Hello all

[drege]

Well after some trail and error I got the 'good' tranny prepped for installation - I made some kinds of mechanical blunder when I had shifted it in to an unknown gear prior to mating it to the differential and when the sealant set and I went to play with the gears I noticed it was stuck in gear, 5th to be exact, seems if you manualy put the gearset into final drive at the meeting point of the dif the shifter shaft does not come with it and locks the gearset into final drive with out the control shaft in its proper place, so I cracked the case open again and reset/insured all gears were attainable from the shift shaft and cleaned my mating surface and reassembled the drivetrain.
The second go it shifts perfectly so I packed the shift shaft housing with hi temp grease and RTV'd the cover and set it in place. Tomarrow my galon of 80/90 lucas comes from the oriley's warehouse and I'll wrestle this thing back in.

As for the tranny that came out of mine, the first thing I noticed is that it had a rattle, and sure enough in the main gearset chamber there was a little bolt setting out in the open, judging from the flared base and size (10mm) it is the same as what I can see from the gearset side of the differential, just in front of the final drive assembly, though mine is not missing any, it must be from deeper inside the transmission, surely it has nothing to do with 3rd & 4th but it most likely explains why it stuck in gear.
When I crack it open I'll find many interesting things to share.

also my clutch looked like it had some life left in it so I degreased it and the pressure plates and reinstalled.

loose bolt

[Petros]

the clutch looks good, I would reuse it. the distance from the surface to the top of the rivet is the amount of life you have in it. odd a bolt will come loose after all those miles. I have had similar things happen, it always spooks me that smething else caused it come loose.

[drege]

That was the easiest tranny reinstallation I have ever seen, I flipped a coin in my head weather or not to try with the input shaft in, but since I had not sealed it with gasket in a tube yet I decided to do it without, two bolts in and I was able to let it all hang and get the input shaft in and the long bolts after cleaning the surface and applying my gasket in a tube.
greased the CV's and "propeller shaft" banged everything into place, filled it up with 80/90, fired it up and the wheels spun telling me that the oil was cycling in the gearbox. Slowly tried all 5 and reverse, no grinding, no chattering from clutch (still up on blocks as I'm exhausted.
Tomorrow I'll try it out on pavement.
Thank you so much Goddolovem!

[drege]

Out to lunch with the wife, no plans of that at first at first we were just going to road test the Terc. 2nd meshes a little catchy but with ample clutch time it's lessened.
All gears cycle and the gearbox is quiet as a lamb.
Though I fear I may have over tightened the steering knuckles as the label on my torque wrench has worn off and I had to just guess.

[dlb]

every tercel i have owned has had worn synchros in the trans. same with my ae95 corolla that i currently drive. i've learned to adjust my driving to each one and live with it, although i will try synthetic gear oil the next time i change it in the corolla.

[irowiki]

The 5050 atf flush tend to help the synchros.

[drege]

I did straight 80/90 in it. 1 gallon lucas HD gear oil, could have sworn that there was a 1.1 gallon situation and poured a couple ounces of the old gear oil from my tranny in too on top of the new stuff, sieved and filtered, so it could be slightly overfull, but I fully expect leakage somewhere during break in period.

[drege]

I wonder if maybe that loose "screw" that was in the gearbox was the root cause of the 3rd/4th issue, seeing this post https://tercel4wd.com/forums/viewtopic.php?p=79333#p79333 it seems plausible in the wake of my OE transmissions problem and Goddolovem's recent problem, I wonder if maybe my 3rd/4th gearset bolt was loose for so long that the gearset wasn't able to entirely pull itself onto the drove gear.
When I have a better allen wrench set I'll pull it apart and report back what I have found, maybe a chance that one aint a parts tranny.

[xirdneh]

taking the tranny apart only requires one allen wrench, a 6mm
if you heat the alum around the allen plug with a propane torch it will break free easier and less likely to twist out the recess for wrench

[drege]

Hell thats gonna have to wait though, Everywhere I go I leave a 1/4 oz of gear oil under my dif, I suspect the input shaft oil seal or cover plate - now I DID overfill the gearbox, but by my calculation I only get about another puddle before I'm actually loosing 80/90 4.1 quarts? I put 1 gallon and about a 1/4 quart of triple filtered old gear oil from old tranny, though it could be coming from a CV oil seal, it looks like its coming from higher up on/in/around the tranny up near the bellhousing.
The trans I put in, had a beat up main input oil seal, I carefully pried mine out witch had a good lip, and installed it in the donor tranny, but I applied the gasket in a tube while under the car, upside down and backwards and immediately torqued the bolts in, Where is the likely spot that the gear oil is coming from?
It only happens after 15+ minutes of driving, long after the gearbox is warm enough for 2nd to stop biting, leaves a neat little 3 1/2 inch stain right under the dif.
Also my CV's are popping, but I'll worry about them after they blow out, I'll still have a rear end to get home with.

[xirdneh]

i would wipe everything down
drive till warm and crawl back under for an inspection
could only be rear main seal related, input seal (i would never trust a removed & reused one), gasket between bell and tranny, drive shaft seals or loose plug or screw on tranny
if its coming out of the space where bell bolts to engine i would say odds are that input seal is the problem
otherwise it would be rear main related.
i have yet to have a rear main seal leak but i have had the gasket between the rear main seal plate and engine disintegrate

[drege]

Rear main like the motor?
If thats what you mean I'm 199% positive its 80/90, its got that weird gear oil smell/viscosity.
Really? Don't trust a reused oil seal? I can see if it's brittle/hairline cracking, but it was healthy, if it is that one I would suspect that it probably should have gotten a coating of gasket in a tube on its outer circumference before I stuffed it in the bell - cause like we alwase pull our CV axels but do we alwase replace the seals? Probably should . . .
I have to go to casa de insurance tomorrow, hope I can remember to wipe it down and park it on a curb to get a real good look at it.

[dlb]

ditto for never reusing an oil seal, removing them deforms them so they won't sit square again.

[Petros]

if the seal is still soft and pliable and undamaged, there is no reason to remove them either. I have left cv axles seals and rear axle seals, as well as the engine seals in place when I pulled the axles out, and than carefully installed the new one.

I have even reused seals when I did not have one handy. You just have to carefully remove them without distortion. Not easy to do, but I did it on a good seal, used Permatex to "glue" it into place in the new part. never leaked. I had a part in the garage with a good seal already installed in it, but needed a seal on my car (front main I think it was). So I carefully pushed the new out of a new oil pump that I had in the box, and installed it in my car.

If it is not damaged, it can be reused.

[drege]

What about some additive? some sort of manual transmission stop leak 'magic potion'
I'm more positive that its leaking from up inside the bell, I feel that its getting harder to shift - but I'm paranoid to autochondria.