Tremec TR-3550 Service Manual
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Tremec TR-3550 Service Manual

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TR-3550 I TKO
SERVICE MANUAl
BULLETIN NUMBER
TRSM-TK0-0711

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Summary of Contents for Tremec TR-3550

  • Page 1 TR-3550 I TKO SERVICE MANUAl BULLETIN NUMBER TRSM-TK0-0711...
  • Page 2 IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all 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.

  • Page 3: Table Of Contents

    I de ntify Your Type of Tremec TR-3550 or Tremec TKO Transm ission ........

  • Page 4: Important Notice-Before You Begin Service

    IDENTIFY YOUR TYPE OF TREMEC TR·3550 OR TREMEC TKO TRANSMISSION This service manual covers the TA-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 briefly describes differences in the TA-3550 and the TKO, as well as design changes tt:lat have been made since the transmissions were introduced.

  • Page 6: Disassembled View

    Clo) # SEE PAGE 2 FOR LATE·DESIGN COMPONENTS TKO MODEL USES UNIQUE PART - SEE PARTS LIST ON PAGES 4·5. • � • � < � � l>...

  • Page 9: To Repl Ace T-5 Transmission With Tremec Tr-3550 Or Tko High Performance Transmissions

    TREMEC TR-3550 AND TKO TRANSMISSIONS TO REPLACE T·5 TRANSMISSION Remove oil drain plug and drain transmission. P roperly dispose of oil. WITH TREMEC TR-3550 OR TKO HIGH PERFORMANCE Remove four nuts retaining exhaust pipes to TRANSMISSIONS exhaust manifold. Remove four nuts retaining exhaust pipes to mufflers.

  • Page 10: Transmission Installation

    TREMEC TR-3550 AND TKO TRANSMISSIONS TRANSMISSION INSTALLATION With the transmission extension housing resting on the engine rear support, slide the CAUTION: Bell housing should be crossmember to its most rearward position aligned to have a runout of no more than .005...
  • Page 11 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY-TRANSMISSION Drain transmission fluid. NOTE: Perform Steps 4 through 13 only if the shift lever is loose. If the shift lever is not loose, go to Step 14. Remove transmission from vehicle as outlined. Remove four shift turret dust cover bolts.
  • Page 12 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY-TRANSMISSION (CONTINUED) Remove four shifting lug inspection cover Remove shift lever assembly. bolts and star washers. Remove shifting lug inspection cover. THIRD AND FOURTH SHIFTING LUG FIRST AND SECOND SHIFTING LUG S1Q03.A S1005·A Inspect ball on end of shift lever for wear (excessive).
  • Page 15 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY -TRANSMISSION (CONTINUED) Using universal dial indicator, measure first, 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. FRONT BEARIN G RETAINING BOLTS Gear rattle or clunking noise indicates possible excessive backlash.
  • Page 16 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY - TRANSMISSION (CONTINUED) Remove input shaft and bearing assembly. Using a pin punch, remove roll pin retaining the selector link pin to the fifth and reverse shift rail. 51019·A NOTE: Be careful not to lose the 17 roller bearings inside the shaft assembly between the input shaft and output shaft.
  • Page 17 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY - TRANSMISSION (CONTINUED) Remove fifth and reverse shifting rail. Remove selector link retaining clip (E-clip) and selector link. FIFTH AND REVERSE SELECTOR LINK REVERSE SHIFT FORK 51025-A S1023·A Remove reverse idler gearshaft. Remove reverse shift fork.

  • Page 18: Disassembly - Transmission

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY - TRANSMISSION (CONTINUED) Remove reverse idler gear assembly as a Remove cluster shaft intermediate roller complete assembly. bearing. NOTE: Be careful not to lose the needle bearings. CLUSTER SHAFT INTERMEDIATE ROLLER BEARING CLUSTER GEARSHAFT...

  • Page 20: Countershaft (Cluster Gear) - Late Th Ree-Piece Design

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY-SUBASSEMBLIES (CONTINUED) Countarshaft (Cluster Gaar) - Late Three-Place Design ¥ ITEM NO. PART NUMBER DESCRIPTION 2605786 Tapered Roller Bearing 2602645 Snap Ring 2606232 Cluster - Head (Fourth) Gear 2606233 Cluster - Third Gear...
  • Page 21 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY-SUBASSEMBLIES (CONTINUED) Assembly 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...

  • Page 22: Disassembly And Assembly-Subassemblies

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY -SUBASSEMBLIES Fifth Gear Synchronizer Assembly Assembly Disassembly Load 43 roller bearings around the fifth gear Remove fifth gear shift fork. clutch cone. Use ET-M11 grease to hold b earings in place. Remove fifth gear and synchronizer ring assembly.

  • Page 23: Reverse I Dler Assembly- Early And Late Designs

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) Reverse Idler Assembl y - Remove bearing end spacer. Earl y and Late Designs Remove reverse gear. Disassembly NOTE: 22 roller bearings are inside the reverse gear of early and late designs.
  • Page 24 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) $1052-A Early Design - Reverse Idler Assembly PART NO. DESCRIPTION ITEM NO. Early Design Late Design 2603695 (2 Req'd) Thrust Washer 2603695 (2 Req'd) N.A. Roller Bearing End Spacer...

  • Page 25: Output Shaft And Gear Assembly - Early And Late Designs

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) Output Shaft and Gear Assembly - Remove input shaft thrust bearing inner race. Earl y and Late Designs Disassembly and Assembly Remove fourth gear synchronizer blocker ring and clutching cone.
  • Page 26 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) 1 0. Remove split collar thrust washer retaining 1 3. Remove second gear. ring. 1 4. Remove second gear roller bearing. Remove split collar thrust washer. 15 . Remove second gear synchronizer blocker 1 2.
  • Page 28 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY -SUBASSEMBLIES (CONTINUED) Remove output shaft rear b earing. OUTPUT SHAFT REAR BEARING 51050-A Late Design -Output Shaft Early Design -Output Shaft Remove speedometer g ear snap ring. To assemble, reverse D isassembly procedure.

  • Page 29: Synchronizer

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTIN UED) Sy nchronizer Case Cover and Shifting Mechanism Disassembly Disassembly Remove synchronizer insert retaining Remove shifting fork roll pins. springs. NOTE: Rotate third and fourth shifting fork Slide synchronizer sleeve off synchronizer to gain access to roll pin.
  • Page 30 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTIN UED) Rotate fifth and reverse shift rail 90-degrees. Remove third and fourth shift rail and shift fork. Remove fifth and reverse shift lever while sliding fifth and reverse shift rail from 1 0.

  • Page 31: Shifting Lugs

    TR E M EC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) Install Allen-head screw plug and tighten to Shifting Lugs 1 4.9-2 1 .6 N•m ( 1 1 -1 6 lb-ft). NOTE: Make sure fifth and reverse shift rail guides are properly positioned on third and NOTE: Serviceable only as an assembly.

  • Page 32: Extension Housing

    TR EM EC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) Extension Housing Disassembly and Assembly Shift Selector Rail Assembly - R emove shift selector finger Allen screw. Late - Remove shift selector finger roll pin with a punch Slide shift selector finger off end of shift selector rail and remove shift selector finger.
  • Page 33 TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) - Remove shift lever socket Assembly assembly Allen screw. To assemble, reverse Disassembly - Align roll pin with hole in the procedure. housing and remove shift lever socket assembly roll pin with a punch.

  • Page 34: Reverse Inhibitor Assembly

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY - SUBASSEMBLIES (CONTINUED) Reverse Inhibitor Assembly Continue inserting the reverse inhibitor shaft until it is properly seated in the extension housing. (Cut out areas on shaft face to the left.) Remove roll pin securing reverse inhibitor to reverse inhibitor shaft.

  • Page 35: Extension Housing Rear Seal

    TREMEC TR-3550 AND TKO TRANSMISSIONS DISASSEMBLY AND ASSEMBLY -SUBASSEMBLIES (CONTINUED) Extension Housing Rear Seal Remove seal from extension housing using a i mpact slide hammer and seal remover tool. IMPACT SLIDE HAMMER SEAL REMOVER TOOL 51037-A To assemble, install n ew extension housing rear seal using extension housing seal installer.

  • Page 36: Assembly - Transmission

    TRE M EC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY - TRANSMISSION Mount transmission case to a bench­ I nstall reverse idler gear shaft. mounted holding fixture. NOTE: Make sure shaft locking pin is Install countershaft assembly. properly positioned i n groove in transmission case.
  • Page 37 TREMEC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY - TRANSMISSION (CONTINUED) With new shims in position, repeat Steps 8 1 0. Measure countershaft end play using 1 3. through 1 0. If end play is within specification universal dial indicator. (0.000-0 004 inch.) go to Step 14.
  • Page 38 TREMEC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY -TRANSMISSION (CONTINUED) 1 6. Install fifth and reverse shift rail through 1 8. I n stall roll pin securing selector pin to shaft. opening in case, through shift fork and into slot in front of case.
  • Page 39 TREMEC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY - TRANSMISSION (CONTINUED) Mate splines in input shaft with splines in Install input shaft through front bearing bore. 2 1 . fourth gear clutching ring. Install output shaft rear bearing race. Install input shaft bearing race.
  • Page 40 TREMEC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY - TRANSMISSION (CONTINUED) Select shims required. Apply anaerobic sealant to mating surface of 31 . front bearing retainer and front bearing Remove front bearing retainer. retainer bolts. Install shims with thickest shim closest to bearing race.
  • Page 42 TREMEC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY - TRANSMISSION (CONTINUED) Lubricate shift rail guide 0-rings. I nstall first and second shifting lug and secure with roll pin. Apply proper coat of anaerobic sealant to extension housing and extension housing bolts. Install extension housing.

  • Page 43: Transmission Diagnosis

    TREMEC TR-3550 AND TKO TRANSMISSIONS ASSEMBLY - TRANSMISSION (CONTINUED) 5 1 . Ensure shifter ball socket bushing is Apply proper coat of RTV sealant to both installed. inspection covers. Apply proper coat of anaerobic sealant to Apply anaerobic sealant to inspection cover the mating surface of the shift turret and bolts.
  • Page 44 TREMEC TR-3550 AND TKO TRANSMISSIONS TRANSMISSION DIAGNOSIS - (CONTINUED) POSSIBLE SOURCE CONDITION ACTION • Floor shift stiff or improperly • Verify jump-out with boot removed. • Transmission jumps out of gear. installed boot. Replace boot if necessary. • Floor shift - interference between •...
  • Page 45 TR EM EC TR-3550 AND TKO TRANSMISSIONS TRANSMISSION DIAGNOSIS -(CONTINUED) POSSIBLE SOURCE CONDITION ACTION • Lubricant level low or wrong type. • Transmission noisy in gear. • Fi l l to bottom of filler plug hole with proper lu bricant.

  • Page 46: Inspection

    TREMEC TR-3550 AND TKO TRANSMISSIONS INSPECTION Inspect transmission case for cracks, worn Replace the output shaft if there is any 1 4. or damaged bearing bores, damaged evidence of wear or if any of the splines are threads, or any other damage that could damaged.

  • Page 47: Specifications

    TREMEC TR-3550 AND TKO TRANSMISSIONS SPECIFICATIONS Sealant Specifications Anaerobic Sealant ET-M29 Sealant Loctite® 493 Grease for Needle Bearings ET-M 1 1 Oil Capacity 3 quarts of GM Synchromesh transmission fluid (GM part no. 1 2345349) Torque Specifications N•m Lb-Ft Allen Screws 1 3.5- 1 9...

  • Page 48: Introduction

    METRICS 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.

  • Page 49: Bolt Strength Identification

    M ETRICS BOLT STRENGTH IDENTIFICATION ENGLISH SYSTEM Grade 1 or 2 Grade 5 G rade 8 Identification marks correspond to bolt strength; increasing number of slashes represent English (Inch) bolts: increasing strength. METRIC SYSTEM Metric bolts: Identification class numbers correspond to bolt strength; increasing numbers represent increasing strength.

  • Page 50: English/Metric Conversion

    M ETRICS ENGLISH/METRIC CONVERSION MULTIPLY DESCRIPTION FOR METRIC EQUIVALENT Acceleration 0.3048 footlsec2 metre/sec2 (m/s2) 0.0254 metre/sec2 inch/sec2 Torque pound-inch 0.1 1 298 newton-metres (N•m) pound-foot 1 .3558 newton-metres (kw) Power horsepower 0.746 kilowatts Pressure Stress inches of water 0.2491 kilopascals (kPa) pounds/sq.

  • Page 51: Decimal And Metric Equivalents

    METRICS DECIMAL AND METRIC EQUIVALENTS FRACTIONS DECIMAL INCH METRIC MM FRACTIONS DECIMAL INCH METRIC MM .01 5625 .397 33/64 1 /64 .51 5625 1 3.097 1 /32 .03 1 25 .794 1 7/32 .531 25 1 3.494 3/64 .046875 1 . 1 91 35/64 .546875 1 3.891...

  • Page 52: Torque Conversion

    METRICS TORQUE CONVERSION NEWTON METRES POUND-FEET POUND-FEET NEWTON METRES 0.7376 1 .356 1 .5 8 . 1 1 0. 8 1 2.2 1 3.6 1 1 . 1 20.3 1 4.8 27. 1 1 8.4 33.9 22. 1 40.7 25.8 47.5 29.5 54.2...

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