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Tremec T-3650 Transmission Service Manual

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Service/Overhaul/Repair/WorkShop Manual of Automatic Transmission Tremec TR-3650, useful resource for those who want to see Tremec TR-3650 exploded views/diagram to rebuilt the transmission
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Content Preview
TREMEC
M.R.
NOTES, CAUTIONS
INDEX
WARNINGS&

NOTES, CAUTIONS & WARNINGS
Appropriate service methods
As you read through the procedures, you will come across NOTES,
and proper repair procedure are
CAUTIONS, and WARNINGS. Each one is there for a specific purpose.
essential for the safe, reliable
NOTES give you added information that will help you to complete a
operation of all motor
particular procedure. CAUTIONS are given to prevent you from making
vehicles as well as the personal
an error that could damage the vehicle. WARNINGS remind you to be
safety of the individual doing
especially careful in those areas where carelessness can cause
the work.
personal injury. The following list contains some general WARNING
that you should follow when you work on a vehicle.
This Manual provides general
directions for
accomplishing service and

Always wear safety glasses for eye protection.
repair work with tested,
effective techniques.

Use safety stands whenever a procedure requires you to be under the
vehicle with the vehicle jacked up.
Following them will help assure
reliability.

Be sure that the ignition switch is always in the OFF position, unless
otherwise required by the procedure.
There are numerous variations
in procedures, techniques,

Set the parking brake when working on the vehicle. It should be in
tools and parts for servicing
REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed
vehicles, as well as in the skill
otherwise for a specific operation. Place wood blocks (4”X4” or larger)
of the individual doing the work.
to the front and rear surfaces of the tires to provide further restraint
from inadvertent vehicle movement.
This Manual cannot possibly
anticipate all such variations
and provide advice or

Operate the engine only in a well-ventilated area to avoid the danger
cautions as to each.
of carbon monoxide.
Accordingly, anyone who
Keep yourself and your clothing away from the moving parts, when
departs from the instructions
the engine is running, especially the fan
provided in this Manual must
and drive belts.
first establish that he
compromises neither his

To prevent serious burns, avoid contact with hot metal parts such as
personal safety nor the vehicle
the radiator, exhaust manifold tail pipe, catalytic converter and muffler.
integrity by his choice of
Do not smoke while working on the vehicle.
methods, tools or
parts.

To avoid 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 of the radiator fan blades, Electric
cooling fans can start to operate at any time by an increase in under
TREMEC
hood temperatures, even though the ignition is in the OFF position.
M.R.
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.

CONTENTS
Introduction 4
Explosive view 5
Transmission Parts 6
Specifications 7
Lubrication 8
General Information 9
Torque Recomendations 10
Axial Clearances 12
Preventive Maintenance 12
Precautions 13
Inspection List 14
Turret Control Disassembly 15
Control Parts Group Disassembly 22
Primary Gear Parts Group Disassembly 24
Secondary Group Disassembly 30
Input Shaft Disassembly 31
Case Parts Group Input Shaft Disassembly 33
Extension Disassembly 36
Reassembly Reverse Gear 38
Troubleshooting Guide 57
Tools 60
3

TR-3650
INTRODUCTION
This manual is designed to provide detailed information
necessary to service and repair the TREMEC 3650
transmission listed on the cover. As outlined in the Table of
Contents, the manual is divided into 4 main sections:
a) Technical Information and reference
b) Disassembly and reassembly of the transmission
c) Troubleshooting guide
d) Tools required
The format of the manual is designed to be followed in its
entirety if complete disassembly and reassembly of the
transmission is necessary. But if only one component of the
transmission needs to be repaired, see the Table of Con-
tents for the page numbers showing that component. For
example, if you need to work on the Shifting Controls, you
will find instructions for removal, disassembly, and reassem-
bly on page into. Service manuals, Illustrated part list,
drivers instructions, and other forms service information for
theses and other TREMEC transmission are available upon
request.
On any repair or parts replacement, always use “original”
TREMEC parts according to the corresponding “Service
part Catalog”.
The use “non original” parts may endanger the operation
and performance of the transmission.
TRANSMISIONES Y EQUIPOS MECANICOS, S.A. DE C.V.
DOES NOT GUARANTEE service parts or failures resulted
for a misuse or not being provided by an authorized
TREMEC distributor.
A product literature order from, service bulletins (detailing
information on product improvements), repair procedures,
and other service related subjects can be obtained by
writing to the following address:
NOMENCLATURE:
PLANT AND GENERAL OFFICES:
Letter designations
Number designations
TRANSMISIONES Y EQUIPOS MECANICOS, S.A. DE C.V.
Av. 5 de Febrero No. 2115
C.P. 76120, Querétaro, Qro.
MEXICO
TR-3650
TREMEC
Design Level
Design
Forward speeds
x10 Capacity nominal lbs-ft
4

31
30
32
31
38
139
30
75
76
77
78
138
23
74
86
87
88
96
94
7
13
18
150
21
89
46
45
141
66
20
45
19
46
102
18
85
39
43
73
89
6
44
36
11
140
3
144
14
35
37
94
41
39
106
4
68
106
151
11
23
102
19
40
148
141
20
147
0
6
11
103
135
10
4
21
11
125
142
9
136
72
149
34
28
22
71
100
46
99
29
42
92
14
24
25
26
27
90
91
70
18
69
89
68
3
60
84
127
93
11
102
18
VIEW
29
40
81
14
15
16
17
1
138
127
126
79
13
33
OSIVE
3
12
33
106
11
82
8
6
105
95
11
104
5
4
5
67
111
EXPL
7
59
105
46
146
97
145
80
109
104
50
130
98
51
129
10
104
104
63
129
58
64
104
3
11
67
129
108
65
134
60
6
133
104
62
107
56
129
3
11
61
7
8
9
52
57
11
11
11
120
121
122
123
124
10
129
104
83
53
104
129
3
11
49
2
55
129
54
48
3
11
132
5
47
11
131
2
11
5
2
11
11
128
5

TR-3650
TRANSMISSION TR-3650 PARTS
1
1
MAGNET
73
1
1st. & 2nd. GATE
*
2
1
ROLL PIN
74
1
1st. & 2nd. FORK SHIFT ASS’Y
3
8
ROLL PIN
75
1
1st. & 2nd. FORK SHIFT *
4
1
SNAP RING SPEEDOMETER
76
1
3th. & 4th. FORK SHIFT ASS’Y
5
1
TAG IDENTIFICATION
77
1
3th. & 4th. FORK SHIFT *
6
1
CENTER INTERLOCK PIN
78
1
SELECTOR RAIL
7
2
SHIFTER INTERLOCK
79
1
ARM SELECTOR INHIBITOR
8
1
BEARING ROLLER CUP *
80
1
SEAT SELECTOR GATE
9
2
ROLLER BEARING SELECTOR ARM
81
4
DETENT PLUG
10
1
SPRING INHIBITOR
82
3
DETENT
11
14
BOLT METRIC HEX WASHER HD
83
3
ACTUATING SPRING
12
2
NYLON STOP
84
1
REVERSE FORK SHIFT ASS’Y
13
1
BEARING INPUT SHAFT POCKET
85
1
REVERSE FORK SHIFT *
14
1
THRUST BEARING ASS’Y
86
1
3rd & 4th. GATE
15
1
THRUST WASHER SHAFT PILOTED
87
1
SHIFTER LEVER ASS’Y
16
AR
SNAP RING 2.30+/-0.05 MM
AS REQU.
88
2
SPACER FONT
17
AR
SNAP RING 2.40+/-0.05 MM
AS REQU.
89
2
THRUST WASHER 3rd GEAR & REV.
18
AR
SNAP RING 2.50+/-0.05 MM
AS REQU.
90
1
3rd & 4th. SYNCHRONIZER ASS’Y
19
AR
SNAP RING 2.60+/-0.05 MM
AS REQU.
91
1
3rd & 4th. SLEEVE *
20
12
SPRING SYNCHRONIZER
92
1
1st. & 2nd. SYNCHRONIZER ASS’Y
21
2
1st. & 2nd. INNER RING
93
1
1st. & 2nd. SLEEVE*
22
2
BLOCKER RING & LINING ASSY 1st. & nd.
94
1
SYNCHRONIZER ASS’Y REVERSE GEAR
23
2
1st. & 2nd. BLOCKER RING
95
1
REVERSE CLUTCH CONE
24
1
SNAP RING HUB SYNCHRO 1st. & 2nd.
96
1
CLUTCH CONE 5th. SPEED. C.S.
25
2
SNAP RING TOP INSERT
97
1
SPRING BASE TURRET
26
1
BEARING CONE & CUP ASS’Y MAIN SHAFT
98
1
RAIL REVERSE INHIBITOR
27
1
BEARING CONE*
99
1
INHIBITOR REVERSE
28
AR
BEARING SHIM C.S.
AS REQUIRED
100
1
PIN INHIBITOR RETAINER BAR
29
AR
BEARING SHIM C.S.
AS REQUIRED
101
1
INTERLOCK SUPPORT
30
AR
BEARING SHIM C.S.
AS REQUIRED
102
1
OIL SEAL BEARING RETAINER
31
AR
BEARING SHIM C.S.
AS REQUIRED
103
1
WASHER SPRING RETENTION
32
1
BEARING CONE & CUP ASS’Y C.S.
104
1
GEAR REVERSE M.S.
33
1
CUP BEARING *
105
1
THRUST WASHER 5th. GEAR C.S.
34
2
ROLLER BEARING GEAR 5th. C.S.
106
1
REVERSE SHAFT RAIL
35
2
ROLLER BEARING GEAR REV. IDLER
107
1
BOLT M8X1.25X60 TORX BOTTON HEAD
36
1
SPACER ROLLER BEARING GEAR REV.
108
1
REVERSE SUPPORT SHAFT
37
2
O’RING INHIBITOR
109
1
O’RING
38
1
CONE BEARING*
110
12
INSERT SYNCHRONIZER
39
1
BEARING CONE & CUP ASS’Y REAR C.S.
111
1
3rd CLUTCH CONE
*
40
1
CUP BEARING REAR C.S.*
112
1
3rd GEAR SPEED ASS’Y M.S.
41
1
CONE BEARING REAR C.S.*
113
1
1st. & 2nd. HUB SYNCHRO *
42
1
SPACER ROLLER BEARING 5th. C.S.
114
1
3rd & 4th. HUB SYNCHRO *
43
1
REVERSE IDLER GEAR
115
2
5th.. & REV. HUB SYNCHRO *
44
2
1st. & 2nd. CLUTCH CONE
116
3
BALL
45
1
1st. GEAR SPEED ASS’Y M.S.
117
1
BALL SPEEDOMETER
46
1
1st. GEAR SPEED M.S. *
118
2
DRAIN PLUG & FILLER PLUG
47
2
BUSHING 3rd GEAR & REV.
119
1
BREATHER
48
1
CLUTCH HOUSING ASS’Y
120
4
2nd. & 3rd NEEDLE BEARING ASS’Y
49
1
CLUTCH HOUSING
*
121
1
BEARING TAPERED ROLLER CUP
50
1
TRANSMISSION CASE ASS’Y
122
1
BEARING TAPERED ROLLER CONE
51
1
TRANSMISSION CASE *
123
1
CAP SCREW HEX HEAD SENSOR
52
1
EXTENSION ASS’Y
124
1
SWITCH ASS’Y BACKUP LAMP
53
1
EXTENSION
*
125
1
TUB RETAINER BEARING*
54
1
MAIN SHAFT
126
4
DOWEL PIN
55
1
SPEEDOMETER ROTOR GEAR
127
1
BUSHING EXTENSION HOUSING
56
1
OIL SEAL EXTENSION
128
1
STUD CLUTCH RELEASE LEVER
57
1
INPUT SHAFT
129
1
SEAL OUTPUT SPLINE
58
1
3rd GEAR SPEED. M.S.*
130
AR
BEARING SHIM 0.55 +/- 0.013 MM
59
1
2nd. GEAR SPEED. ASS’Y M.S.
131
AR
BEARING SHIM 0.61 +/- 0.013 MM
60
1
2nd. GEAR SPEED. M.S. *
132
AR
BEARING SHIM 0.66 +/- 0.013 MM
61
1
5th. GEAR SPEED. M.S.
133
AR
BEARING SHIM 0.71 +/- 0.013 MM
62
1
SYNCHRONIZER ASS’Y 5th. GEAR C.S.
134
AR
BEARING SHIM 0.76 +/- 0.013 MM
63
1
5th. GEAR C.S. *
135
AR
BEARING SHIM 0.81 +/- 0.013 MM
64
2
5th: & REVERSE SLEEVE *
136
AR
BEARING SHIM 0.83 +/- 0.013 MM
65
1
CLUSTER GEAR
137
1
SNAP RING
66
4
BLOCKER RING 3rd/4th./5th & REVERSE
138
1
SPRING CENTERING SHIFT CONTROL
67
1
1st. & 2nd. SHIFT RAIL
139
2
BOLT SHOULDER
68
1
3rd & 4 th. SHIFT RAIL
140
14
BOLT METRIC HEX. WASHER HEAD
69
1
5th. & REV. SHIFT RAIL
141
4
BOLT METRIC HEX. WASHER HEAD
70
1
5th. FORK SHIFT ASS’Y
142
9
PAD SHIFT FORK
71
1
5th. FORK SHIFT*
143
1
SENSOR SPEEDOMETER
72
1
1st. & 2nd. GATE ASS’Y
* SOLD ONLY IN ASS’Y
6

SPECIFICATIONS
The transmissions series TR-3650 have five forward speeds and one reverse, of advanced design that offers to you, the
most efficent relation of capacity of partorsion-weight, that any other transmissions of 5 speeds within its rank.
IMPORTANT
All TREMEC transmissions TR-3650 are identified
by the model and serial number, and date. This
information is stamped on the transmission identifi-
cation tag and affixed to the case.
TRANSMISSION MODEL
ASSEMBLY DATE
TRANSMISSION NUMBER
SERIAL NUMBER
MODEL
GEAR RATIOS
1st.
2nd.
3rd.
4th.
5th.
REV.
OIL CAPACITY
TR-3650-1/2
3.38
2.00
1.32
1.00
0.67
3.38
3800 C.C.
TR-3650-3/4/5
3.38
2.00
1.32
1.00
0.62
3.38
3800 C.C.
NOTES
1
Lengths measured from clutch housing face to cover rear (extension).
2
Weights include shift bar housing, clutch housing, less shift lever assembly, and
clutch parts. For more information on available application, see the
transmission’s illustrated parts list. All weights are approximate.
3
Oil capacities are approximate, depending on inclination of engine and transmis-
sion. Always fill transmission, with proper grade and type of lubricant, to level of
filler opening. See LUBRICATION.
7

TR-3650
L U B R I C A T I O N
Proper lubrication procedures are the key to a good all
Thus, all parts are amply lubricated if these procedures are
around maintenance program.
closely followed:
If the oil is not doing its job, or if the oil level is ignored, all
the maintenance procedures in the world are not going to
keep the transmission running or assure long transmission
Maintain oil level. Inspect regularly
1
.
life.
Change oil regularly
2
.
TREMEC Transmissions are designed so that the internal
parts operate in an oil circulating bath by the motion of the
Use the correct grade and type of oil.
3
gears and shafts.
Buy from a reputable dealer
4
.
OIL SPECIFICATIONS
MODEL
API SPECIFICATION
TREMEC
OIL
TRANSMISSION
SPECIFICATION
CAPACITY
TR-3650
Mobil 1 Synthetic ATF
ET-M-99
3.8 Lts.
Dexron III
1300-244-006
CHANGE AND INSPECTION OF THE LUBRICANT
PROPER OIL LEVEL
Use oil ET-M99 specification.
Additives and friction modifiers are not recommended for
use in transmission TR-3650.
PROPER OIL LEVEL
Make sure oil is level with the filler opening. Because you
can reach oil with your finger does not mean oil is at proper
level.
DRAINING OIL
Drain transmission while oil is warm. To drain oil remove
IMPROPER OIL LEVEL
the drain plug at case bottom.
Clean the drain plug before re-installing.
OIL CHANGE AND REFILLING
Clean case around filler plug and remove plug from case
side. Fill the transmission to the level of the filler opening.
The exact amount of oil depends on the transmission
inclination and model. Do not over fill this causes oil to be
forced out of the case and cause a deficients lubrication.
when adding oil, types and brands of oil should not be
mixed because of possible incompatibility.
8

G E N E R A L I N F O R M A T I O N
The TR-3650 transmissions have five forward speeds and
1
3
5
one reverse, and are shifted as you would shift any
synchronized transmission manual, following the simple 5
speed shift pattern.
N E U T R A L
Follow the simple 5 speed shift pattern:
2
4
R
POWER FLOW
The transmission must efficiently transfer the engine’s
3 Torque is delivered along the countershaft to all
power, in terms of torque, to the vehicle’s rear wheels.
countershaft gear.
Knowl-edge of what takes place in the transmission during
torque tranfer is essential when troubleshooting and making
4 Torque is transferred to “engaged” mainshaft gear.
repairs.
The cross section illustrates 1st speed gear position.
5 Engaged mainshaft gear internal clutching teeth
1 Power ( torque ) from the engine is transferred to
transfers torque to mainshaft through synchronizer
the input shaft and drive gear.
assembly.
2 Torque is transferred to the countershaft drive gear.
6 Mainshaft transfers torque directly to driveshaft t
through rear yoke.
9

TORQUE RECOMENDATIONS
TR-3650
Correct torque application is important to assure long
wrench to obtain recommended torque ratings. Do not
transmission life. Over or under tightening of fasteners can
torque capscrews dry. Apply teflon to threads of all
result in a loose installation and, in many instances, can
capscrews before in installing definitive.
eventually cause demage to the transmission. Use a torque
2
1 0

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