I figured that I would break this topic off from
my main build thread because its dealing with a few common issues that the 1st gen Insights have. My 5 speed manual transmission currently has a slightly noisy input shaft bearing that will need to be replaced as well as the notorious 2nd gear grind. I'll be doing the synchro modification to get rid of the grind as its a zero cost mod. I haven't removed the transmission yet, but I imagine I'll probably be replacing the clutch while I'm at it. At the very least I'll be doing something with the flywheel and pressure plate as clutch engagement is not super smooth.
So far I have two nights after work working on the transmission removal. I've been taking my time on it.
I started by removing the airbox.
Then the starter came off.
Then the clutch slave cylinder.
I then removed the battery box because I had difficulty with the shifter linkages. This isn't necessary if you can get to it, but it does make it easier. However, pulling that box is kind of a chore too. It is very hard to squeeze out of its slot.
And, to remove the shift cables I ended up just unbolting the bracket that holds them to the trans vs trying to remove the cables from the bracket (which I found to be quite hard).
Along the way I unplugged multiple sensors and a couple brackets for the wiring. Take note that apparently you do not need to disconnect the 3 big orange wires going to the IMA system. I thought you did, but the service manual says nothing about removing them.
So, the next step was to pull the axles out. But, wait... lets drain the trans fluid first.
Pull the wheel off, and you'll see the axle nut you need to remove. I removed everything (all brake components) as I'll be going through them, lubing the slides and inspecting things. Insert a punch to deform the axle nut so it can spin off. An impact wrench really comes in handy to remove these nuts, but this one didn't seem to require a ton of oomph as it came off fairly easily.
Next, I disconnected the hub from the strut so I could pull the hub away and give room to get the axle out. Give the axle a good tap with a hammer to loosen it from the hub before pulling it out. Despite the car being 17 years old, it came out quite easily.
Repeat that for the other side and you're almost ready to pull the transmission out.
