Rebuilding The Gearbox...

[Jimlad]

Ok... I read a topic over on imoc where a guy with the help of his freind has just rebuilt his gearbox.

With my gearbox it's 5th gear which has gone which he says is actually the first gear you come to when opening the box, and doesn't seem to think it would be too hard a job to do.

Anyone got any experience with this sorta thing?

Basically I've lost 5th gear and when driving the box makes alot of noise now, assumingly it's because parts of 5th gear are flaoting around in the box.

Would it simply be a case of replacing 5th (where would I get the parts) and also making sure the box is clear from debris etc?

thanks for any help.

[Jimlad]

Basically this is the conversation so far....

defo seems possible to fix....

IMOC gearbox thread

Some PM's I received from the very helpfull Mark Edwards.

" 5th is easy to change, just take of the end of the casing and you'll see 2 cogs, one with a selector fork around it. I'm guessing either the fork is broken or the syncro hub that it goes around."

"Parts would have to be straight from toyota unless you have access to a spare box to nick bits from? The noise could be the gear running against the broken fork, but it could be anything TBH. Just have to take the casing apart an see whats what really and go from there. "

[Roytoner]

Just had a look on the Disc I sent you and there are at least 2 tools you need to get hold off.

[Jimlad]

yeah I was looking at that too... what the heck are those tools ?? ... lol.

[Roytoner]

Top one is used to find out if things are running true i.e. as here the gap on the thurst washer, the second is a puller to get the gear off.

[JappyBeast]

Goto a garage!

[newtomymr2]

I'm gonna sort of hijack your thread here Jim sorry , but have you considered any other options, i.e. are there any other boxes that will fit the 2? It just seems that the standard box is pretty week

or does anybody else know of any other options for the 2?

I'm sure mine is on its way out, bit clunky at times, crunching into 4th at speed etc etc

[Jimlad]

never heard of any other options. I suppose you could go with something like a HKS 6 speed box or a custom made box, but both would be stupidly expensive.

[dawesy]

ive completely stripped and rebuilt one of these boxes (and im doing another one) first one was to patch up the 3rd gear synchro with bits salvageable from another box that had blown the 3rd gear sync ring. it can be done without too many specialist tools. a dial guage and magnetic stand are availiable from machine mart as are a set of gear pullers (not to be confused with two or three leg pullers) the hardest bit is getting the countersunk torx screws that hold the bearing plate on out as they are very tight and are threadlocked!!

IMHO it would be better to strip the whole box than to just replace the 5th gear as a lo of swarf will be floating around in side. i do have a complete 5th gear set availiable if needed, let me know

if you want a stronger box then go for a rev 3 box. these are the same as the ST-205 GTfour and fensport are currently putting aver 650bhp and 500lbft through them quite reliably

[newtomymr2]

Any mods required to fit a REV3 box to a REV2 ?

[Stef Derner]

If you have trouble with threadlock, heat it up. One of those paint stripper guns is useful to raise the temperature to around 100 degrees C and the screws will fly out. Just apply the heat and keep trying the screw until it comes out.

[Jimlad]

ive completely stripped and rebuilt one of these boxes (and im doing another one) first one was to patch up the 3rd gear synchro with bits salvageable from another box that had blown the 3rd gear sync ring. it can be done without too many specialist tools. a dial guage and magnetic stand are availiable from machine mart as are a set of gear pullers (not to be confused with two or three leg pullers) the hardest bit is getting the countersunk torx screws that hold the bearing plate on out as they are very tight and are threadlocked!!

IMHO it would be better to strip the whole box than to just replace the 5th gear as a lo of swarf will be floating around in side. i do have a complete 5th gear set availiable if needed, let me know

if you want a stronger box then go for a rev 3 box. these are the same as the ST-205 GTfour and fensport are currently putting aver 650bhp and 500lbft through them quite reliably

←

a rev3 box eh ?? I thought the box on all revision mr2s were weak?

What would you be looking for for the 5th gear set?? Obviously the box would need to be openened to see exactly what's what.