Here's a general breakdown of the process and parts you'll likely need. This is NOT exhaustive; consult a repair manual specific to your transmission model for complete details.
I. Pre-Disassembly:
1. Identify the Transmission: Find the transmission ID tag. This is crucial for ordering the correct parts.
2. Gather Tools & Materials: This includes transmission jack, various wrenches (metric and standard), sockets, screwdrivers, a torque wrench, transmission fluid, gasket sealant, cleaning solvent, shop rags, a parts cleaning container, and possibly a dial indicator for setting bearing preload.
3. Acquire a Repair Manual: A Haynes or Chilton manual, or a factory service manual, specific to your year and transmission is absolutely essential. It will provide detailed instructions, torque specifications, and diagrams.
4. Gather Parts: This is where things get model-specific. You'll need to identify worn or damaged parts before ordering replacements. However, generally you'll need:
* Bearings: Input shaft bearing, output shaft bearing, countershaft bearings (multiple), possibly main shaft bearings.
* Syncronizers: These often wear out and cause grinding. You'll need one for each gear.
* Shift Forks and Rails: Check for wear and bending.
* Seals: Input shaft seal, output shaft seal, various other seals.
* Gaskets and Seals: Transmission case gasket, various smaller seals.
* Clutch release bearing (Throwout bearing): While not part of the transmission *itself*, it's often replaced during this type of overhaul.
* Clutch disc and pressure plate: These are also often replaced when doing a transmission rebuild.
II. Disassembly:
1. Drain Transmission Fluid: This is a must before removing the transmission.
2. Remove the Transmission: This usually involves disconnecting the driveshaft, shifter linkage, and bellhousing bolts. Use a transmission jack to support the weight.
3. Disassemble the Transmission: This is a complex process involving removing the case, separating the various shafts and components, and carefully removing the bearings and gears. The repair manual will provide the sequence. Pay close attention to the order of parts removal; take detailed photos/notes as you go.
4. Clean Parts Thoroughly: Use a suitable solvent and brush to remove all traces of old grease and debris.
III. Inspection & Part Replacement:
1. Inspect all Parts: Carefully examine each component for wear, damage, or excessive play. Replace any parts that show signs of significant wear.
2. Replace Worn Parts: Install new bearings, seals, gaskets, synchronizers, and any other damaged components.
IV. Reassembly:
1. Reassemble the Transmission: Follow the repair manual precisely, paying close attention to bearing preload and proper gear mesh.
2. Install the Transmission: Carefully reinstall the transmission into the vehicle using a transmission jack.
3. Reconnect linkages, driveshaft, etc.: Make sure everything is securely fastened.
4. Fill with Transmission Fluid: Use the correct type and amount of transmission fluid as specified in your owner's manual or repair manual.
V. Post-Reassembly:
1. Test Drive: Test drive the vehicle to ensure proper shifting and operation. Listen for any unusual noises.
Important Considerations:
* Specialized Tools: You'll likely need specialized transmission tools for bearing installation and adjustment.
* Precision: Rebuilding a transmission requires precision and attention to detail. Errors can lead to premature failure.
* Safety: Always use safety glasses and appropriate work gloves.
* Professional Assistance: If you're not comfortable with this type of repair, consider taking it to a qualified transmission shop. The cost of a professional rebuild might be less than the cost of damaged parts from an incorrect rebuild attempt.
This is a general overview. The specific parts and procedures will vary significantly depending on the exact transmission model in your 1989 Chevy S10. Refer to a repair manual specific to your transmission for detailed instructions and part numbers. Without that information, any parts list would be unreliable and potentially dangerous.
