First issue

General discussion about our beloved Tercel 4WD cars
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Jonymoto
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My tercel:: 1983, DLX 4wd wagon with 4.1 manual gearbox, tow bar). Manual steering. 313,000 kms. Tercel 4WD SR5, 1987, 500,000kms. Other car - 2003 Rav4, AWD, 2l manual, Peugeot 407 Diesel (93,000 miles) in Ireland for use when on holiday there.
Location: Melbourne, Australia

Re: First issue

Post by Jonymoto »

Archinstl, your makeshift puller looks like a very good idea.
When you lose, don't lose the lesson - The Dalai Lama
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simon84
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Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

Yeah, I'll keep soaking it with liquid wrench and might try ATF as well after that.
I won't get back to it for a couple of days so it can soak until then.
I think I will make a puller attachment. Cool to see your guys versions on here. I will have to post a pic when I get one made up.
Always fun to problem solve these things but it always adds time to the process.
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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helipilot77
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My tercel:: 1984 SR5 wagon
Location: Seattle, WA

Re: First issue

Post by helipilot77 »

I had to make several of Toyota Special Service Tools for the 1KZ-te deisel motor I'm rebuilding for my 4Runner. Have the right tool for the job always makes it so much easier.
. / TOYOTA
./_| |/|/ |]
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simon84
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Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

I modified and fixed a puller that I had. and gave it a go. It moved about 1mm and the puller is getting all bent up. I will try to post a pic.
I am going to work on a better puller and now I have a little more room in behind to get in there.

One question: Is there any way to get the little metal key out? will that make it easier to pull the gear off? I've never had to do this before. I even had a deformed key on my last tercel and got it apart. Ended up replacing that gear and key as they were deformed.
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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simon84
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Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

Image
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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simon84
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Joined: Wed Nov 03, 2004 2:18 pm
Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

A friend just suggested that I need to take out the key stock first.
This was not mentioned in xirdneh's video.
I thought I'd be able to pull it out with it on...
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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ARCHINSTL
Goldie Forever
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Joined: Sat Apr 30, 2005 1:52 pm
My tercel:: Goldie is a 1986 SR5 attualmente con Weber/also owned the first T4WD in STL in late '82
Location: Kirkwood, a 'burb of St. Louis

Re: First issue

Post by ARCHINSTL »

You have to remove the Woodruff key. I went through the same drill, based on past experience with a different machine (and also not mentioned in xirdneh's video).
I removed the key by carefully tapping on its "back" with a bluntish pick. This rotated the key's "front" up enough to to pull it up and out with a ViseGrip. You might have to drive the gear back to its original position, though, to give the key some "slack;" I did.
I had to clean up the key a bit with a file to get it back into the slot - but I was able to get it to work, and it has been fine.
My photo of my puller shows it with the key removed - I should have mentioned it in the photo.
Good Luck!
Tom M.
T4WD augury?
"Oh, do not ask, 'What is it?' Let us go and make our visit."
T.S. Eliot - "The Love Song of J. Alfred Prufrock"
"Now and then we had a hope that, if we lived and were good, God would permit us to be pirates."
Mark Twain
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Petros
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My tercel:: '84 Tercel4wd w/extensive mods
Location: Arlington WA USA

Re: First issue

Post by Petros »

I have never had to remove the key before I got the belt sprocket off, it just slips over the keyway. seems too difficult to remove if it is in the way, but if the key is deformed there may be no other way ti get the belt sprcokect off.
'87 Tercel 4wd SR5 (current engine swap project)
'84 Tercel 4wd (daily driver, with on going mods)
'92 Mazda MPV 4wd (wife's daily driver)
'85 Tercel 4wd DLX auto(daughter's daily driver)
'01 Honda Civic (other daughter's daily driver)
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simon84
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Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

I tapped the bear back in with a large socket on it to protect it.
I was able to get the key to move a bit but vise grips won't pull it out. I will try again in a bit but I need a break from this.

This seems to be another one of those repairs that never ends!
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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simon84
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Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

And I meant gear instead of bear
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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Goldie Forever
Posts: 6369
Joined: Sat Apr 30, 2005 1:52 pm
My tercel:: Goldie is a 1986 SR5 attualmente con Weber/also owned the first T4WD in STL in late '82
Location: Kirkwood, a 'burb of St. Louis

Re: First issue

Post by ARCHINSTL »

Petros wrote:I have never had to remove the key before I got the belt sprocket off, it just slips over the keyway. seems too difficult to remove if it is in the way, but if the key is deformed there may be no other way ti get the belt sprcokect off.
My key was not deformed; the gear simply would not move over it. Perhaps the key was a micron too large to begin with, back in late '85?
When the key "rotated" a smidge, I was also able to raise it a tiny tad by inserting a sharpened icepick at the joint of the key and the slot and pried upwards - this rotated it a bit more, but I still had to use the (padded) ViseGrip.
With the key removed, the gear "slipped off" with relative ease using the puller.
Tom M.
T4WD augury?
"Oh, do not ask, 'What is it?' Let us go and make our visit."
T.S. Eliot - "The Love Song of J. Alfred Prufrock"
"Now and then we had a hope that, if we lived and were good, God would permit us to be pirates."
Mark Twain
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simon84
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Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

Yeah, I got the key to move a little bit. It popped out a couple millimeters at the front end but won't come out. I've tapped it in and out a bunch now but no luck. I'm starting to think I won't replace that seal after all. It does not seem to be leaking there too bad but hard to say for sure. It was leaving oil spots for sure. I managed to turn a few of the oil pan bolts as that seems like where some of the oil might be coming from.

I can do the camshaft seal. And I did replace the O ring on the little coolant pipe above the water pump that often leaks.

I just noticed a good brake fluid leak from one of the front calipers while I was under there.
As I said, the repairs that never end. Seems to be that way on this car.
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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ARCHINSTL
Goldie Forever
Posts: 6369
Joined: Sat Apr 30, 2005 1:52 pm
My tercel:: Goldie is a 1986 SR5 attualmente con Weber/also owned the first T4WD in STL in late '82
Location: Kirkwood, a 'burb of St. Louis

Re: First issue

Post by ARCHINSTL »

Well - the seal will not heal itself, so ... Persevere!
My go-to phrase: "In for a dime, in for a dollar."
Tom M.
T4WD augury?
"Oh, do not ask, 'What is it?' Let us go and make our visit."
T.S. Eliot - "The Love Song of J. Alfred Prufrock"
"Now and then we had a hope that, if we lived and were good, God would permit us to be pirates."
Mark Twain
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simon84
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Joined: Wed Nov 03, 2004 2:18 pm
Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

It would be nice to be able to get this off and do the seal.
Did it on my last tercel and cleared up the oil leaks.
I just checked on Rockauto and they have the crankshaft gear on there.
If it gets wrecked in the process, I can always get a new one. At this point I'm wondering if I'll have to grind the thing off.
The woodruff key is already showing some signs of abuse. I assume it's not hard to get a new one of those.
I think last time I had a similar issue, I managed to get a gear and key at a wrecker. That was about a decade ago though. They are more rare now.
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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simon84
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Joined: Wed Nov 03, 2004 2:18 pm
Location: Banff, Alberta, Canada

Re: First issue

Post by simon84 »

I just noticed that Rock Auto also has woodruff keys.

Anyone know the size?

I hope that if I can get it out that I can still determine what size it is. Although I am thinking that whatever method I use to get it out, it may not be the same size as it used to be when the dust settles.
I am seriously thinking of firing up the angle grinder and going at this thing.
It won't happen for another week or so now so I have some time to think it over...

Might just put in the parts order though since it tends to take a couple of weeks to get stuff from Rock Auto up here in the great white north.
Driver: 87 Tercel SR5, white, 4ac, weber carb (aka the Tercedes)
Road Tripper:95 Mitsubishi Delica L400 2.8L Turbo Diesel
Motorbike: 94 Kawasaki Ninja ZX6
Project Car:Red 68 Plymouth Sport Fury III
Previous Tercel:Orange 84 Tercel 4wd (aka the pumpkin)
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