Keisler stocks several thousand...
Keisler stocks several thousand individual components to build manual and automatic overdrive transmission systems for the aftermarket. Everything is barcoded and a wireless scanning system updates the server as to shipping and sales needs.
Out on the expressway, the T45-RS performed very well with no complaints. Whether at low or high speeds, I could hear absolutely no gear whine whatsoever. In fact, this transmission is one of the quietest transmissions I have driven in any vehicle...ever. Even at high speed at 75-80 MPH, there still was no indication of any vibration through the shifter and that fact truly surprised me. Most cars have some drivetrain vibration at some point in their power curve (especially manually-equipped cars) but I never found it with the T45-RS and I was truly amazed by that fact. I drove the car for about an hour and I enjoyed every minute of it. In fact, I may just use this transmission for one of our new project cars this coming year.
At the end of the day the bottom line was clear; If you are looking for a manual overdrive transmission that shifts great, can handle adequate power without breaking, is dependable, durable, has all the latest upgrades and features expected in today's transmissions, has a warranty and costs about $1000 less than a TKO package, then the new Keisler T45-RS should be a serious consideration for your next C3 Corvette project. One last thing: We videotaped the test drive and we now have the drive on corvettefever.com as well as the keislertv.com website. You can also see the two Keisler versions of the drive on youtube.com so check it out.
Special fixtures are used...
Special fixtures are used to disassemble and assemble the T45-RS. The mainshaft is built up, and then assembled to the transmission along with the shifter rail, forks and shims.
At the rebuild stations, assembly...
At the rebuild stations, assembly parts are set to the rebuild area by job. Each unit's information is barcoded and stored on the server, including builder, day, quality check associate, and sales order.
One of Keisler's key ingredients...
One of Keisler's key ingredients to their transmission kits is their driveshaft program. Keisler builds all their driveshafts in-house on their Hines driveshaft cell from lightweight, high strength steel that is automatically welded and computer balanced with premium solid sealed U-joints. Here Shafi explains the first step of their in-house Hines driveshaft manufacturing cell. At this process a specially prepared lathe cuts the driveshaft tubing, chamfers it both inner and outer for a deep penetration weld.
Next, these precision yoke...
Next, these precision yoke chucks hold the parts so they don't galled up or bind during the pressing stage. Keisler invested more than $150,000 in this Hines Driveshaft manufacturing cell. The cell builds OEM grade driveshafts for the highway, which is a requirement for many road going commercial vehicles.
C3 Corvette components shown,...
C3 Corvette components shown, in preassembled form. L-R: Keisler's forged slip yoke with 4140 billet caps; Neapco HD sealed permanently lubed high performance u-joints assembled to Spicer weld flanges.
Michael is doing the first...
Michael is doing the first stage of assembling the driveshaft. Here the individual components are set to the Hines driveshaft press. A hydraulic ram presses all of the components together with precision alignment.
Here Michael is building a...
Here Michael is building a Corvette driveshaft on a Hines Spicer driveshaft machine. Runout is measured at each end of the shaft and the middle-3 places in total. Runout in the middle is corrected by the hydraulic ram with linear scale (lifted up). Next, the driveshaft is automatically welded. Next, the dynamic balance is checked, and balance weights are welded at the correct rotation angle, as needed. The d/s then goes on to masking, paint, then serialized with a sticker of certification.
In the fabrication and welding...
In the fabrication and welding shop, we can see Keisler's C2-C3 Corvette replacement crossmember and frame brackets. The crossmembers are box construction to minimize driveline flex, mig or tig welded, then powder coated. In the background are A-41 automatic transmission extension housings and Camaro crossmembers.
Kit components including clutches,...
Kit components including clutches, bellhousings, speedo-cables, shifters and numerous other parts are picked and scanned at the pack-out lines, where they are married up with the boxed transmission from the assembly lines. In 2006, Keisler went to a Lean Production System, with the help of the University of Tennessee's Industrial Engineering department. This dramatically reduced inventory and lead time, customer satisfaction went up and less floor space was used to get the job done.