Transmission Repair Notes

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xirdneh
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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

Transmission Repair Notes

Post by xirdneh » Fri Jan 03, 2014 10:52 pm

Updated 12-24-2015
Tercel Z52F & Z54F 4WD Manual Transmission Notes
Early Tercel mfr date 1982 - Aug 1984, Late Tercel mfr date Sept 1984-1987
Trannys I checked and measured are model year 1987, 1983 & 1986
Use this info in conjunction with Factory Service Manual (FSM)
Due to the fact that bearings and other parts for these trannys are difficult to get I recommend saving broken trannys for parts in the future. Save the two wheel drive trannys too as many of the parts are interchangeable.
When you take a tranny apart take lots of pictures and follow FSM instructions or you will have a problem getting it apart. TA-25


Tranny Kit BK224WS (Petros found this for $541.00) has bearings, seals, gaskets and syncros. Kit does not have two bearings: KOYO 28NQ4020NRD in aft end of Main Case for Output Shaft and Bearing KOYO BTM1825A pressed in to Extension Housing for very aft end of Countershaft (see 3a and 5b below) . Does not have granny gear synchro. (Updated 04-29-2014)

Special Note 1: If you set the tranny in a vise like the FSM shows, watch out when re-assembling tranny. If you get carried away like me and start tightening the bolts between the Transmission Case and the Intermediate Plate the tranny will twist out of the vise and fall on the floor. I got lucky ‘cause it did not land on a shaft but it banged up the aluminum Intermediate Plate. It worked out fine but could have been bad.

1. Four different 83-88 Tercel 4wd trannys (that I have found so far):

X. 1983 all Shift Forks are steel and Idler Shaft forward end is small (.826” dia/21mm).

Y. 1986 Shift Forks are steel except two aluminum Forks at first/second gear Hub and fifth gear. Idler Shaft forward end is small (.826” dia/21mm).

Z. 1987 Shift Forks are steel except for three aluminum Forks at first/second gear Hub, third/fourth gear Hub and fifth gear. The #1(upper) and #2(mid) Shift Fork have gadgets on the forward ends and both shafts are longer than the X and Y trannys. Idler Shaft forward end is larger (1.182” dia/30mm). See Note 19

ZZ. 1987 Shift Forks are steel except for three aluminum Forks at first/second gear Hub, third/fourth gear Hub and fifth gear. Has shorter than above Shift Fork Shafts and no gadgets on end of shift shafts. Idler Shaft forward end is larger
(Updated 04-05-2014)

2. Early trannys have two Wire Plugs for Sensors. Later trannys have three Wire Plugs for Sensors. 4wd (small white plug on driver side) 7/8” or 22mm wrench, back-up lights (large white plug on passenger side) 1-1/16”or 27mm wrench, & extra low gear (black plug on top rear on Later trannys) 1-1/16”or 27mm wrench.

Special Note 2: When unbolting Transfer Adapter Case from Transmission Case there are two 12mm bolts inside, one 3-13/16” long and one 1-3/16” long. See 33e.

Special Note 3: How do you know if a bearing is bad? Sometimes it’s obvious like when it’s busted and other times it’s not so obvious. The roller bearing located at the top of the tranny (for Input Shaft) is the first to lose oil when the tranny is low on fluid. Examine the Input Shaft surface the bearing rides on, is it pitted, colored blue or grooved? If none of these things are there the bearing is probably good. When the Input Shaft is installed does it rotate quietly or is there noise? If you wiggle the installed Input Shaft how much does it move, it should not move much at all? If it is wobbly the bearing and the bearing surface on the shaft are probably bad. Recently I had a wobbly Input Shaft that was most likely caused by the missing Pilot bearing that is supposed to be in the end of the crankshaft, the Input Shaft needs that extra support. Bearings should be smooth and quiet when rotated. I have had some luck finding bearings for these trannys online and at local tranny shop. I have heard that kits with bearings are available and have been mentioned on tercel4wd.com. I have had local tranny shops examine bearings for me for free. Just make sure they do not have to disassemble anything. $$$

To find Bearings and Synchros Google the Toyota Part Number
To find part numbers use below
http://www.partsbase.org (use below to get to 6 speed tranny)
http://www.partsbase.org/toyota/tercel- ... -gear-mtm/ (this is the best site for finding Toyota part numbers)

http://quickparter.com/oem-parts/ (find parts from here to Japan)

Conicelli http://www.conicellitoyota.com/index.htm http://toyotapartsestore.com/ (good place to get parts)

http://partsfactory.camelbacktoyota.com/oe-toyota/

Villagetoyota.com
Note: synchros are not available
(Updated 12-20-2015)

1 800 409 3632 “Locate Ball Bearings” for bearings B25-145 NSK (received NSK B25-145 C4 SDRS) $29.00, 32RT06S3LRN C3 NACHI $39.50 (LRN means groove and snap ring) KOYO, 6306NR $28.23, KOYO RNU070614 59.00, All above + 9.95 shipping. 6306N from Amazon.com $27.50 (includes shipping and tax) 6306N has no shields but that’s OK.
KOYO RNU070614 available at Silverdale Transmission $17.50 (part #184) (thru alltransmission.com Portland Ore $29.25 1-800-345-7500) . N/O …..Not Available (Updated 03-31-2014)

3. Bearing on AFT end of Input Shaft is same as forward bearing on front end of Output Shaft 25BC544JN NACHI, B25-145 NSK .9845” ID x 2.479” OD x .689” Thk. Has groove for 2.375” ID x .066” Thk snap ring. 25mm x 63mm x 17.5mm. Toyota part No. 90363-25015 & 16. Snap ring 90520-59002 “Available” (Updated 04-08-2014)

3a. Bearing in aft end of Main Case for Output Shaft is KOYO 28NQ4020NRD 1.1012” ID x 1.573” OD x .7843 THK, 28mm x 40mm x 20mm. Has groove for snap ring. Toyota part No. 90369-28002 “Radial Cylindrical Roller” abt $40.00 (Updated 04-08-2014)

4. Input Shaft Roller Bearing info. This Bearing is inside the tyranny pressed into the Intermediate Plate. Approx 1.339” ID x 2.282”OD x .549” or .510” Thk.
It is located at the highest point in the tranny subject to wear first, if oil level is too low.
KOYO RNU070614 Toyota part # 90365-34003 34mm 58mm 14mm recess .03mm
KOYO RNU0713 N/O Unknown 34mm 58mm 13mm .02mm
NSK VP34-2 N/O 90363-25025 34mm 58mm 14mm .03mm
NSK VP34-1 N/O 90365-34003 & 01 34mm 58mm 13mm .02mm
They all have a recess cut around one outside edge (53mm dia) and it is used for a retainer (12mm bolt and small plate) to lock bearing in place. The 14mm Thk bearing protrudes aft far enough for the large Idler Gear to make contact and that is probably why the 13mm Thk bearing is used. The Idler Gear is unlikely to hit the bearing because the angled teeth force the Gear aft away from the bearing. I have not seen any sign of interaction on trannys with 14mm bearing. KOYO RNU070614 Available” (Updated 04-08-2014)

5. Bearing (roller) for forward end of Counter Shaft (pressed in Intermediate Plate) D8(or B)503004 NSK TORR, KOYO BTM3021A. 1.1805” ID x 1.497” OD x .916” Thk. 30mm x 38mm x 23mm Toyota part No. 90364-30003 “Drawn Cup Needle” (Updated 04-08-2014)

5a. Bearing near middle of Countershaft 32RT06S3LRN C3 NACHI 1.252” ID x 2.362” OD x .785” Thk. 32mm x 60mm x 20mm “Available” Toyota part No. 90365-32009 (Updated 04-08-2014)

5b. Bearing for aft end of Counter Shaft pressed in Transfer Case KOYO BTM1825A, IKO TA1825 , NSK-RHP FJL-1825 .706” ID x .985” OD x .98” THK. 18mm x 25mm x 25mm. “Drawn Cup Needle” “Available out of China and England” Toyota part No. 90364-18001. abt $21.00. Maybee BTM182520 would work, its just a bit shorter. b](Updated 04-08-2014)[/b]

5c. Bearing in aft end of TransAxle/Bell Housing for very front end of Counter Shaft is KOYO 20BTM2920 or DB501901.765” ID x 1.141” OD x .7825” THK, 19.5mm x 29mm x 20mm. “Drawn Cup Needle” ( Updated 04-29-2014)

6. Bearing on forward end of Idler Gear NACHI 6306NSL, NSK 6306N, NSK HR6306NX2, NSK 6306NR, GM 12334745, 2947761,907423, NISSAN 4321021050,43215A0150, RENAULT 23312714. 1.178” ID x 2.833” OD x .748 Thk. Has groove for 2.625” ID x .066 Thk snap ring. 30mm x 72mm x 19mm. Toyota part No. 90363-30019 & 45. This bearing is "Widely Available" 6306NR the NR means it has a groove and snap ring. Bearing can be with or without shields. I clamped the bearing in a vise so the Idler shaft was pointing up and set a dial indicator at the highest point (on the side) and wiggled the top end of the shaft. The range of the worst moved .045” and the best .020” (new bearing .010”). The one that moved .038” came out of a tranny that had a bad input shaft bearing (the roller in tranny) and the good one out of a tranny with only 130,000 miles on it. When I held the good one in my hands and tried to feel the movement it was hardly noticeable but the worst one was very noticeable. (Updated 04-08-2014)

6a. Bearing for aft end of Idler Gear and pressed into Main Case KOYO BTM2520A, HK2520, DAF 332532, SKF RHNA253220, KOMATSU 0612002520,1404313160, FAG DHK2520 .983” ID x 1.26” OD x .7833” THK, 25mm x 32mm x 20mm. This bearing is common and “Available” Toyota part No. 90364-18001 (4wd), 90364-25002(2wd) these are probably the same. “Drawn Cup Needle” (Updated 04-08-2014)

7. Bearing on forward end of Extention Housing Output Shaft NACHI 62/32 C4, NSK 62/32@2, NSK 62/32. 1.255” ID x 2.5575” OD x .6675” THK, 32mm x 65mm x 17mm. “Available” (Updated 03-31-2014)

Special Note 4: How do you know when a gear is bad? Look for chipped or missing teeth. Look at the color, is it blue from overheating (lack of oil). Look at the teeth, are there obvious shiny wear patterns, probably caused by gears that move back and forth on the shaft, they should be nearly (.0118")solidly located. A gear with a missing tooth may work for a long time if the tooth was broken due to a floating piece of metal in the tranny but it may whine a bit. If the tooth was lost due to wear or lack of oil other teeth might be ready to fall off too.

9. Gear Size for 1987 for 1983 1986
On Output Shaft listed forward to aft
*** Denotes difference
A. 5th gear 1.901” OD x 21 Teeth 1.901” OD x 21 Teeth
B. 4th gear 2.054” OD x 35 Teeth 2.052” OD x 35 Teeth
C. #2 Clutch Hub/Reverse gear 3.323” OD x 32 Teeth 3.26” OD x 32 Teeth***
D. 3rd gear 2.466” OD x 23 Teeth 2.462 OD x 23 Teeth
E. 2nd gear 2.869” OD x 28 Teeth 2.873” OD x 28 Teeth
F. 1st gear 3.354” OD x 33 Teeth 3.507” OD x 35 Teeth***
G. Extra Low gear 3.542” OD x 31 Teeth 3.47” OD x 30 Teeth***

10. Gear Size for 1987 for 1983 1986
On Counter Shaft listed forward to aft
H. 5th gear 2.785” OD x 32 Teeth 2.785” OD x 32 Teeth
I. 4th gear 2.596” OD x 44 Teeth 2.591 OD x 44 Teeth
J. 3rd gear 2.297” OD x 21 Teeth 2.297” OD x 21 Teeth
K. 2nd gear1.866” OD x 17 Teeth 1.866” OD x 17 Teeth
L. 1st gear 1.419” OD x 12 Teeth 1.38” OD x 12 Teeth***
M. Extra Low gear 1.155” OD x 8 Teeth 1.235-1.248” OD x 8 Teeth ***

11. Gear Size for 1987 for 1983 1986
On Idler Gear
N. 4.83” OD x 86 Teeth 4.83” OD x 86 Teeth
O. 2.078” OD x 18 Teeth 2.468” OD x 23 Teeth***

12. Gear Size for 1987 for 1983-1986
Reverse Idler Gear
The shaft this gear rides on is different between early and late trannys so Intermediate plate and main case are different due to shaft diameter
P. 3.005” OD x 28 Teeth 2.877” OD x 28 Teeth ***

1st gear ID 1.105” at shaft 0.000” OD, 2nd gear ID 1.417” at shaft 1.416” OD, 3rd gear ID 1.417” at shaft 1.415 OD, 4th gear ID 1.005 OD at shaft , 5th gear 1.104 or 1.161” ID depending on early vs late model .944 OD at shaft , countershaft behind 5th gear 1.108” OD.
1.4173 is 36mm, 1.005 is abt 25.5mm, .9449 is 24mm , 1.1084 is abt 28.006mm, 1.1024 ix 28mm, 1.161” is abt 29.5mm.
2nd and 3rd gear should be tight on shaft when new. Gear ID seems to wear before shaft when ran low on oil.
(Updated 12-24-2015)


13. Input Shaft Gear 2.045-2.05” OD x 35 Teeth (all years)

14. Extension Housing Gear 2.328” OD x 27 Teeth (all years)

15. Clutch Sleeves install with tapered side forward (except No 1 and 2 Clutch Sleeve bevel aft).The bevel is large on 5th, Extra Low and 4wd Clutch Sleeve and the bevel on #1 and #2 Clutch Sleeve is small. (Updated 03-11-2014)

Special Note 5: To get at the gears you will need a puller and snap ring remover. It is recommended that the snap rings not be re-used but getting new ones is next to impossible. The snap rings can distort when removed so you will have to reshape them. I use channel lock pliers to squeeze them back into shape. Measure the diameter of the groove on the shaft so you can reshape to that size. Install snap ring carefully using just enough force to get it on. After it is installed use channel locks to squeeze clip and tighten it up. Also there is a sheet metal plate that goes on last when installing 5th gear on Counter Shaft. The hole in the middle of that plate must clear the snap ring and it will not do that if snap ring is distorted. Shaft diameter for snap ring at 5th gear is .786” (20mm) and hole in metal plate is .97-1.005 dia. so OD of snap ring cannot exceed that. Shaft diameter on aft end of Output Shaft (4wd transfer) is .895 dia (23mm). (updated 01-16-2014)

16. “O” ring between Transaxle and Tranny 2.125” ID x 3/32” THK

17. Steel balls for Shaft Spacers and Speedo Drive Gear are .185” Dia.

18. Interlock Pin for Shift Fork No 4 shaft is .46” long x .22 Dia. This pin goes in the hole under the approx 3x3 four bolt Transmission Case Cover on top/rear of tranny. On top of the pin is a steel ball (.305 dia) and a metal sleeve (.853 long) with spring inside over ball.

19. Shift Fork Shafts lengths (all years are .512” Dia)
1987 1983 1986
#1 (upper) 13.125” Long #1 (upper) 12.187” Long
#2 (middle) 13.125” Long #2 (middle) 12.187” Long
#3 (lower) 15.65” Long #3 (lower) 15.65” Long

Special Note 6: Check the Shift Forks for excessive wear and check to see if they are bent. Shift Fork for 1st / 2nd and 5th Gears are Male. Shift Fork for 3rd/4th Gear is Female. Shift forks for early cars are cast steel and can be brazed with brass to fill worn area and shaped to original size. This is easy to do if fork is only worn on one side. Have had a local machinist repair 3rd/4th gear fork that was worn on both sides for $150.00. (updated 05-15-14)

20. Shift Fork at No 1 Clutch Hub and Sleeve is male (serves 1st and 2nd gears). Width of fork fingers is .297” for aluminum and .216” for steel.
Shift Fork No 1 Clutch Sleeve slot width: 1987 .307” 1983 & 1986 .218-.224”

Shift Fork at No 2 Clutch Hub and Sleeve is female (serves 3rd and 4th gears) Slot in fork is .210” for aluminum forks and .264-.268” for steel forks.
Shift Fork No 2 Clutch Sleeve protrusion width 1987 .197” (alum shift fork ) 1983 & 1986 .236-.253” (steel shift fork)

Shift Fork at No 3 Clutch Hub and Sleeve is male (serves 5th gear). Width of fork fingers is .294” for aluminum and .224” for steel.
Shift Fork No 3 Clutch Sleeve slot width: 1987 .306” 1983 & 1986 .232”

Shift Fork at No 4 Clutch Hub and Sleeve is male (serves Extra Low gear). Width of fork fingers is .266” steel.
Shift Fork No 4 Clutch Sleeve slot width: 1983 -1988 .272”

Shift Fork 4WD Clutch Hub and Sleeve is male (serves rear driveline). Width of fork fingers is .317” steel.
Shift Fork 4WD Clutch Sleeve slot width: 1983 -1988 .326”
(Updated 03-26-14)

21. No 1 Hub Clutch Sleeve info: 3.266 OD x .716” Thk (all years) (1 & 2 Gears)
No 2 Hub Clutch Sleeve info: 3.248-3.265 OD x 1.043” Thk (all years) (3,4 & Reverse )
No 3 Hub Clutch Sleeve info: 2.833 OD x .822” Thk (all years) ( 5th Gear)
No 4 Hub Clutch Sleeve info: 2.833 OD x .822” Thk (all years) (Extra Low Gear)
4x4 Hub Clutch Sleeve info: 2.875OD x 1.032” Thk (all years) (engage Driveline)
Clutch Sleeves install with tapered side forward (except No 1 and 2 Clutch Sleeve bevel aft).The bevel is large on 5th, Extra Low and 4wd Clutch Sleeve and the bevel on #1 and #2 Clutch Sleeve is small.(Updated 03-26-14)

22. Shift Fork Shaft ball bearings .31” Dia (8mm) w/spring .845 long x .31” dia. Under three plugs located on passenger side of tranny. I recommend using heat around the plugs (propane) so they will come out easily and not get damaged in the process. (6mm Allen wrench)

Special Note 7: If you should have to remove gears you will need to check the syncro rings. They are brass colored when cleaned up. Look for cracks, chips and missing or damaged teeth. The extra low 4wd gear syncro gets the least amount of wear so you can use it to compare. With oil on surfaces press syncro against bearing surface and twist it while pushing, it should not twist very far before stopping (gripping) if it slips for too long it is probably bad. Also check the gap, zero gap means totally worn ring. I have measures gaps of 0” to .032”. (Updated 02-06-14)

23. Interlock Pins for Shift Fork Shafts .582” long (top) .382” long (mid) .582” long (bot), all are .19 diameter.

Colonialseal.com or 856 432 0012 order by mm. “ A” means all rubber outside & SINGLE lip. AS is all rubber outside & Double lip.

24. Seal for Extension Housing Shift Shaft hole, Toyota Part # 90311-18013 is 8mm Thk, Timken 1015N does work but its 6mm Thk, Napa 6610 is 7mm thk. Hole in tranny 1.099” OD, shaft dia .709”18mm. Seal .6595” ID x 1.111” OD x .319” thk. Colonial Seal size A 18x28x8. (Updated 12-22-15)[/b

25. Output Seal for rear driveline: Orig equip # AH1904F, O’reilys 223252, Beck/Arnley #052-3899 SKF #12745. Hole in tranny 2.042” 52mm dia, Shaft dia 1.259” 32mm. Seal 1.184” ID x 2.055” OD x.432” thk. Colonial Seal size A or AS 32x52x11 (Updated 12-23-15)

26. Input Shaft Seal (top/front of tranny). Timken/Natl #222655, Hole in tranny 1.884” dia, dia of shaft 1.022”26mm. Seal .958” ID x 1.899” OD x ID.272” Thk. Colonial Seal size AS 26x48x7 (Updated 12-22-15)

27. 4wd Shift Lever Seal in Transfer Hsg. Timken 16x24x6, SKF 552505, ???O’reilys 221410???. Hole in tranny .938dia. Shaft dia .628”16mm. Seal .593” ID x .954 OD x .235 Thk. Colonial Seal A 16x24x7 (Updated 12-23-15)

28. If you have to press in any bearings I recommend first heating aluminum housing with propane torch to get hole to expand a bit. Keeping bearing in ice box will shrink it a bit. Be careful not to let bearing get cock-eyed as its being pressed in so alum housing does not get damaged.

29. When installing Main Housing to Intermediate Plate ensure the Shift Fork Shaft #3 (bottom) does not move. If it moves too much the reverse Idle Gear connection between Shift Fork Shaft #1 & 3 could get disconnected. Temporarily wire it in place. (Updated 01-21-14)

Special Note 8: For the Extension Housing remove the three 12mm bolts on the front and inspect the oil pump for excessive wear (grooves on outside of ring). Also check the Shift Shaft seal for damage or hardening. If you slide the Shift Shaft backwards into the seal, before putting tranny together, make sure it has some grip on the shaft. If the Extension Housing had a bunch of gear oil in the shifter area when you took it apart that would be a sure sign the seal was bad. Also before installing Ext Hsg, center the oil pump so it will engage with the pump thing on the end of the Counter Shaft. Shaft seal is available, see 24. (updated 01-17-14)

30. Restrict Pin (top/center of tranny) under 24mm plug and has spring 2.562 long x .362 dia. TA-26 (6.)

31. Those three small pieces of metal inside the Clutch Hubs that work with the Syncros are called Shifting Keys or Detents. They have two thin spring clips or small coil springs under them. The Detents for fifth gear are .73” long x .213” wide with number 53 on backside. Detents for 1st/2nd gear have number 51 on backside. (updated 03-26-14)

32. Allen Wrench for plugs 6mm (.237”).

33. Oil Pump drive shaft is “left handed” thread, its 17mm and I use an electric impact driver to get it off. Just make sure you pull the correct trigger. Clockwise to loosen and Counter Clockwise to tighten. (Updated 02-11-14)


34. Tranny holds 4.1 Quarts of Gear Oil SAE 90 or 80w-90 API GL-5. Some like to mix in a quart of Synthetic Gear Oil 75-90w. (Updated 02-11-14)

35.1983 FSM approx length of bolts:
a. Shifter Retainer plate on top of Extension Housing 12mm bolts six 3/4” long
b. Transmission Case Cover TA-25 (7.) 12mm bolts, three 25/32” long, one 1-11/64” long.
c. Extension Housing to Transfer Adapter Case TA-26(11.) 12mm bolts, nine 1-5/16” long.
e. Transfer Adapter Case to Transmission Case TA-27 (15.) 12mm bolts, three 3-13/16” long, six 1-11/64” long.
f. Bearing Retainer on front of tranny TA-47 (24.) 12mm bolts, three 5/8” long

36. Shift Lever Bushing (plastic cup) Toyota Part # 33548-16010. .705” Diameter to fit in shifter arm .708-.712” Dia. abt $6.00 each. (Updated 02-24-14)

36a. Shift Lever retainer snap ring is abt 2.1875” OD (Added 04-29-14)

37. The 6mm Allen plug on top of the Main Case had been a mystery to me. One day I was trying to install the Main Case and it would stop about 3/8” from where it needed to be and it felt like something soft and squishy was holding it back. I figured I had put too much gear oil in the bearing area for the aft end of the Idler Shaft so I tilted the tranny and let some drain out. Later it occurred to me that the plug might be a vent so next time I get that rubbery feel I will loosen the plug. Also think the plug could be for adding gear oil to that bearing after the tranny is put back together. It is at a high point and could get starved for oil. (added 01-19-14)

Special Note 9: When tranny is being moved around or being installed, be aware of the problem that can be caused if the No3 (lower) Shift Fork Shaft gets moved. The shaft sticks out the front of the tranny and has the 5th gear Shift Fork attached to it. If the tranny is in neutral or reverse the shaft can be moved towards the tranny about 3/8” and if it does get moved it will lock up the tranny making it impossible to shift. This problem can be corrected by pulling the shaft back out. If the tranny got installed in the car the rear tranny mount will have to be disconnected so tranny can be lowered enough to get at the 17mm Plug on the top right side of the tranny, located just in front of the 4 bolt cover plate (about 3” x 3” sq). 17mm Plug can be tight. Insert screwdriver in hole and push forward to move Reverse Idle Gear forward. Screwdriver will hit gear at 1.375” in and when pushed forward the distance will be 2.125”. Another way to prevent this is to put tranny in 1st, 2nd, 3rd, 4th or 5th gear before moving it around or installing it. Today I finished assembling a tranny and the shift shaft would not move forward enough to install the Select Lever (TA-53 58-1, I removed the 17mm Plug and pushed the gear forward. That fixed it. Note: this problem may not happen on 87-88 trannys.(updated 02-06-14)

Special Note 10: To get some of the “C” clips off I use a pair of needle nose pliers putting the tips on each end of the clip and tapping ends of the pliers handle. Be sure to put a paper towel or rag under the clip to catch it when it flies off. Some use two equal length screw drivers.

Special Note 11: The gaskets between housings usually are damaged when the tranny is disassembled. 1/64” thick gasket paper that is oil resistant is what I use. I glue the sheet to the flat end of housing (no protrusion alignment pins) and cut off excess. Tapping the hole areas with a ball-peen hammer will clear out the gasket for the bolt holes. Another option is not using a gasket but using silicone gasket compound. I have taken apart several trannys that had the red colored stuff.

Special Note 12: Installing the #1 Hub onto Output Shaft. Heat up the Hub till its just a bit to hot to hold and slide it on a cold shaft. It may slide right into place and shrink tight when it cools. It might need a little coaxing so having a short length of pipe to slide over the shaft will come in handy so you can tap it home. (added 02-11-2014)

Special Note 13: Cleaning Roller Bearings. I put the bearing in a sealable plastic container with a bit of gasoline and let it soak for a while. Then I gently move the container around to loosen up the oil and debris. Remove bearing and blow dry with air compresser. (added 01-16-2014)

Special Note 14: Clutch Hub Sleeves vary between years. The Sleeves for 1st / 2nd & 5th Gears have slots for the Shift Forks. The Sleeves for 3rd / 4th Gears have a protrusion for the Shift Fork. The Sleeve slot/protrusion for steel Shift Forks is different from the slot/protrusion for alum Shift Forks. Basically the slot/protrusion for steel is smaller than the slot/protrusion for alum. (added 01-20-14)

Special Note 15: Shift Fork Shafts and their connection to the Shifter Lever in the Transfer Case. In other words this is what moves when you shift gears.
Dogs on Shaft #1 (upper, usually painted white) #2 (middle, usually painted yellow) #3 (bottom, the big weird shaped one)
First Gear: The #1 Shift Fork Shaft is moved Aft
Second Gear: The #1 Shift Fork Shaft is moved Forward
Third Gear: The #2 Shift Fork Shaft is moved Aft
Fourth Gear: The #2 Shift Fork Shaft is moved Forward
Fifth Gear: The #3 Shift Fork Shaft is moved Down and Aft
Reverse Gear: The #3 Shift Fork Shaft is moved Down and Forward

The ends of the Shift Fork Shafts at front of front face of removed tranny.
Neutral Position : The #1 (top) & #2 (mid) are nearly flush #3 (bot) is protruding 3.5625” (or center of shift fork is 1.875 from face)
Movement of various Shafts while others STAY at Neutral position
First Gear: The #1 (top) Shift Fork Shaft is moved Aft (.32” from face)
Second Gear: The #1 (top) Shift Fork Shaft is moved Forward (.395” from face)
Third Gear: The #2 (mid) Shift Fork Shaft is moved Aft (.32” from face)
Fourth Gear: The #2 (mid) Shift Fork Shaft is moved Forward (.395” from face)
Fifth Gear: The #3 (bot) Shift Fork Shaft is moved Aft (Shaft protruding 3.1875”) (or center of shift fork is 1.437” from face)
Reverse Gear: The #3 (bot) Shift Fork Shaft is moved Forward (Shaft protruding 4”) (or center of shift fork is 2.25” from face)(Updated 02-24-14)

Special Note 16: When installing Output, Counter, Idler and Reverse shafts to Intermediate plate, heat up the plate so bearings slide in easier. (Added 03-09-14)

38. Synchro Info: Tercels 1979 thru 1988 have these Synchros
Synchro Ring measurements: for 1st and 2nd gear min 2.161ID, max 2.793OD (2.643 dia between tabs)
2.607 dia x .319 thick. Has 33 Teeth. Toy Part 33367-16060 or 16010
Synchro Ring measurements: for 3rd and 4th gear min 1.905ID, max 2.579OD (2.39 dia between tabs)
2.265 dia x .313 thick. Has 30 Teeth. Toy Part 33368-16020 or 16010
Synchro Ring measurements: for 5th and Extra Low gear min 1.681ID, max 2.329OD (2.133 dia between tabs)
2.025 dia x .315 thick. Has 27 Teeth. Toyota Part 33369-16010
http://partsfactory.camelbacktoyota.com ... 3336716060
“C” Spring for 1st and 2nd gear Synchro Toyota Part 33371-16010
“C” Spring for Extra Low gear Synchro Toyota Part 33391-16010
“C” Spring for 5th gear Synchro Toyota Part 33391-16010
(Updated 04-08-14)

39. Shift Pin for Extension Housing Toy Part 33280-16020 Note: this part gets rusty and plunger gets stuck in in or out position . To fix it, drill a 5/32” dia hole in center of head, insert a suitable pin or nail with point flattened in the hole and hammer the pluger out then hammer it back in doing this over and over with oil added till it is free. Plug hole with something. (Added 04-08-14)

40. Main Output Shaft is interchangeable between early and late years.
Countershaft is not interchangeable between early and late years. !st and Extra Low gears are slightly different in diameter.
The shaft the reverse idler gear rides on is different between early and late trannys so Intermediate plate and main case are different due to the different shaft diameters (Updated 12-24-15)

41. Oil Pump Rotor Outside Toyota Part 33468-16010, Oil Pump Rotor Inside Toyota Part 33467-16010. Oil Pump Toyota part No. 33405-16010. (Updated 04-08-14)

42. Not 100% sure on alum vs steel with the part numbers, this is my best guess, i am working on it
Ist & 2nd Gear Shift Fork (Aluminum)Toyota Part 33212-16011.
Ist & 2nd Gear Shift Fork (Steel)Toyota Part 33212-16010.
3rd & 4th Gear Shift Fork (Aluminum)Toyota Part 33213-16011 & 20.
3rd & 4th Gear Shift Fork (Steel)Toyota Part 33213-16010.
(Updated 04-08-14)

43. Thrust Bearing in front of 4th Gear Toyota Part 90374-30002 (Added 04-08-14)

44. Open Half Cage Needle Bearing under 4th Gear on Output shaft Toyota Part No 90364-25003 ( 2 required) . (Updated 04-08-14)

45. Thrust Bearing aft of 4th Gear Toyota Part 90374-29001 (Added 04-08-14)

47. Open Cage Needle Bearing under 1st Gear Toyota Part 90364-36001 (Added 04-08-14)

48. Open Cage Needle Bearing under 6thGear Toyota Part 90364-36001 (Added 04-08-14)

49. Open Half Cage Needle Bearing under 5thGear Toyota Part 90364-24003 & 24007 (need both parts) (Added 04-08-14)

50. Snap ring for 5th gear on Countershaft Toyota Part 90520-20015 Thru 20021 Various thickness 1.8-1.85, 1.85-1.9, 1.9-1.95, 1.95-2.0, 2.0-2.05, 2.05-2.10, 2.10-2.15mm. (Added 04-08-14)

51. Snap ring for 5th gear on Output Shaft Toyota Part 90520-23001 Thru 23003. Various thickness 2.45-2.5, 2.5-2.55, 2.55-2.60mm. (Added 04-08-14)

52. Speedo Gear Snap Ring on Output Shaft Toyota Part 90520-23008. (Added 04-08-14)

53. Speedo gear number of teeth. 20 on early, 22 on late models. (Added 09-29-14)

Special Note 17: If Input Shaft is pitted or grooved where inner roller bearing rides the tranny will be noisy. The test is to start the engine and let it idle. If there is noise coming from the transmission it could be the pilot bearing (in aft end of crankshaft), the throw-out bearing or the inner input shaft bearing. Push in the clutch. If the noise stops its probably the bearing. The pilot bearing would be noisy with clutch in or out. The throw-out bearing would be quiet until the clutch was pushed in. (Added 04-29-14)

Special Note 18: Can the Input Shaft bearing surface for the inner roller bearing be repaired? Yes it can, I had surface turned down to remove the pitting/groove and a hardened sleeve pressed over it and turned down to suit new bearing (abt 1.336 ). Done by local machinist for $88.00 Sleeve was 1.125 ID x 1.375 OD x 1.25 long and produces two sleeves. Roller Bearing size is 34mm 58mm 13 or 14mm (Updated 05-15-14)

YOUTUBE VIDEOS
"Toyota Tercel 4wd Manual Transmission Disassemble" http://www.youtube.com/watch?v=0wJ1QurZ-w4
"Toyota Tercel 4wd Manual Transmission Assemble" http://www.youtube.com/watch?v=TTGCFP7fCq8
https://www.youtube.com/watch?v=FtM4IqmoXUU "Tercel 4WD Manual Transmission (part 1) Output Shaft"
Taking the 1983-1988 Toyota Tercel Manual Transmission Output Shaft apart and putting it back together. Gears, Bearings, Synchros, Snap Rings, Shift Keys, Sliders
http://www.youtube.com/watch?v=Ta4KTrcfgtg "Tercel 4WD Manual Transmission (part 2) Countershaft"
https://www.youtube.com/watch?v=vhFGYj_xTuA "Tercel 4WD Manual Transmission (part 3) Input Shaft"
http://www.youtube.com/watch?v=mjYj6h0kBv4 "Tercel 4WD Manual Transmission (part 4) Idler Shaft"
https://www.youtube.com/watch?v=-YZz2iIEmy4 "Tercel 4WD Manual Transmission (part 5) Intermediate Plate Assy"
http://www.youtube.com/watch?v=Vj1H78QZgJA "Tercel 4WD Manual Transmission (part 6) Main Case Assy"
http://www.youtube.com/watch?v=BVeTzW3merk "Tercel 4WD Manual Transmission (part 7) Extension Housing"
http://www.youtube.com/watch?v=6OvzgtbKvfo "Tercel 4WD Manual Transmission(part 5th gear instal and final assy steps"
http://www.youtube.com/watch?v=YG68HLkyMq8 "Tercel 4WD Manual Transmission (part 9) 1. Shift Fork Information (good vs bad), Steel and Aluminum Forks. 2. Shift Fork Repair by Brazing. 3. Gasket Making. 4. Restrict Pin Inspection and Repair. 5. Bracket for installing tranny and how to use and build it.
https://www.youtube.com/watch?v=l7TwqUEFZtk (part 10) transaxle Remove and Install Bearing (KOYO 20BTM2920 or DB501901) for end of tranny counter shaft. Install Seals
Last edited by xirdneh on Fri Dec 25, 2015 12:24 am, edited 62 times in total.
Love those Tercell 4x4 wagons but they sure suffer from road noise.

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dlb
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My tercel:: none currently, 7 previous
Location: shawnigan lake, bc, canada

Re: Transmission Repair Notes

Post by dlb » Fri Jan 03, 2014 11:23 pm

super impressive. it's now a sticky. great work, rob.

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xirdneh
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Posts: 1683
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: Transmission Repair Notes

Post by xirdneh » Sat Jan 04, 2014 12:02 am

hopefully there are no major errors
i did manage to put a tranny back together this week
i have take quite a few apart but not put any together
it had a busted aluminum shift fork (3rd and 4th gear)
and a broken 5th gear hub
i had the spare parts
seems to shift Ok on the bench
Love those Tercell 4x4 wagons but they sure suffer from road noise.

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Gottolovem
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Posts: 1635
Joined: Fri Jun 29, 2012 4:28 pm
My tercel:: 1985 SR5 with snow plow,1987 auto 1984 parts car,1987 FX-16 GTS
Location: Reno

Re: Transmission Repair Notes

Post by Gottolovem » Sat Jan 04, 2014 10:10 am

That's all super info
Now I'm glad I have 4 or 5 trannys stuffed in the back of a parts car.

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xirdneh
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Posts: 1683
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: Transmission Repair Notes

Post by xirdneh » Fri Jan 17, 2014 10:27 pm

I have been updating (edit) this as I learn more about transmissions
if anyone has some comments or has something to add to this
please let me know
Love those Tercell 4x4 wagons but they sure suffer from road noise.

gnarnold
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Posts: 260
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My tercel:: 1983 SR5 4x4 with a tummy tuck and a nose job
Location: jordache ,ca

Re: Transmission Repair Notes

Post by gnarnold » Fri Sep 18, 2015 1:01 am

The front plate on the transaxle if I take off are springs and crap gonna come flying out that is where my problem is broken teeth on the gear or whatever it is that is visible from the fill hole behind cv hole
I used to laugh at the man with a pinto :lol: , until I became a humble servicer of a tercel :|

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Gottolovem
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Posts: 1635
Joined: Fri Jun 29, 2012 4:28 pm
My tercel:: 1985 SR5 with snow plow,1987 auto 1984 parts car,1987 FX-16 GTS
Location: Reno

Re: Transmission Repair Notes

Post by Gottolovem » Fri Sep 18, 2015 6:57 am

No flying springs watch the videos their great

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xirdneh
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Posts: 1683
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: Transmission Repair Notes

Post by xirdneh » Fri Sep 18, 2015 12:53 pm

gnarnold wrote:The front plate on the transaxle if I take off are springs and crap gonna come flying out that is where my problem is broken teeth on the gear or whatever it is that is visible from the fill hole behind cv hole
nothing but broken pieces will fall out when the front cover of the transaxle is removed
no springs in there
Love those Tercell 4x4 wagons but they sure suffer from road noise.

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helipilot77
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Joined: Tue May 03, 2016 9:03 pm
My tercel:: 1984 SR5 wagon
Location: Seattle, WA

Re: Transmission Repair Notes

Post by helipilot77 » Thu May 12, 2016 11:46 am

If you need to replace your worn out shifter seat Marlin Crawler offers a urethane replacement.

Image

It can be found here:

https://www.marlincrawler.com/transmiss ... duty-seats

The white one is the one that fits our cars, part number MCTM-522
They also offer a urethane shift lever socket bushing available here:

https://www.marlincrawler.com/transmiss ... ty-sockets

They also offer the shifter boot

https://www.marlincrawler.com/transmiss ... ndle-boots

*edit*
I tried fitting all my shifter parts today and they were both too big. I'll have to see if they offer a smaller version that fits our transmissions.

*update*
The blue seat used for transfer case shifters is a perfect fit! I have been using one for awhile now and it shifts so tight and precisely. This is a great, cheap upgrade.
. / TOYOTA
./_| |/|/ |]

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