —— DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Install Allen-head screw plug and tighten to 14,9-21.6 Nem (11-16 lb-ft), NOTE: Make sure fith and reverse shift rail guides are properly positioned on third and fourth shift rail FIFTH AND REVERSE SHIFT LEVER ‘THIRD AND FOURTH SHIFT RAIL SHIET LEVER GUIDE TAB 1043-8 9, Install three shift interlock ball bearings. 10. _ Install three shift interlock springs. 11, _ Install shift interlock spring support cover and bolts. Tighten to 16.2 - 21.6 Nem (12-16 \b-ft) in alternating sequence. 12. Lubricate O-ring seals on shift rail guides using petroleum jelly. 18. Install shift rail guides. NOTE: Do not hwist, pinch or cut O-ring ‘seals when installing shit rail guides. Shifting Lugs NOTE: Serviceabie only as an assembly. MATCH tock SHIFTING LUG PISTON SPRING SHIFTING LUG29 TREMEC TR-3550 AND TKO TRANSMISSIONS 29 — DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Extension Housing SELECTOR SeLecToR Disassembly and Assembly FINGER in Shift Selector Rail Assembly Early Design — Remove shift selector finger Allen screw. Late Design — Remove shift selector finger roll pin with a punch Slide shift selector finger off end of shift selector rail and remove shift selector finger. EXTENSION HOUSING 1020-4 Early Design — Shift Selector Finger SELECTOR FINGER ‘s1030-8 ig Shift Selector Finger30 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) ign — Remove shift lever socket ‘Assembly assembly Allen screw. 1. Toassemble, reverse Disassembly Late Design — Align roll pin with hole in the procedure, housing and remove shift lever socket assembly roll pin with a punch. Early Design — Tighten Allen screw to 19.5-19 N.m. (10-14 Ib-f). Hold shift ever socket assembly and slide shift selector rail out of front of extension. ‘Late Design — Install new roll pin. housing assembly and shift lever socket assembly. Remove shift lever socket assembly from ‘extension housing. SHIET LEVER ‘SELECTOR, tink EXTENSION HOUSING Early Design — Shift Lever Socket Assembly SHIFT LEVER Ker SELECTOR tic EXTENSION HOUSING Late Design — Shift Lever Socket Assembly31 TREMEC TR-3550 AND TKO TRANSMISSIONS 31 le ee ee EEE DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Reverse Inhibitor Assembly Continue inserting the reverse inhibitor shaft Remove roll pin securing reverse inhibitor to reverse inhibitor shatt. Remove Allen screw securing reverse inhibitor shaft to extension housing. Slide reverse inhibitor shaft through guide hole in front of extension housing. While sliding reverse inhibitor shaft out, remove reverse inhibitor and reverse inhibitor spring AEVERSE INHIBITOR, REVERSE INHIBITOR SPRING EXTENSION ee HOUSING INHIBITOR 1032-8 ‘To assemble, install reverse inhibitor shaft through guide hole in extension housing While inserting reverse inhibitor shaft, position reverse inhibitor spring and reverse inhibitor properly on the shaft. Until it is property seated in the extension housing. (Cut out areas on shaft face to the left) Install Allen screw securing reverse inhibitor shaft to extension housing, Tighten Allen screw to 9.4-12 Nem (7-9 Ib-f). Install roll pin securing reverse inhibitor to the reverse inhibitor shatt. Position tab on reverse inhibitor spring in the spring guide of the extension housing. REVERSE INHIBITOR, SPRING TAB GUIDE HOLE EXTENSION HOUSING REVERSE INMIBITOR, SHAFT GUIDE HOLE Inspect reverse inhibitor for proper movement.32 TREMEC TR-3550 AND TKO TRANSMISSIONS 32 DISASSEMBLY AND ASSEMBLY — SUBASSEMBLIES (CONTINUED) Extension Housing Rear Seal 1. Remove seal from extension housing using a impact slide hammer and seal remover tool, IMPACT SLIDE HAMMER s1037-A To assemble, instaif new extension housing rear seal using extension housing seal instalfer. SEAL INSTALLER, S1006-4ASSEMBLY — TRANSMISSION Mount transmission case to a bench- mounted holding fixture. Install countershaft assembly. NOTE: Make sure countorshaft front bearing race is properly positioned in transmission case. ‘TRANSMISSION CASE CLUSTER GEAR ASSY 3. _ Install countershaft to case intermediate bearing 4. Install reverse idler gear assembly. ar in $1027-4 NOTE: Make sure locking tabs on the front and rear thrust washers are propetly locked into position. TREMEC TR-3550 AND TKO TRANSMISSIONS Install reverse idler gear shat. NOTE: Make sure shaft locking pin is properly positioned in groove in transmission case. TRANSMISSION CASE ASSY REVERSE IDLER SHAFT LOCKING BIN GROOVE ioe REVERSE ILER, ‘SHAFT LOCKING PIN, Rotate counter gears against reverse idler gears to ensure free movement and proper gear mesh. Install fit gear assembly without shift fork. Install countershaft rear bearing. NOTE: Make sure countershaft rear bearing ‘ace is installed in extension housing. For initial measurements, do not install any shims removed during disassembly. Install extension housing NOTE: Do not apply anaerobic seaiant. Tighten to 56.9-67.7 Nem (42-50 Ib-f})34 TREMEC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY — TRANSMISSION (CONTINUED) Measure countershatt end play using universal dial indicator. (0.000-0.004 inch.) UNIVERSAL DIAL. INDICATOR sate" RAITEROMET ocugscn esas CAUTION: If proper shims are not selected and proper end play specification is not obtained, damage to transmission may occur. Select shims required. 2. Remove extension housing and fifth gear synchronizer. Install shims with thickest shim closest to countershaft bearing race. CLUSTER GEARSHAFT REAR BEARING CONE, 13. With new shims in position, repeat Steps 8 through 10. if end play is within specification g0 to Step 14, CAUTION: Make sure countershaft rotates freely. 14, Install fifth and reverse selector link and. retaining clip (E-clip). SELECTOR LINK Por REVERSE IDLER. ASSY. FIFTH AND REVERSE SELECTOR UNK ‘$1025. 15. Install reverse shift fork. REVERSE SHIFT FORK REVERSE IDLER, GEAR ASSY 1024-435 TREMEC TR-3550 AND TKO TRANSMISSIONS 35 ASSEMBLY — TRANSMISSION (CONTINUED) 16. Install fith and reverse shift rail through 18. Install rol pin securing selector pin to shatt. in case, through shift fork and into slot in front of case. IETH AND. REVERSE SHIFT Aa FIFTH AND REVERSE SHIFT RAIL, REVERSE SHIFT FORK 1025-4 17. Install shift rail selector link pin into shift rail and rotate into position. ‘SELECTOR Reverse pirta ASE Shierrork Ghar Aan EYER36 TREMEC TR-3550 AND TKO TRANSMISSIONS 36 ASSEMBLY — TRANSMISSION (CONTINUED) 20. Install input shaft through front bearing bore. ROLLER BEARINGS ‘THausT BEARING THRUST BEARING RACE ‘s1062-4 NOTE: Ensure 17 roller bearings, roller thrust bearing and race are property positioned. SHAFT. INPUT SHAFT. WanseS™ Tocase BEAMING RACE BEARING ‘s1018 Mate splines in input shaft with splines in fourth gear clutching ring Install output shaft rear bearing race. Install input shaft bearing race. Install front bearing retainer. NOTE: Make sure front bearing race is properly installed in bearing retainer. Do not apply anaerobic sealant and do not install shims. Tighten front bearing retainer bolts to 16.2-21.6 Nem (12-16 Ib-f). Install extension housing and tighten bolts to '56.9-67.7 Nem (42-50 lb-ft) Measure input shaft end play using universal dial indicator (0.000-0.004 inch. FRONT BEARING ‘COVER ASSY ‘TRANSMISSION CASE ASSY CAUTION: If proper shims are not selected and proper end play specification is not obtained, damage to transmission may occur.37 TREMEC TR-3550 AND TKO TRANSMISSIONS 37 ASSEMBLY — TRANSMISSION (CONTINUED) Select shims required. Remove front bearing retainer. Install shims with thickest shim closest to bearing race. INPUT SHAET: ‘TO-CASE BEARING BEARING, RETAINER FRONT SHAFT BEARING a ‘TRANSMISSION CASE ASSY S101eA With new shims in place, repeat Step 26. If end play is within specification, go to Step 31 CAUTION: Make sure main shaft assembly rotates freely. 31. Apply anaerobic sealant to mating surface of front bearing retainer and front bearing retainer bolts 3.2mm (1/8NCH) BEAD SEALER BEARING RETAINER ee Install front bearing retainer. Tighten bolts to 16.2-21.6 Nem (12-16 Ib-tt). Install steel ball into hole located in rear of countershaft Install thrust washer on countershaft, Install fifth gear synchronizer assembly. ‘SOUNTER- FIFTHGEAR FIFTH GEAR, SHAFT SHIFTFORK SYNCHRONIZE SY s1013.438 TREMEC TR-3550 AND TKO TRANSMISSIONS 38 NN ASSEMBLY — TRANSMISSION (CONTINUED) NOTE: Install fifth gear shift fork with synchronizer as an assembly. Install fifth gear shift fork rol pin. Measure first, second and third gear end play (0.000-0.016 inch, 0.018 inch maximum) using universal dial indicator (reference only). DIAL INDICATOR (OUTPUT SHAFT xssY SHOI5-A 38. Measure gear backlash on first, second and third gears using universal dial indicator (0.000-0.016 inch) (reference only). ‘SCREWORIVER, DiaL INDICATOR, FIRST GEAR Make sure all synchronizers are in NEUTRAL position. Apply proper coat of anaerobic sealant to transmission case, cover-to-case mating surface and bolts Install transmission case cover and shifting mechanism, TRANSMISSION CASE COVER AND SHIFTING MECHANISM TRANSMISSION ~— aaa A Rn f es S101 42, Install 10 transmission case-to-cover bolts. Tighten to 24.4-29,8 Nem (18-22 Ib-f) using proper tightening sequence.39 TREMEC TR-3550 AND TKO TRANSMISSIONS 39 ST ASSEMBLY — TRANSMISSION (CONTINUED) Lubricate shift rail guide O-rings. 49. Install first and second shitting lug and secure with rol pin. 1. Apply proper coat of anaerobic sealant to extension housing and extension housing EASNANO glast AND bots. SheTaAL SHETNGLUG 5. Install extension housing CAUTION: Do not pinch or cut O-ring seals on shift rail guides when installing extension housing. . Install extension housing bolts. Tighten to '56.9-67.7 Nem (42560 Ib-ft) using proper sequence. NOTE: Transmission identification tag attached to top bolt on RH side. 1. Rotate selector shift rail into position and install fith and reverse shifting lug. Secure with roll pin, FIFTH AND REVERSE SHIFTRAIL 1056-4 47. Potate selector rail shift ink to the lett. 48, Install third and fourth shifting tug and secure with roll pin. ‘THIRD AND FOURTH HFT RAIL, THIRD AND FOURTH SHIPTING LUG. FIETH AND /ERSE SHIFTING LUG. SELECTOR FINGER.40 TREMEC TR-3550 AND TKO TRANSMISSIONS 40 ASSEMBLY — TRANSMISSION (CONTINUED) Ensure shifter ball socket bushing is installed. Apply proper coat of anaerobic sealant to the mating surface of the shift turret and Apply proper coat of RTV sealant to both inspection covers. Apply anaerobic sealant to inspection cover bolts. shift turret bolts, Install inspection covers. Tighten inspection ‘cover bolts to 16.2-21.6 Nem (12-16 lb-ft). Install shift lever turret assembly. NOTE: Check position of shift lever. Flat Apply proper coat of anaerobic sealant to side to the right. drain plug and install drain plug. Tighten to 18.5-27.1 Nem (10-20 lb-ft). Install shift turret bolts. Tighten to 24.4-29.8 Nem (18-22 ib-ft) in proper sequence. TopP Fill transmission with 3 quarts of GM ‘Synchromesh transmission fluid (6M part no. 12345349), Apply proper coat of anaerobic sealant to fill plug and install fill plug. Tighten to 13.5-27.1 Nem (10-20 Ib-), Re-install transmission as outlined. TRANSMISSION DIAGNOSIS. ‘CONDITION, POSSIBLE SOURCE ‘ACTION ‘Transmission Shifts Hard ‘Improper clutch release, *Comect contion as instructed by manufacturer. “+Remove transmission and free up shift mechanism, + Remove and check for burrs or fit. ‘Check alignment and service as required “Drain and refill with Gbt ‘Synchromesh Transmission Fluid, 12345940, obotiom of flr plug + Internat shift mechanism binding ‘Sleeve to hub tt. ‘Binding condition between input shaft and orankshalt pilot bearing ‘Improper fd ‘Gears Clash When Shifting from (One Forward Gear to Another. “Engine idle speed too high ‘Improper clutch release. “Binding condition between ‘transmission input shaft and crankshatt plot bushing. + Wor or damaged shifter forks, ‘synchronizer assembly, or gear clutch teeth, “Adjust engine idle speed. + Ensure complete clutch release. ‘+ Remove transmission and replace pilot bushing. +Service of replace as required.“1 TREMEC TR-3550 AND TKO TRANSMISSIONS 41 SS ‘TRANSMISSION DIAGNOSIS — (CONTINUED) CONDITION POSSIBLE SOURCE ‘ACTION, ‘Transmission jumps out of gear. | «Floor shift — stif or improperly * Verify jump-out with boot removed, installed boot Replace boot if necessary. '+Floor shift — interference between | « Adjust console to eliminate shift handia and console. imerterence. ‘Transmission to engine mounting _| «Tighten bolts to specification, loose. + Flywheel housing to engine ‘Replace parts as required. crankshatt out of alignment. +sImproper engagement between ‘Replace parts as required. transmission pilot and flywheel housing. + input shat pilot bearing worn. ‘Replace pilot bearing. +" Worn or damaged internal “*Check input and output shafts far ‘components. ‘excessive end play, shift forks for loose mounting of shift ralis, wan pads, shift rail detent system for wear of damage, synchronizer sliding sleeve and gear clutch teeth for wear or damage. Service or replace as required. * Transmission will not shift into one_| +Fioor shit, interference between shift | + Adjust console or cut out floorpan Gear — all other gears OK. handle and console or floor cut out. | eliminate interference “Restricted travel of intemal shitter | *Rlamove transmission. Inspect shit components. rail and fork system, synchronizer system and gear clutch-teeth for restricted travel. Service and replace as required. * Transmission is locked in one gear. | + intemal shitter components wom or | « Remove transmission. Inspect the MWannot be shitted out of that damaged, problem gear or gear shit rails and gear. fork and synchronizer for wear or damage. Service of replace as required. +Selector arm finger broken, ‘+Remove transmission. Replace selector arm assembly. ‘Bent shifter forks at pads and ‘Service or replace as required. selector slot ‘Transmission will not shift into Worn or damaged interna! ‘“Flamove transmission, Chack for reverse (All others OK). ‘components ‘damaged reverse gear train, misaligned reverse relay laver, shift all and fork system, Service ‘oF replace as required.42 TREMEC TR-3550 AND TKO TRANSMISSIONS 42 SS TRANSMISSION DIAGNOSIS — (CONTINUED) ‘CONDITION POSSIBLE SOURCE ‘AGTION ‘Transmission noisy in gear. * Lubricant level low or wrong type. | Fill to bottom of fiter plug hole with proper lubricant, ‘Transmission to flywheel housing | «Tighten bolts to specification, and flywhee! housing 10 engine block bolts loose. + Pilot bushing worn or damaged. ‘+Remove transmission. if noise is how during start-up, check plot bushing. Check for loose flywheel ‘and housing alignment. Service or replace as required * improper transmission pilot + Roplace housing or input shaft engagement into flywheel housing. | bearing retainer as required, + Worn or damaged internal ‘Disassembie transmission. inspect ‘components. input, output and countershaft bearings, gear and gear teeth for ‘wear or damage. Service or replace as required. + Transmission leaks. Excessive amount of iurcantin | «Check level and type. Fil to ‘ransmission — wrong type. bottom of filer plug hole, +Other component() leaking “Identify leaking tid at engine, ‘power steering andor False report. Iransmission + Remove ll races of lubricant on exposed transmission surfaces, Check vant or tree breathing. Operating transmission and inspect for new leakage. Service *Worn or damaged internal as required components + Remove transmission. Inspect for Jaks atthe input shaft boaring retainer seal and gasket, op cover ‘gasket. Inspect case for sand holes. Service or replace as, “Inadequate thread sealant on required threads, “Apply proper sealant to bolt threads.43 nec ee ee al TREMEC TR-3550 AND TKO TRANSMISSIONS INSPECTION Inspect transmission case for cracks, worn cor damaged bearing bores, damaged threads, or any other damage that could affect operation of the transmission. Inspect the front face of the case for small nicks or burrs that could cause misalignment of the transmission with the flywheel housing. Remove all small nicks or burrs with a fine file. Replace any cover that is bent or distorted. Make sure that the vent hole in the turret is open. Check the condition of the shitt levers, forks, shift rails, and the lever and shafts. Inspect the bearings. Replace roller bearings that are broken, ‘wor of rough, and check their respective races. Replace the countershaft (cluster) gear if the teeth are chipped, broken or wom. Replace the countershaft if itis bent, scored or wom. Replace the reverse idler gear or sliding gear if the teeth are chipped, worn or Broken, Replace the idler gear shattif bent, worn of scored, Replace the input shaft and gear ifthe splines are damaged or ifthe teeth are chipped, wom or broken. If the roller bearing surface in the bore of the gear is worn or ough, or if the cone surface is damaged, replace the gear and gear rollers. Replace all other gears that are chipped, broken or worn Check the synchronizer sleeves for free movement on their hubs. Make sure that the alignment marks (if present) are properly indexed. Inspect the synchronizer blocking rings for widened index slots, rounded clutch teeth, and smooth internal surfaces (must have machined grooves). With the blocker ring on the cone, the distance between the face of the blocker ring and the clutch teeth on the ‘gear must not be less than 0.50mm (0.020 inch). Replace speedometer drive gear if teeth are stripped or damaged. Make certain to install correct size replacement gear. Replace the output shatt if there is any evidence of wear or if any of the splines are damaged. Inspect bushing and seal in the extension housing and replace seal. Replace ‘extension housing if bushing is worn or damaged. Replace the seal in the input shaft bearing retainer. TRANSMISSION CLEANING ‘Wash all parts except bearings, O-rings and seals in a suitable cleaning solvent. Brush or scrape all foreign matter from the parts. Be careful not to damage any parts with the scraper. CAUTION: Do not clean, wash or soak transmission seals in cleaning solvents. Dry all parts with compressed ai Rotate bearings in a cleaning solvent until all lubricant is removed. Hold bearing assembly to prevent it from rotating and dry it with ‘compressed air. Lubricate bearings with petroleum jelly and wrap them in a clean, lint-ree cloth or paper until ready for use. Clean the magnet in the bottom of the case with kerosene or mineral spirits.44 TREMEC TR-3550 AND TKO TRANSMISSIONS 44 SPECIFICATIONS Sealant Specifications ‘Anaerobic Sealant ET-M29 TV Sealant. Loctite® 493, Grease for Needle Bearings ETI il Capacity 3 quarts of GM Synchromesh transmission fluid (GM part no. 12345349) ‘Torque Specifications Description Nem. Allen Screws 13.5-19 Sensors 162-216 Backup Lamp Switch 162-216 Inspection Cover Bolts 162-218 ‘Turret Shifter Pin Bolts $6.2-21.6 Spring Interlock Bracket Botts 162-216 Case Cover Bolts, 244-298 Shift Turret Bolts 244-298 Extension Housing Bolts 569-677 Fill Plug 43.5-27.1 Drain Plug 135-271 Front Bearing Retainer Bolts 162-216 Reverse Inhibitor Allen Screw 94-12 ar Ratios ath 1.00 1.0045 METRICS 45 INTRODUCTION Most threaded fasteners are covered by specifications that define required mechanical properties, such as tensile strength, yield strength, proof load and hardness. These specifications are carefully considered in initial selection of fasteners for a given application. To ensure continued satisfactory vehicle performance, replacement fasteners used should be of the correct strength, as well as the correct nominal diameter, thread pitch, length, and finish. ‘Most original equipment fasteners (English or Metric system) are identified with markings or numbers indicating the strength of the fastener. These markings are described in the pages that follow. Attention to these markings is important to ensure that the proper replacement fasteners are used. Further, some metric fasteners, especially nuts, are colored blue. This metric blue identification is in most ‘cases a temporary aid for production start-up, and color will generally revert to normal black or bright after startup. NOMENCLATURE FOR BOLTS ENGLISH SYSTEM METRIC SYSTEM Bolt, 4/2-13x1 Bolt, M12-1.75x25 C4 Grade Marking P—Property Class* (bolt strength} (bolt strength) Length, (inches)** L—Length (milimeters)-* ‘T—Thread Pitch T—Thread Pitch (thread width (thread/inch) crest to crest mm) D—Nominal Diameter D—Nominal Diameter (inches) | (millimeters) “The property class is an Arabic numeral distinguishable from the slash SAE English grade system. “"The length of all bolts is measured from the underside of the head to the end.46 METRICS 46 BOLT STRENGTH IDENTIFICATION ENGLISH SYSTEM EF EF SP Grade 1 or 2 Grade 5 Grade 8 English (Inch) bolts: Identification marks correspond to bolt strength; increasing number of slashes represent inereasing strength. METRIC SYSTEM Metric bolts: Identification class numbers correspond to bolt strength; increasing numbers represent increasing strength. Common metric fastener bolt strength property are 9.8 and 10.9 with the class identification embossed on the bolt head. HEX NUT STRENGTH IDENTIFICATION ENGLISH SYSTEM METRIC SYSTEM Grade Hex Nut Hex Nut Hex Nut Hex Nut Grades Grage 8 Pe 3 Clase 6 Dots Arabic 9 Arabic 10 Increasing dots represent increasing strength. | May also have blue finish or paint daub on hex flat, Increasing numbers represent increasing strength. OTHER TYPES OF PARTS Metric identification schemes vary by type of part, most often a variation of that used of bolts and nuts. Note that many types of English and Metric fasteners carry no special identification if they are otherwise unique. 3 — Stamped U-Nuts. ver) CLASS CLASS_-—CCLASS. en 10.9 98 38 = — Studs, large studs may carry the property — Tapping, thread forming and certain other ‘class number. Smaller studs use a case hardened screws. geometric code on the end,47 METRICS ENGLISH/METRIC CONVERSION 47 MULTIPLY FOR METRIC EQUIVALENT. foovsect ‘metre/sec® (Ws") inchisec* metre/sec ‘pound-inch ‘Rewton-metres (Nem pouris-foot ewton-metres horsepower kilowatts (kw) inches of water Kklopascals (kPa) ‘poundsyeq. in. kilopascals (kPa) poundesq. in. bar BTU joules pound-foat joules (J) ‘Kiiowatt-hour Joules (J = one Wes) Toot candi Tumens/mete® (mime) miles/ga ‘klometressitre (kr) ‘galile ites/ilometre (Vim) miles/hour ‘lometresihr.(krtvh) inch a ‘milimetres (mm) foot 0.3048 metres (m) ard 0.9144 metres (a) 1.600 kilometres (km) 452 rmilimetres® (mar) foot? 645, centimetres (cm) 0.0929 metres* (m') yard 0.8361 metres! inch quart 16,387.0 oom? 16.587, om 0.0164 Tires @) 0.8364 3.7854 Titres Titres [gallon yard? 0.7646 metres? (my pound 0.4536. kilograms (kg) ton 007.18 Kilogram (kg) ton. (0.90716 tonne (t) ‘Kilogram 9.807" newions (Np ‘ounce 0.2780, ewtons: pound’ 4.448 newtons: degree farenhelt (FY CF -32) 0.556 degree Celsius (O)48 METRICS SS DECIMAL AND METRIC EQUIVALENTS FRACTIONS | DECIMAL INCH | METRIC MM. FRACTIONS | DECIMAL INCH | METRIC MM 1164 015625 397 33/64 515625 18.097 1/32 03125 Toa 17/32. 53125 13.494 64 046875 7.191 38/64 548875 13.891 416 0625, 1.588 916 5625 14.288 5/64 078125 1.984 ‘37/64 578125, 14.684 3/32 09375, 2.381 19/32 59375 15.081 7i64 109375, 2.778 30/64 609375, 15.478 118. 125 3.175 5/8 625 15.875 9/64 140625, 3.572 41/64 640685 16.272 5/32 15625 3.969 21/32 65625 16.669 11/64 171875 4.366. 43/64 871875 17.066. 316 1875 4.763 T1N6 6875 17.463 13/64 203125 5.159 45/64 703125 17.859. 7132 21875, 5.556 23/32 71875 18.256 15/64 234575 5.953 47164 734375, 18.653 14 250 6.35 34 750 19.05 17/64 265625 6.747 49/64 ‘765625 19.447, 9/32 28125 7.144 25/32 78125 19.844 19/64 296875, 7.54 51/64 796875 20.241 5/16 3125 7.938 13/16 ‘BI25 20.638 21/64 ‘328925 6.336 53/64 828125 21.034 14/92 34375 8.731 27/32. 84375 21.431 23/64 359375 9.128 55/64 1859375 21,828 3/8 375 9.525 78 875. 22.225 25/64 390625, 19.922 57/64 890625, 22.622 13/32 ‘40625, 10.319 29/32 90625, 23.019 27/64 421875, 10.716 ‘59/64 921875, 23.416 76 A375, 14.113 15/16 9375 23.813 29/64 453125 11.509) 61/64 953125 24.209 15/32 46875 11.906. 31/32 96875 24.606 31/64 484375, 12.303) 63/64 984375 25.003 12 500) 127 1 7,00 25.449 METRICS 49 SS TORQUE CONVERSION NEWTON METRES | POUND-FEET POUND-FEET | NEWTON METRES (LB. LB-F (Nem) 1,356 27 40 54 68 81 95 5.9 10.8. 66 322 74 13.6. 11.4 20.3 14.8 27.4 18.4 33.9 22.4 40.7 25.8 475 29.5 542 36.9 61.0 443 67.8 316 746. 58.0 B14 66.4 88.1 73.8 94.9 B11 101.7 88.5 108.5 95.9 422.0 103.3, 135.6. 110.6 149.4 118.0 162.7 125.4 176.5 132.8 189.8 140.1 203.4 1475, 216.9 166.0, 230.5 186.4 244.0 (0.7376, 15 22 3.0 37 44 52 eo oo] ~s]o>Jor] m feo|ro|