86 transmission rebuild help

[overs10ded]

My 86 Tercel started popping out of first gear...suddenly-to the point of not able to use first! So I suspect a broken sincro ring. This is a FWD car however my question is generic for this trans. I've got the trans/differential out and am needing info on separating the trans from the mediary plate. The manual says use 10mm bolt against the 8mm bolt respectively situated in the four specified holes. I don't seem to have any 10mm bolts in my limited nut-n-bolt collection, what other ways can I separate this thing or what bolts can I "borrow" from else where on the car? Thanks for any help.

Good times!

Bruce

[Petros]

usually when it pops out of gear it means the main shaft bearings (teh front and back end of the main shaft) are so worn and sloppy that it allows the main shaft to shift forward enough so it pops out of gear. the shift fork that holds the gear slider is attached to the housing, when the gear cluster shifts forward becasue of the gear helix, it pops the slider (spline sleeve) out as if it was pulled out of gear. It needs to be rebuilt, but it is a major job. finding a wrecking yard trans is cheaper than buying a rebuild kit.

I do not recall needing a bolt to remove the main shaft, but I do recall there is a complicated sequence of parts to remove from both the front and back of the trans before you can pull that center plate out. You will need some specialized clip pliers and gear pullers too, half of the instructions in the FSM to dismantle the trans will not work. for example, you will never get the circlips off by holding two screw drivers on the ends and hitting them at teh same time with a mallot. YOu need to use some sturdy circlip pliers, and likely have to grind the tips so they will stay on the clip.

I would try and replace the trans rather than rebuild it, likely there are many other parts worn out of tolerance as well as the main shaft bearings.

[overs10ded]

Hey Petros, thanks for the information and advice. I'm looking!!! Meanwhile I'll tear this thing apart and see what damage I can do.

Good times!

Bruce

[overs10ded]

usually when it pops out of gear it means the main shaft bearings (teh front and back end of the main shaft) are so worn and sloppy that it allows the main shaft to shift forward enough so it pops out of gear. the shift fork that holds the gear slider is attached to the housing, when the gear cluster shifts forward becasue of the gear helix, it pops the slider (spline sleeve) out as if it was pulled out of gear. It needs to be rebuilt, but it is a major job. finding a wrecking yard trans is cheaper than buying a rebuild kit.

I do not recall needing a bolt to remove the main shaft, but I do recall there is a complicated sequence of parts to remove from both the front and back of the trans before you can pull that center plate out. You will need some specialized clip pliers and gear pullers too, half of the instructions in the FSM to dismantle the trans will not work. for example, you will never get the circlips off by holding two screw drivers on the ends and hitting them at teh same time with a mallot. YOu need to use some sturdy circlip pliers, and likely have to grind the tips so they will stay on the clip.

I would try and replace the trans rather than rebuild it, likely there are many other parts worn out of tolerance as well as the main shaft bearings.

So are there any other models that run the same transaxle? Or just the 82-86 Tercel Petros?

[Petros]

i think the first gen '80-82 tercel uses the same trans in the 2wd tercel. they look the same, there might be a different shift linkage but I would expect you can swap that over from the old tran.

[overs10ded]

Thanks Petros. Probably only 4spd too. Don't know when the 5spd came out. I'm still looking!

Good times!

Bruce

[dlb]

i think the 83-86 hatchbacks and 1st gens came in both a 4- and 5-spd manual, though i've only seen the 2wd wagon as a 5-spd manual. that's what i've noticed in ads for all of them.

[irowiki]

My 1st gen has a 5 speed manual, and isn't a SR5! A 4 speed manual was an option as well.

Good to know I have a wide range of replacements available if the tranny kicks the bucket!

[Petros]

I have seen both the first gen and second gen 2wd Tercels with "SR5" trim, that had the 5 speed, they may have been an option on the DLX trim line as well. I have also seen the 5 speed in the 2wd DLX wagons.

[ARCHINSTL]

The 4-speeds on Gen 2 were only on the stripper 2-door hatch.
Tom M.

[Petros]

stripper? you referring to this Toyota truck accessory?

[xirdneh]

i use needle nose pliers to knock off the C clips
put a rag or papertowel under C clip to catch it
put each end of needle nose on each end of C clip
tap end of pliers handle

[overs10ded]

Well I'm going to rebuild (repair only) the trans because I'm having a hard time finding one....that I want to spend $300 on. I'd rather spend that kind of money on a press! So I found a shop that will work with me. Two months is too damn long to have this thing torn apart!!

Good times!!

Bruce

[overs10ded]

I have got the thing back together and did it with simple tools. Replaced the bearing and all is good. Only had to pay a shop $20 to press bearing off and on. Good time for the new clutch too.

Thanks xirdneh and Petros for your help!!

Good times!!

Bruce