R154 synchro replacement

[EldarO]

hey all,

my second gear synchro is sad, and my fourth gear has been known to make some monkey noises from time to time, in protest of going in.

so im contemplating removing the box, replacing the synchros, and whacking it back in.

hoping to do it before the gears are too far gone.

now, ive got some simple questions for people that have done stuff like this...

- approximate costs
- stuff that i should do while ive got the box apart (replace all synchros? buy/machine up a solid thrust washer?)
- any tips and tricks to help
and lastly,
- approximate time involved? a day, weekend, two weekend job?

thanks all!

Elmo.

[blacktop]

Hey,

I'm thinking about doing the same with my T50, i don't know if this will help but it shed some light on a few things for me.

Its for a Porscha but still gave me some good info.

http://home.san.rr.com/pb914/rebuild/

[Jonny Rochester]

Getting the gearbox onto your bench and removing the bellhousing and front seal section is easy. You have to remove a circlip or 2 on the front bearings. Then try and remove the alloy casings. You have to wiggle the shifter housing to get it off, but still easy. Then You should be left with just the shafts, gears, shift linkages all mounted on the sandwich plate. You can hold the sandwich plate in the vice. Inspect, and change gears so you understand what gear is what.

It gets harder now.

Remove the rolled pins in the shift linkages with a punch. Remove the detent springs and balls in the sandwich plate, remove all shift linkages. Now you are just left with the shafts and gears. The input shaft will be seperate on the bench now.

Now it gets hard. You probably want to remove reverse gears and 5th maybe. You will start to need pullers. You need a puller kit, maybe a few. If you are at home, chances are you need a puller you havn't got. And if you try to use what you got you may chip a tooth. Oh well, shit happens. It gets harder from here on, Ill leave you to it.

Parts:
Toyota Seal Packing, Red (just a tube of silicon will do)
front seal, rear seal
syncros of your choice
gears you chip

I havn't bothered with thrust washers and stuff. The manual will tell you to measure this and that and get different width circlips and stuff. I havn't done that too much, just put it back together with new bearings.

[JZA70 R]

wow +rep.

You just made me never want to pull my gb apart!

[Big rob]

http://www.marlincrawler.com/htm/tra...ansmission.htm

[2jzhilux]

i would rip out the gearbox and take it to a gearbox specialist unless you are really confident in rebuilding it
it sucks getting it all together and putting it in to find out you fucked something up and have to rip out the box again
well worth the 500 dollars or so they will charge you to rebuild it
while it was out i would replace all bearings all syncros and inspect all the gears for pitting/wear on the bearing surfaces and replace the ones that dont look any good
check the all the shafts for wear
also i have heard about a thicker 1st gear thrust washer but dont know what is involved maybe just reducing the thrust clearance of first gear

[EldarO]

ive got the supra TSRM for the R154, i was planning to print it out and have it next to me on the bench, but now that ive heard a proper account of it, and not just the TSRM instructions, im thinking i might get a quote, then get them to do it unless its some stupid amount of money.

AFAIK the gears are fine, so they wont need replacing (unless i break them) just the synchros, speaking of, should i replace them all while the box is apart? are they one of those "cheap parts" that should be replaced while its all apart?

i was thinking the thrust washer too, although i have nfi what or how it does what it does, but ive heard its a weaker point of the R154, thought i might as well replace it while its all apart.

main reason im asking is that ive got a daily now (after i fix it) so i can afford to have the supra off the road while im doing it all.

tanks everyone who replied

Elmo.

[Jonny Rochester]

Yeah, the R154 is a serious gearbox, big and expensive. I would not rebuild one unless in a workshop with a big press and a selection of pullers. (And a large hammer). I think some of these have double syncros as well? Which are a puzzle to get back together. I love those tricky puzzles, one area where experience does not always play a part, and I can outsmart the forman.

[EldarO]

hehhehhe, glad its a past time of yours, puzzles and all, did ya want me to ship you over a puzzle with a few extra bits you gotta find a home for?

Elmo.

[2jzhilux]

haha puzzle never though of it that way
if you do it eldaro and get stuck i could help you out