Manual Transmission Removal and Re-Installation

Here's some good repair guides for your Tercel :) Look here for help first!
xirdneh
Highest Ranking Member
Posts: 2038
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: Manual Transmission Removal and Re-Installation

Post by xirdneh » Fri Jun 22, 2012 10:58 am

the rear of the engine needs to be as low as it wil go
then the rear of the tranny has to be pushed up
i wonder ifthe tranny jack is hampering this
Love those Tercell 4x4 wagons but they sure suffer from road noise.

xirdneh
Highest Ranking Member
Posts: 2038
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: Manual Transmission Removal and Re-Installation

Post by xirdneh » Fri Jun 22, 2012 11:04 am

oh
i am assuming you are pulling tranny along with bell housing/differential (the whole unit)
as thats what my write up covers
you can pull just the tranny, leaving the bell housing/differential on
i have never done that
Love those Tercell 4x4 wagons but they sure suffer from road noise.

Tres
Newbie
Posts: 5
Joined: Thu Jun 21, 2012 10:47 pm
My tercel:: 1986 4x4 Tercel w/out a few parts
Location: Lynnwood, WA

Re: Manual Transmission Removal and Re-Installation

Post by Tres » Thu Jun 28, 2012 9:20 pm

Yep that was the issue. the floor jack was keeping the tranny and rear of the engine from dropping all the way down. We took the jack out from under and some extra wiggle got it out. Thanks again

tercle
Top Notch Member
Posts: 200
Joined: Sat Aug 27, 2011 9:57 am
My tercel:: 1985 SR5
Location: Seattle

Re: Manual Transmission Removal and Re-Installation

Post by tercle » Sun Aug 26, 2012 9:34 pm

I am in the process of replacing a front-wheel-drive transmission.
I also installed a Sachs clutch kit.
I removed the input shaft before I hooked the transmission onto the motor.

But now the input shaft will not go all the way in.
I had someone work the clutch while I tried to move it.
I tried tapping on the back.

When I remove and install the input shaft on the old transmission, it initially gets stuck at the same point - with about a 1/8" gap under the snap ring.
Moving it around and pushing gets it past that point and all the way in.
Seems like this indicates it is an alignment issue with a seal or gear in the transmission, rather than the clutch assy.

I tried the same movements with the "new" transmission and tried it with the clutch depressed, but the input shaft still would not go all the way in.

User avatar
Petros
Highest Ranking Member
Posts: 11386
Joined: Sun Jan 28, 2007 6:31 pm
My tercel:: '84 Tercel4wd w/extensive mods
Location: Arlington WA USA

Re: Manual Transmission Removal and Re-Installation

Post by Petros » Mon Aug 27, 2012 10:35 am

The relationship between the trans and the flywheel should not change, the bell housing has idexing lugs, make sure the trans is all the way "home", and you might try having someone rotate the crank while you push the input shaft home. Put grease on all the surfaces, make sure the clutch is properly centered (that alone will stop it from going in, did you use pilot tool or input shaft to install the clutch? If not you will have to pull the trans and do it over).

xirdneh
Highest Ranking Member
Posts: 2038
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: Manual Transmission Removal and Re-Installation

Post by xirdneh » Mon Aug 27, 2012 11:30 am

if you depressed the clutch at the wrong moment
like when the input shaft was not at least barely started into the pilot bearing
the clutch would drop
and be misaligned now
not sure if you will be able to find a way to re-align it
not much room to work through the input Shaft hole

tercle
Top Notch Member
Posts: 200
Joined: Sat Aug 27, 2011 9:57 am
My tercel:: 1985 SR5
Location: Seattle

Re: Manual Transmission Removal and Re-Installation

Post by tercle » Mon Aug 27, 2012 9:11 pm

I did use the plastic pilot tool that came with the kit. (I didn't think of using an actual input shaft for this)

I wonder if I can reinstall the tool through the open input shaft housing and adjust the friction disc while the clutch is depressed momentarily, to the point where the pilot tool removes with the least drag. (making sure all feet are away from the clutch pedal when I remove it, of course).
Or, fish fish around until the nose of the tool finds the pilot bearing. If that's the alignment problem.

Alignment is pretty close, because the the input shaft stops about 1/4 inch from home.

If I can get home earlier tomorrow, I will see what I can do.

I didn't think of intentionally rotating the crank.
I accidentally moved it when I was torquing down the pressure plate.
I have to back it up and then move forward to TDC mark to put distributor back on anyway.
Last edited by tercle on Mon Aug 27, 2012 9:39 pm, edited 1 time in total.

xirdneh
Highest Ranking Member
Posts: 2038
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: Manual Transmission Removal and Re-Installation

Post by xirdneh » Mon Aug 27, 2012 9:39 pm

might work
unless the clutch plate has dropped as low as it can go
that would make it very difficult
you would have to use a narrow tool to work the clutch plate up while someone worked the clutch pedal
then get it aligned enough to get the input shaft thru the clutch disc
then have someone depress the clutch
the input should go right in
the pilot bearing would be the only thing that could hold it up

i once pulled a pilot bearing with a special small slide puller tool
i did not notice that the bearing broke in half
so there was a thin ring still in there when i installed the new pilot bearing
luckily i noticed the new pilot did not go in quite as far as it probably should have
so i double checked everything

tercle
Top Notch Member
Posts: 200
Joined: Sat Aug 27, 2011 9:57 am
My tercel:: 1985 SR5
Location: Seattle

Re: Manual Transmission Removal and Re-Installation

Post by tercle » Mon Aug 27, 2012 9:54 pm

I just went out with a flashlight and beer and tried inserting the plastic tool in the old transmission, but the ring at the end and the step right before are too wide. It won't go in far enough.

I wonder how hard it would be to remove that gear and big bearing from my spare input shaft?
I don't have an arbor press or anything.

Because if I could get that stuff off the input shaft, that improvised tool should work as a last-minute re-alignment tool.

I don't think the input shaft could have gone in as far as it did if the clutch disc had slipped that far. It's going through the disc splines.

Oh, Petros - since the clutch was working OK before,
and after reading about after-market pilot bearings being noisy sometimes,
and how you successfully re-installed the old Toyota bearing,
I left the factory Toyota bearing in.

xirdneh
Highest Ranking Member
Posts: 2038
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: Manual Transmission Removal and Re-Installation

Post by xirdneh » Tue Aug 28, 2012 12:48 am

the gear cannot be removed
just the bearing can be removed

tercle
Top Notch Member
Posts: 200
Joined: Sat Aug 27, 2011 9:57 am
My tercel:: 1985 SR5
Location: Seattle

Re: Manual Transmission Removal and Re-Installation

Post by tercle » Wed Aug 29, 2012 10:59 pm

I think I have to hit it harder.

User avatar
Petros
Highest Ranking Member
Posts: 11386
Joined: Sun Jan 28, 2007 6:31 pm
My tercel:: '84 Tercel4wd w/extensive mods
Location: Arlington WA USA

Re: Manual Transmission Removal and Re-Installation

Post by Petros » Thu Aug 30, 2012 3:51 pm

put some light grease on all the parts that make contact (pilot bearing journal, spline, gear, bearing seat, etc.), insert it all the way you can push it, and than lightly and rapidly tap the back while keeping forward pressure on it. the vibrations should allow it to wiggle into place and seat all the way. Usually I leave it in place, but several times I removed it when I had trouble clearing the input shaft, it too stuck right where yours is when I reinstalled it. I used a plastic dead-blow hammer with a block of wood "punch" and it finally popped into the place. If it is into place but only the last 1/8-1/4", it is all lined up, it just has to seat the bearing all the way forward. Make sure all the parts are very clean, free of grit, dirt, etc. You might even blow out the bearing seat in the bell housing, that is likely the hang up, everything else should slip back and fourth.

good luck.

North of 64
Top Notch Member
Posts: 237
Joined: Wed Feb 29, 2012 2:04 pm
My tercel:: "Bones" & "The Gray" both 87 SR5 4WD
Location: Dawson City, Yukon

Re: Manual Transmission Removal and Re-Installation

Post by North of 64 » Thu Aug 30, 2012 3:59 pm

[quote=" I used a plastic dead-blow hammer .[/quote]

NOT to be confused with a ball peen hammer!!

tercle
Top Notch Member
Posts: 200
Joined: Sat Aug 27, 2011 9:57 am
My tercel:: 1985 SR5
Location: Seattle

Re: Manual Transmission Removal and Re-Installation

Post by tercle » Sat Sep 01, 2012 11:40 am

Thanks everyone!
Input shaft installed Saturday morning.
I tried hitting it again - nothing.
The I inserted the tool, worked the clutch lever and moved the handle upwards.
Then I tried the input shaft again, and it started going in with light tapping.

I modified the pilot tool by removing the ring and adding a bamboo handle.
I used a strip of newspaper and gorilla glue to attach the bamboo.
I also rounded the nose a little.

Image

tercle
Top Notch Member
Posts: 200
Joined: Sat Aug 27, 2011 9:57 am
My tercel:: 1985 SR5
Location: Seattle

Re: Manual Transmission Removal and Re-Installation

Post by tercle » Sat Sep 01, 2012 9:19 pm

Hmmm.
Last edited by tercle on Sun Sep 02, 2012 1:19 pm, edited 1 time in total.

Post Reply