Manual Transmission Removal and Re-Installation

Here's some good repair guides for your Tercel :) Look here for help first!
TURTCEL
Highest Ranking Member
Posts: 662
Joined: Mon Dec 10, 2012 11:42 am
My tercel:: 1985 4WD SR5 Wagon, Brown (TURTCEL)
Location: Everett, WA

Re: Manual Transmission Removal and Re-Installation

Post by TURTCEL » Wed Mar 06, 2013 5:13 pm

So I am going into my 3rd day on my clutch job tomorrow. Turning out to be a real PITA. I have had tool problems and seal problems and clutch problems.

I truly never want to do one of these clutches again. My friend needs one done on her Terc and I told her today that I would prefer to not be involved with the job.

It seemed a lot easier and quicker in the posts that I have read. I have kept my cool but this is the longest most ridiculous clutch job I have ever done. This is hands down the crappiest job I have had to get into with TURTCEL.

Peace
1985 Tercel 4wd SR5 Wagon, WEBER Carb, Brown (TURTCEL)
1988 Corolla DLX All-Trac Wagon, 4 speed AT, Silver (Wife's new car)
1993 Ford Escort Wagon LX, 5 Speed, Smurf Blue (Smurfette)...selling

User avatar
marlinh
Highest Ranking Member
Posts: 1530
Joined: Sun Apr 08, 2012 9:15 am
My tercel:: 'Everett' Blue mint 4WD wagon and 'Rocky' 86 4WD Wagon
Location: Kootenays

Re: Manual Transmission Removal and Re-Installation

Post by marlinh » Wed Mar 06, 2013 6:27 pm

Gee Turtcel, Sorry to hear that you haven't enjoyed doing the clutch job. If you have never pulled a transmission before there is a learning curve, and the next time is always easier.

User avatar
Petros
Highest Ranking Member
Posts: 11338
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 » Wed Mar 06, 2013 6:55 pm

Removing the trans for any reason is one of the most complex and difficlut things to do on these cars. you have the front cv axles and the rear drive shaft to remove, plus two shift levers, and all the mounting bolts and side plates.

It goes in a lot better, and now that you have done it once, next time should take half as much effort.

But it is the one job I hate doing the most, particularly because most of it has to be done on my back on the garage floor. A lift would make this job much less troublesome.
'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)

TURTCEL
Highest Ranking Member
Posts: 662
Joined: Mon Dec 10, 2012 11:42 am
My tercel:: 1985 4WD SR5 Wagon, Brown (TURTCEL)
Location: Everett, WA

Re: Manual Transmission Removal and Re-Installation

Post by TURTCEL » Wed Mar 06, 2013 7:14 pm

I have pulled plenty of trannies. I worked in a few wrecking yards for about 5 years back in WA State, pulled everything under the sun actually. I have just never pulled one on a 4wd Terc before. I can't say pulling the trans was tough, more like all the B.S. that has to come off in order to get the trans free.

So I don't forget...Is it correct that the flywheel bolts get torqued to 55ft lbs? That is what I read in the FSM, but just wanted a confirmation from someone who has done this job before. I have caught errors in the FSM before and I don't want this to be one that I was unaware of. 55ft lbs seemed just a little low to me, but like I said I have never done a Terc clutch before.

The main concern that I have is the rear main seal not leaking. When I finally got the trans out and flywheel off so I could inspect the rear main I noticed some concerning things. First the oil pand bolts on the rear of the oil pan all needed to be snugged up...I noticed a slight leaking from there. Should I be resealing the oil pan while the trans is out upon finding this leak, or will snugging bolts usually fix this on these cars? I don't lose any oil that I have ever had to add to because it got low.

But the rear main would not come out easy so I ended up pulling the rear main body off the engine block and installed the seal while it was out. The worst thing about this was that whoever did the rear main before only put 2 of the 6 rear main housing bolts back in. It wasn't leaking but seriously who the hell misses bolts like that? I used Ultra Grey sealer from Permatex (always been happy with this sealer) on the rear cover plate gasket and for the bottom where it mates to the oil pan. This has to slide in which kinda scrapes the sealer off at the same time if the oil pan is not off. What are the chances it will leak from the rear of oil pan area where the rear main cover fits to? Should I just pull the oil pan and reseal it now since everything is outta the way, or is it a good chance it will seal back there? I really want to do it the right way the first time.

Also, I installed the new pilot bearing but how far does it go in? Do I bottom it out? I have left that one as my first priority to look at tomorrow before the clutch goes on in case I need to set it in further or back it out. I will check the FSM to see what it says too.

Thanks again for all the help on this job guys. It's not that bad, it has just taken me longer than expected. I got my shift covered at work tomorrow so I could finish the car. Which actually makes me lose money now. Getting the trans in is the easy part, it's bolting everything back on an making sure nothing went wrong in process? Any tips on what I should check before completely reassembling the car while it is high on stands and is suggested to do?

Thanks guys

Peace
1985 Tercel 4wd SR5 Wagon, WEBER Carb, Brown (TURTCEL)
1988 Corolla DLX All-Trac Wagon, 4 speed AT, Silver (Wife's new car)
1993 Ford Escort Wagon LX, 5 Speed, Smurf Blue (Smurfette)...selling

User avatar
rer233
Highest Ranking Member
Posts: 918
Joined: Sat Jan 01, 2011 1:49 pm
My tercel:: Multiple

Re: Manual Transmission Removal and Re-Installation

Post by rer233 » Wed Mar 06, 2013 8:43 pm

done clutches on 4 t4's (five if you count the one i did twice 2 yrs apart.) i've been lucky- did 'em all on a lift with a trans jack- one of the FEW benefits of working on cars professionally. did pull one on my back in my garage out of a car i was junking but didn't have to re-install it (obv.) would not be looking forward to wrestling that heavy sucker back in on my back 'tho... think you'll find "in" is a whole lot harder than "out." hopefully, you managed to get the input shaft out- makes one less thing to line up while wrestling the trans back in.

one other thing i've done while the trans is out is remove the 6 bolts that hold the shifter cover on (some will probably break) clean the crap out of the cavity, and drill a 3/16" hole thru the lower rear part of the cavity to act as a drain (can't remember whether on the right or left side- it should be obvious- the wrong side would penetrate the gearbox.) i then load everything up with grease- keeps everything working smoothly. i know you said your boot was in great shape, but who knows how long it will stay that way? i've seen cars in which that cavity got so rusted-up from years of standing water that the shift linkage wouldn't move. like you, i HATE doing things over. just my 2 cents.

Good luck!
if it aint there, there's a good chance it won't break!
83 SR5 Silver/Blue (Snowmobile/work beater)-totaled but drivable
85 SR5 Blue
88 SR5 White (the 'good' one)-not anymore-totaled
87 fwd silver wagon a/t
87 4wd dx Cream (a/t- not anymore- now m/t)

User avatar
Petros
Highest Ranking Member
Posts: 11338
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 » Wed Mar 06, 2013 9:04 pm

you are probably okay on the rear seal, but you did break the seal on the oil pan gasket. It would be much easier to remove it now and put in a new gasket, but it is still a bit of a hassle because you have to remove the oil pick up tube from the front. I do not think I would do it, the oil pans gaskets are usually reliable and do not leak. I suspect the oil you got out of it was from squeezing it, it likely ran down from somewhere else. be careful not to over tighten the little 10mm bolts holding on the pan, over-tightening them can crush the gasket and cause it to leak, I think the FSM says something like 14 in-lbs (not ft-lbs) for the oil pan bolts. I just snug them down with the tiny 1/4" drive socket with a long extension and the 10mm socket on it, making sure all feel evenly snug, not tight.

Other than the pan gasket, sounds like you are good to go.
'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)

TURTCEL
Highest Ranking Member
Posts: 662
Joined: Mon Dec 10, 2012 11:42 am
My tercel:: 1985 4WD SR5 Wagon, Brown (TURTCEL)
Location: Everett, WA

Re: Manual Transmission Removal and Re-Installation

Post by TURTCEL » Wed Mar 06, 2013 10:09 pm

I noticed the seeping oil before I snugged them down. There is no gasket on the oil pan...just silicone. They make an aftermarket gasket but the Toyota dealer said they only use Ultra Black.

Now knowing that there is no gasket and jut Ulte Grey in there now, does that change your thoughts on the oil pan gasket situation?

Peace
1985 Tercel 4wd SR5 Wagon, WEBER Carb, Brown (TURTCEL)
1988 Corolla DLX All-Trac Wagon, 4 speed AT, Silver (Wife's new car)
1993 Ford Escort Wagon LX, 5 Speed, Smurf Blue (Smurfette)...selling

TURTCEL
Highest Ranking Member
Posts: 662
Joined: Mon Dec 10, 2012 11:42 am
My tercel:: 1985 4WD SR5 Wagon, Brown (TURTCEL)
Location: Everett, WA

Re: Manual Transmission Removal and Re-Installation

Post by TURTCEL » Thu Mar 07, 2013 7:19 pm

With the BAD ASS help from Larry "The Man" Mcgrath (my name for him now) I finally got my trans in. That's it though, nothing else bolted up yet at all. A very discouraging job to say the least. I will be back at it tomorrow (day 4). WTF!

I have to back the trans off again because I can't get the long bolts for the input shaft in. No damn clearance.

I have reconsidered helping my friend with hers now. Too much stress and frustration with out a lift.

I just hope once I get everything bolted back together that everything works fine and I don't have any leaks.

Thanks again to all the advice on this real PAIN IN THE ASS job.

Peace
1985 Tercel 4wd SR5 Wagon, WEBER Carb, Brown (TURTCEL)
1988 Corolla DLX All-Trac Wagon, 4 speed AT, Silver (Wife's new car)
1993 Ford Escort Wagon LX, 5 Speed, Smurf Blue (Smurfette)...selling

User avatar
marlinh
Highest Ranking Member
Posts: 1530
Joined: Sun Apr 08, 2012 9:15 am
My tercel:: 'Everett' Blue mint 4WD wagon and 'Rocky' 86 4WD Wagon
Location: Kootenays

Re: Manual Transmission Removal and Re-Installation

Post by marlinh » Thu Mar 07, 2013 7:27 pm

Don't back off the trans. Lower the trans mount and it will hang low enough to get the bolts in.

TURTCEL
Highest Ranking Member
Posts: 662
Joined: Mon Dec 10, 2012 11:42 am
My tercel:: 1985 4WD SR5 Wagon, Brown (TURTCEL)
Location: Everett, WA

Re: Manual Transmission Removal and Re-Installation

Post by TURTCEL » Thu Mar 07, 2013 7:37 pm

It is completely unbolted but I still don't have room. When my friend was here shaking the trans I was able to get them out but maybe now that I am solo it I might need help from a friend again.

Peace
1985 Tercel 4wd SR5 Wagon, WEBER Carb, Brown (TURTCEL)
1988 Corolla DLX All-Trac Wagon, 4 speed AT, Silver (Wife's new car)
1993 Ford Escort Wagon LX, 5 Speed, Smurf Blue (Smurfette)...selling

User avatar
rer233
Highest Ranking Member
Posts: 918
Joined: Sat Jan 01, 2011 1:49 pm
My tercel:: Multiple

Re: Manual Transmission Removal and Re-Installation

Post by rer233 » Thu Mar 07, 2013 8:04 pm

distributor hitting firewall??
if it aint there, there's a good chance it won't break!
83 SR5 Silver/Blue (Snowmobile/work beater)-totaled but drivable
85 SR5 Blue
88 SR5 White (the 'good' one)-not anymore-totaled
87 fwd silver wagon a/t
87 4wd dx Cream (a/t- not anymore- now m/t)

TURTCEL
Highest Ranking Member
Posts: 662
Joined: Mon Dec 10, 2012 11:42 am
My tercel:: 1985 4WD SR5 Wagon, Brown (TURTCEL)
Location: Everett, WA

Re: Manual Transmission Removal and Re-Installation

Post by TURTCEL » Thu Mar 07, 2013 8:26 pm

Nope, dizzy is out. The oil pan bottoms out on the rack and pinion so definitely all the way down. I just removed them earlier with a friend here but now i can't do it when I am solo. I think my headache is causing some of the issues. I am done for the night on the Terc...all will go right together tomorrow.

Peace
1985 Tercel 4wd SR5 Wagon, WEBER Carb, Brown (TURTCEL)
1988 Corolla DLX All-Trac Wagon, 4 speed AT, Silver (Wife's new car)
1993 Ford Escort Wagon LX, 5 Speed, Smurf Blue (Smurfette)...selling

xirdneh
Highest Ranking Member
Posts: 2023
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 » Thu Mar 07, 2013 9:10 pm

thats odd, i have always been able to get the bolts in with rear mount dropped and engine sitting on steering rack
Love those Tercell 4x4 wagons but they sure suffer from road noise.

TURTCEL
Highest Ranking Member
Posts: 662
Joined: Mon Dec 10, 2012 11:42 am
My tercel:: 1985 4WD SR5 Wagon, Brown (TURTCEL)
Location: Everett, WA

Re: Manual Transmission Removal and Re-Installation

Post by TURTCEL » Thu Mar 07, 2013 9:15 pm

Makes me think I am "special" since it sounds like I am the only one having a problem with this.

Peace
1985 Tercel 4wd SR5 Wagon, WEBER Carb, Brown (TURTCEL)
1988 Corolla DLX All-Trac Wagon, 4 speed AT, Silver (Wife's new car)
1993 Ford Escort Wagon LX, 5 Speed, Smurf Blue (Smurfette)...selling

User avatar
MorToy
Member
Posts: 49
Joined: Wed Aug 04, 2010 2:47 pm
My tercel:: 1983 4WD Wagon.. Added Inclinometer
Location: Eugene, OR

Re: Manual Transmission Removal and Re-Installation

Post by MorToy » Fri Mar 08, 2013 12:02 am

Smart taking dizzy out...I cracked the casing on mine man-handling the tranny and engine trying to get them to mate.

Pilot bearing: I think I tapped it in so it was pretty much flush. No issues afterwards. I went with gasket on pan, but have successfully used ultra black too.

Keep at it TURTCEL! Best part about this job, is saying you *did* it--past tense! For some unknown reason, my wife can't understand why I choose a hobby that will enrage me at times!

Home stretch.

Post Reply