oh dear there goes teh gearbox

[markiii]

right Redline MT 90 and transfer pump ordered  :-) :-) :-)

[BenF]

Mark,

Sorry to hear that - I'd go with what Arron recommended above (LoL - I made identical suggestions over on IMOC) to check to see if it is the gearbox oily bits or something like the clutch giving out.

Might be worth Speaking to Patrick @ Rogue about the gearbox, if you're thinking about getting it rebuilt, or rebuilt with some stronger internals ?

FWIW my 6 speed box seems OK with the PE Turbo, but I don't think I'm pushing as much torque through it as you are with the Hass kit. I'm at around 190 ft/lbs of torque.

Ben.

[kanujunkie]

bloody hell, a few hours away from here and theres bugger loads of posts  s:shock: :shock: s:shock:  

Mark, personally i think we should take Si up on the offer of those straps, its going to save us a bugger load of time fart arseing about and it'll also alleviate the need for finding a second jack to help drop the box out. I'm with Aaron though, the physical dropping of the box doesn't look hard at all, my only worry is getting it physically out from under the car without a lift.

Dan, you know those ramps you bought off Mark, you may find you get a call saying can we borrow them back  s:wink: :wink: s:wink:  

I did wonder that if Adam does have a box then i can go and pick it up and bring it along with me, providing i take the pax seat out and its resonably clean

anyone know the weight of the block btw?

[BenF]

BTW - if you're dropping the gearbox, a common trick if you're doing work on Mk1 or Mk2s (eg gearbox / engine) is to use an engine hoist ... to lift the back end of the car  s;-) ;-) s;-)

Slide the gearbox in/out on a pallet and lift the rest of the car so you get clearance.

[kanujunkie]

problem is though Ben is the engine will be hanging in mid air with only one mount in place, could be had to lift it up

[aaronjb]

Dan, you know those ramps you bought off Mark, you may find you get a call saying can we borrow them back  s:wink: :wink: s:wink:  

And I have a set, if Dan wants to be mean  s:lol: :lol: s:lol:

anyone know the weight of the block btw?

I don't, but it can't be that much, surely.. it's all aluminium, for a start..  Ah, found a post on SC that states ~200lb in a crate.  Presumably that's with no ancilliaries, so we can say 300lb at the top end with fluids, or 136Kg for the engineers among us  s:) s:)

[kanujunkie]

marvelous, i've got some karabinas at home here somewhere, they can handle that sort of load, i also remembered that theres one of those slings that Si was talking about at my parents place, so i'm picking it up tomorrow afternoon as well

[Tem]

right Redline MT 90 and transfer pump ordered  :-) :-) :-)

You don't need the pump though.  s;) s;)

There's a filler hole on top of the transmission, on the rear side. Easy to access with out layout, kinda like they designed it to be used on a MR car, not FF.  s8) s8)

[kanujunkie]

plus next time you need one remember i can get syringes from work

[aaronjb]

plus next time you need one remember i can get syringes from work

Mechanic, this jet engine needs 50cc of oil, STAT!

 s:lol: :lol: s:lol:   s;) s;)

Ahem, anyway..

[kanujunkie]

plus next time you need one remember i can get syringes from work

Mechanic, this jet engine needs 50cc of oil, STAT!

 s:lol: :lol: s:lol:   s;) s;)

Ahem, anyway..

LLLLLLLLLLOOOOOOOOOOOOOOOOOONNNNNNNNNNNNNNNNNNNNNNN!!

  s:wink: :wink: s:wink:

[kanujunkie]

well we've had a bit of fun in the last 24hrs and i think Mark probably wants to cry about now  s:( s:(  . By the looks of it, one of the bearings has had a bad day and shredded itself, there was metal filings everywhere so it did a good job of it, just for the record a gearbox out will need a pit or a lift, not something that can be done at home, its awkward at best and we had problems mainly with seized bolts and crap access, cant wait to do the install  s:roll: :roll: s:roll:  

i'll post some more photos in the morning, rushing out the door at the mo!

anyway heres what we found when we split the gearbox   s:( s:(  

[GSB]

Ouch...

  s:shock: :shock: s:shock:

[heathstimpson]

Mark just to let you know I have a local friend in Milton Keynes who owns a business that solely rebuilds gearboxes. His business is in Oxford but the box could by dropped off in MK  s:wink: :wink: s:wink:  Let me know if you want an approx price.

[GSB]

6 speed upgrade time, surely...

[heathstimpson]

6 speed upgrade time, surely...

I forget Mark had the five speed  s:? :? s:?

[loadswine]

Well chewed bearing for sure, but good job that it didn't total other bits and break a shaft or something.
I suppose the job of removing the box must have been a bit like dodgy tag team wrestling.  s:lol: :lol: s:lol:

[rtbiscuit]

so is it a case of just replacing the bearing now, or will you have to change all the bearings in there to be on the safe side, or are you just going to change the gearbox all together and put the 6 speed in?

[markiii]

well thanks to Stu and Arron for spending a day an a bit helping me do battle.

Whilst it was a pain, that was largely down to us feeling our way and in practice I reckon it would be a lot easier 2nd time around.

couldn't have done it without the pit though.

looks like it's seriously lunched itself.
  s:shock: :shock: s:shock:   we found bits of what was once ball bearing and plastic in addition ot that in Stu's photos

however on the plus  side since all of teh fluid is out I get to fit my TRD clutch line whilst we are in there.

  s:wink: :wink: s:wink:  


Heath, I'll definately get a quote from your mate, however at the moment a 6 speed upgrade is looking possible

had a quote of £599 inc vat for a recon 6 speed with LSD and 6 month Warranty, not sure if thats good or bad at the mo?

next question, are teh cables the same for a 6 speed? I know teh shift cage is different?

[GSB]

From memory of fitting the 6 speed in adams car, the cables are exactly the same. The shift cage can be modified with a file in about five minutes flat. The plastic just has to be fettled slightly to allow a slightly longer left-right throw on the shifter. I say this because I measured them once, and was pretty certain I could mod my 5 speed TRD shifter to fit, if only I could be bothered to strip the interior out the car, again...  s:roll: :roll: s:roll:  

£600 for a recon box with warranty sounds like a bargain, I paid £350 for a rebuild on a boggo Escort RS turbo box once, and that was nearly 10 years ago...

[markiii]

cheers Grant

Adams was teh celica 6 speed box though, you reckon thats still stands for teh roadster box?

[GSB]

Reckon so... I'm pretty sure the cables came from a 5 speed car, and the required extra throw is only a very small amount. A five speed shifter will work a 6 speed box, but its a pain in the arse to get reverse gear, as the extra left throw isnt allowed for in the original layout. I'd lay money on it that you wont have a problem with your existing cables. What you will need though, is a buzzer or light to tell you when you've selected reverse instead of first.

[aaronjb]

so is it a case of just replacing the bearing now, or will you have to change all the bearings in there to be on the safe side, or are you just going to change the gearbox all together and put the 6 speed in?

It would be rebuildable - but you'd have to strip everything down and check every single mating surface with a good set of micrometers, all clearances would need to be checked, definitely some replacement parts (including some replacement gears, probably some selector rings and dog gears too)..

Once you've gone that far you might as well replace all the bearings..

And effectively you'd end up pretty much only reusing the casing and possibly the main shafts - it'd likely cost almost as much as replacing it (given we wouldn't get trade prices on bits), and take a lot of time - not to mention a pretty steep learning curve.

I've no doubt that between us we could rebuld it - but it's a cost vs. time thing.. and in this case I think cost wins over time  s;) s;)

What you will need though, is a buzzer or light to tell you when you've selected reverse instead of first.

Surely the crunching sound when he reverses into Chris's Merc is adequate indication?  s;) s;)


On an unrelated note, good lord I ache now!

[grumpy]

With the Celica box the cables are the same. You would need a shortened shifter shaft also with the Celica. At least with the USA versions. The engine without accesories weighs if I recall correctly just under 300 lbs. The 6-speed Celica transmission with LSD is between 75 and 80 lbs.

Every time you take it out and put it back in it gets a bit easier. Frustrating but easier.  s:wink: :wink: s:wink:

[kanujunkie]

well thanks to Stu and Arron for spending a day an a bit helping me do battle.

not a prob Mark, just let me know when you want me to come and leave more bits of blood and skin all over your car  s:roll: :roll: s:roll:  

Whilst it was a pain, that was largely down to us feeling our way and in practice I reckon it would be a lot easier 2nd time around.

it would have been a lot quicker the first time round as well if we did have chronic gas issues every 2 seconds  s:twisted: :twisted: s:twisted:  

as for the box itself personally i think its fubar'd, what you may not be able to see in those pictures is the chips out of the teeth, they were small but will create future issues if left, personally i'd just replace it for a new box