Mullet's Metro Project

[Johnny Mullet]

Ok, so lets get this transmission out now. Remember all that fun you had removing the shift rod? Get back under there and directly above it, you will see the rear mount from the firewall to the trans.

Remove the 2 lower nuts from mount (2 14MM)
Remove the bushing bolt and nut and remove that bracket piece (14 MM)
Remove the trans mount bolts and remove from trans (3 14MM)
Use the floor jack holding engine to help you.
While there, remove the one bell housing nut below starter (14 MM nut)
Get out of there and remove the rear brace where battery was (3 14MM bolts)



Before removing the rest, look on the steel coolant tube and remove the bolt going to the trans case. It's easy to miss this and you don't want to break that tube.

Under car remove bell housing flywheel plate (2 10 MM bolts)
Top of car, remove the starter (2 12 MM bolts)
Make sure you removed bell housing nut under starter on earlier step (14 MM)
Remove 3 remaining bell housing bolts (3 14 MM)
Lean over car and grab trans (like you love it) and begin carefully wiggling the trans loose from the engine and use a pry-bar to help pry away from block. Stop part way out and go back under the car and pop the other (right) axle shaft. Finish yanking and carefully set it on the ground or get help from someone if you are not as buff as me

Now remember in step #1 I mentioned jacking the car so the tire is at least 4" off the ground? If you didn't, the trans won't clear and you will have the engine on a piece of wood and be attempting to raise the car. Good luck with that.







Now it is time for the clutch. This is gravy work now. Hopefully you got all the proper parts and supplies like a brand new -=Sachs=- Clutch kit and 3 quarts of Synchromesh trans oil from Pennzoil, GM, or Castrol. The shop I work at only uses the best products and that is what I used.



Replace throwout bearing on trans side
Remove the old clutch (6 12 MM bolts)
Replace the pilot bearing from flywheel (I made a tool)
If you want to resurface, then remove the flywheel instead. I simply used a medium grit Roloc and carefully scuffed mine. These engines have like 55 HP so I am 100% sure this was sufficient.



Use the alignment tool provided with the kit and verify which way the clutch faces. Install the clutch and pressure plate and use threadlocker on the clutch bolts. Draw them down evenly and get them tight. Use torque specs if you want from a manual. As you are tightening, wiggle the guide tool and make sure clutch is centered.



This is what I have accomplished so far. My junkyard replacement trans is at the shop awaiting new axle shaft seals because I don't want any leaks at all. It is also going to get a bath in the parts washer and maybe even paint if I feel like throwing some "Kentucky Chrome" on it. I will post some installation pics possibly tomorrow or the weekend and let you all know how it goes.

There is so much more fun stuff to do to this car.

Junkyard Transmission = $250.00
Sachs Clutch kit = $90.00
Axle seals = $19.00
3 QT Synchromesh = $25.00
Silver paint = $0.00

Total cost = $384.00
Labor time = 8-10 hours

[bennelson]

Thanks for the great post, Johhny.

I think all your photos of transmission work might just save my @$$ trying to reinstall my tranny with an electric motor attached!!!!

[johnpr]

awesome right ups!! keep up the great work!

[Johnny Mullet]

I took the junkyard trans and set it right in the parts washer at work and cleaned it and flushed it with the plug out. I then set it up and put one quart of regular ATF trans fluid and let it sit for an hour. I drained that out to make sure it was clean inside. I then added a fresh coat of "Kentucky Chrome" to the entire case and installed 2 new axle seals................



Putting the trans in was a real nightmare. Getting the wife to help was OK minus all the complaining. I hung over the driver's fender and had her on the floor with a milk crate. Got it into position finally, but she had a hell of a time trying to get the passenger axle shaft in while I tried to wiggle it into place. In the process, coolant started leaking from the long coolant tube that goes along side the block and into the back of the water pump. The O-ring in there must have torn. I guess I will fix that tomorrow somehow.

I decided to take it for a spin to see if it was OK even though the leak was going on. I drove it 1/4 mile up the road and the car shifted very smoothly and made no noises at all. It was like a completely different car.

[bhazard]

Wow you really cleaned that trans up.

The most Ive done with a trans is drop the valvebody out of the autos in the shadow and spirit and took them apart and cleaned them inside with brake cleaner. I then made a homemade shift kit for them. Hey, quicker, firmer shifts and less slipping = better mpg right?

[Johnny Mullet]

That is right! I rip transmissions out of Heavy Duty Diesel trucks now and then at work and those are really fun.

[johnpr]

thats so pretty!! im assuming kentucky chrome = spray can chrome?

[Jigsaw]

Wow, that is nice work there Johnny! I always loved dipping my rifles parts in solvent and admiring the stuff when it came out.
Again, very nice!

[vtec-e]

Awesome work Johnny Mullet. You remind me of a guy i worked with in NZ. He used to work on oil rigs as a welder and also had a mullet. Fear The Mullet!!!!!

ollie

ps: that lucky finger bit has me laughing uncontrollably! The Mrs is looking at me funny!

[metroschultz]

All this time I thought it was Carolina Chrome. Silly me. I love it anyway.
I told some guys at work that after I finish the body and other repairs on my Metro I would paint the whole thing with Canned Chrome.
OOHH that really got em up in arms.
Truck techs are a funny breed, don't you think?
Apparently everyone but me thinks it is a bad idea. Most even think it is illegal.
I ask "Is it illegal to make your Harley all chrome?" No you say, then why is it illegal for me to make my Motorcycle powered ride all chrome? Hmm?
Keep it up.
I like this thread.
The Gubmint won't let me take my parts in to the washer at work.
Too bad, so sad,
Schultz.