25 replies to this topic

[orangeLJ]

Im going to be whipping the engine/frontend/gearbox out from under the lj in the next month (engine upgrades )

I know it could do with a new clutch, so will have the flywheel skimmed (yella terra lightweight) as I know it has a few hot spots from some exhuberent driving....

So im keen to get the box looked at by a pro, its a celica 5 speed, steel cased.

Ive read in other threads that roller bearings are a good upgrade, but what else? Can you still buy off the shelf parts to suit?


So I also need some reccomendations, I have one joint here on the coast, nut thought someone might know a specialist?

Also think it would be wise to reco/upgrade the shifter assembly as the lottle nylon balls seem to get so dam sloppy, so any suggestions there?

[76lxhatch]

I was helping a mate look for some rebuild parts on the Internet a while ago and we did find some reasonably priced kits in the US somewhere so they are available, didn't save any links though sorry.

If the shifter is sloppy then fixing that will definitely be an upgrade, the only problem is that the bushes are very expensive - Toyota will charge you two thirds of the price of a new short shifter which comes with the bushes:
http://www.facebook....10291986?v=info
http://www.trademe.c...?member=2669944
(he has a web site but I can't find it at present, he used to list on eBay also)

[Toranamat69]

I think you will find your gearbox already has the upgraded bearings.

They all did straight out of the box except the very early ones.

The little round bush on the bottom of the shifter costs bugger all from Toyota locally here - was $10 or something like that.

The larger bush that shifter pivots on I am not sure of the cost from Toyota as I got the harder replacement from Marlin crawler in the US.

http://www.marlincra...ever-ball-seats

They are a pack of A$$holes to deal with though and now will not ship internationally but there are ways around that.
If you get a short shifter, as emntioned above, you will get those bits anyway.

[orangeLJ]

Well its nice to see there are a few options, those shifters are nice, expensive, but not out of my options.

Would it be overly difficult to strip it down and replace bearings etc myself?

[76lxhatch]

I wouldn't hesitate to do it myself, can't trust anyone else!

Local Toyota dealer quoted me around $140 for both bushes, the cheaper version of those two shifters is only $190... I would have thought they were having me on except I've enquired about other basic parts before and they are always that bad

[dattoman]

Dellow sells Toyo bits too
They have some bits on ebay now you might be interested in

[orangeLJ]

Let me rephrase that, how difficult/involved is it.to do the job myself? Im just hesistant about circlips, springs washers.etc etc and when theu go twang as you are pulling things apart haha, if they arent too fiddly, then Id be sweet.

Off to ebay I go methinks!

[76lxhatch]

To be honest I haven't had occasion to rebuild a Toyota box to date (famous last words), but haven't come across a manual box that is difficult yet - things like T5 WC need a press to get some of the gears off but other than that all you need is a bit of patience and some decent circlip pliers. Its one of those jobs that a lot of people are scared of for no good reason, and you have a lot more money left over for beer and further parts if you do it yourself.

[orangeLJ]

Alright I think ive been convinced to give it a go myself.

Should I be pulling it down, seeing whats worn and then buying specific bits, or is there a kit I can buy? Im hopeless at rwmembering bits when they are left for more than a week or two, so would realistically like to pull it down and rebuild it at the same time.

Who actually sells bits for these? And not shotty, bad qc style taiwanese bits?

[76lxhatch]

Before you start you want to find some documentation, whether it be a workshop manual or just an exploded view (often a rebuild kit will come with a one page version) - this will help a lot if there are any tricks you need to know. Its unlikely that many parts can go in more than one place, with some sort of documentation you won't have any hassles.

When I was looking for parts strangely enough it seemed to be US suppliers that were most common, most of them do kits which have a number of parts but you're unlikely to find one that covers everything, you'll probably need to mix and match a little. Quality isn't too much of an issue with the US suppliers either as they are mostly targeting conversions rather than OE installations.

I tend to be a bit slow with finishing some jobs so I try to allocate a bench (or half a bench) where I can spread the parts out without fear of losing them amongst everything else (sometimes it even works!). You'll also need a nice clean work space. Plastic containers of any description are always useful.

[orangeLJ]

thanks for that, I had a quick google and found a few places, it seems like the biggest issue is identifying the gearbox by its physical characteristics, would be much nicer if it was a part number basis!

Definitely going to set up a bench dedicated to laying out each individual gearset, clips etc, when I get on a real computer instead of my phone, I will see if I can find some form of manual, I have some exploded views from a couple us suppliers.

If all else turns to shit, I have a spare box haha.

[Toranamat69]

I have the full factory service manual for my R154 box that I downloaded from the net and it sounds easy as to rebuild. I will be doing it myself very shortly - I bought all the overhaul kit and upgrade parts from the US.

Not sure where the best place to get ovehaul kits for the Celica box is though - would have to surf the net to see what is around.

[orangeLJ]

Most pf.the box is apart.now, jist having trouble with getting the main shaft etc out of the casing

Anyone done this and jave any tips?

[76lxhatch]

I haven't had occasion to rebuild a Toyota box to date (famous last words)

What did I say? Took several teeth off second gear so the box is now on the bench with a second parts box in a million pieces waiting for the rebuild kit to arrive...

Does the steel case box mount everything in the sandwich plate the same as the alloy ones? If so you have to remove everything from the back, fifth gear and the bearing behind it were particularly stubborn and even my modified long reach puller wouldn't do both at once so I carefully cut the old bearing off and removed fifth gear by itself. The Toyota SST (special service tool) is actually two plates with threaded rods that push them apart and they push fifth gear off against reverse.

I may be barking up the wrong tree here if I didn't understand which bit you are trying to remove the box is a little different, so perhaps post some pics of what are looking at if that doesn't help. If the box is similar I have a PDF service manual here that I found which I can send you.

[orangeLJ]

that PDF would be awesome.

this is where we are stuck at the moment-





I can get the sandwich plate to slide backwards about an inch, but no further.

The reverse idler (on the right) is reatained behind the plate, so im guessing its not that as it would be impossible to get it off from inside??

I'll pm you my email address, if you could send the PDF ASAP that would be excellent

[orangeLJ]

got it out, my Dad was trying to remove the main shaft through the front ala aussie box, once I flipped the two circlips off the front it all slid out the bum nicely.

The pdf would still be ace!

Thanks,
chris

[orangeLJ]

while not identical, Ive found this P51 gearbox manual, that could be handy

http://www.toymods.o...air-manual.html

basically the same box just built by porshce (so has a few minor differences)

[76lxhatch]

Sounds like you've got it sussed now, everything mounts in that sandwich plate so the housings slide away from the gears as opposed to what you'd normally expect in a top or side loading box. Sent you the PDF, a few differences by the looks but same basic construction.

Now that you've got the case off, mount the sandwich plate in the vice and work on removing first the shift rods (don't lose the little detent balls etc!) then there will be another snap ring around the output shaft bearing behind that screw-on retainer and it all should slide out the front of the sandwich plate. From there its just remove each gear individually from the main shaft in the press and you're pretty much done.

[TerrA LX]

I would like a PFD for steel case too if someone could send me one please.

[76lxhatch]

It is too big. I can share it but its not for this box as stated, would be better with the right one.

A quick search turns up this, looks quite useful:
http://members.iinet...ta/gearbox W50/

[orangeLJ]

the P51 manual that I put up is near identical, with that and some exploded views I nabbed off Toymods, it was a cakewalk! REALLY happy with how easy it was.

Some of the Syncros were a little bit worn in spots, but not enough to worry about, was very surprised to see the gearsets looked like new! no chipped or overly worn teeth etc.

Have it all back together bar one bearing (on the smaller cluster in the rear housing)

so once thats on I can mount the rear housing and its all done.

I'll put up pictures of my modified puller that I used to remove the bearings, worked perfectly and no need for the press.

used a $36 stanley medium sized 3 leg puller from supercheap and some long lengths of flat bar. I surprised myself with how well my idea worked!

Thanks for the help and tips all!

Anyone who wants to know anything about pulling one of these apart, just ask, Its all fresh at the moment!

[76lxhatch]

Its not identical but looks pretty close. The most useful thing to know with gearboxes is the little tricks and special tools to remove the gears, and that can be quite specific, so its handy to have the exact manual if you can get it.