Manual Transmission Overhaul for Toyota W58

[agoodfriend]

completely empty housing ,,,,,,

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[helper_learner]

Another great diy...

BTW, no need no re-pack the transmission, you can use it like shown in picture

[agoodfriend]

checking some old parts which need to be changed ,,,,,,,,,, this is the 1st and 2nd gear hub sleeve ,,,,,,,, its badly worn and need to be changed ,,,,1st gear slips because of this ,,,,,, another thing i want to add here is that this is not the only reason of gear slip ,,,,,,, out put shaft main bearing play also a reason of gear slips ,,,, i am sure new will not be available so will search it from some old parts shop ,,,,,,,,,,

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[agoodfriend]

synchronizer rings,,,,,,,, 5 in total ,,,,,,almost all are gone ,,,,, they fail to lock the gears ,,,,most of them are touching the gears slimline end ,,,,,,,

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[agoodfriend]

output shaft main bearings ,,,,,,,,both have excessive play ,,,,,,, one has a broken ball cage ,,,,,, need to replace both,,,,,,,,,,

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[agoodfriend]

another worn out thing is this 1st and 2nd gear fork ,,,,, it move the hub sleeve on gears ,,,,,, this i belive is the main reason of 1st gear slips ,,,, second is the bearings and third is the hub sleeve ,,,,,,,,

[agoodfriend]

purchased some new parts ,,,,, synchronizer ring,,,,,,,,

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[agoodfriend]

bearings and seals ,,,,,,,,,

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[agoodfriend]

buy 1st and 2nd gear hub sleeve ,,,,,,,, remaining 2 will be reused ,,,,,,,,

[agoodfriend]

also replacing this gear lever,,,,,,,,, it was not its original lever ,,,,,,,

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[agoodfriend]

dont find this fork ,,,,,,,,, so i plan to remake this ,,,,,, aluminum weld on one side and carefully grind it with a file ,,,,,,,,

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[agoodfriend]

paper seals also not available,,,,,,,, so i have to make it from a sheet ,,,,,,,,

[agoodfriend]

started assembling,,,,,,,,, do check all synchronizer rings on gear,,,, check the braking effect of synchronizer rings ,,,,,,, also clean gear cone with sand paper ,,,, i use 320 grit to slightly coarse the cone area ,,,,,, also do check the clearance between synchronizer ring back and gear spline end ,,,,, as per manual it must be min 0.5mm ,,,,,,,

[agoodfriend]

these are synchronizer rings clutch hubs ,,,,,,

[agoodfriend]

counter shaft roller bearing,,,,,,,, i am not replacing them ,,,,,

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[agoodfriend]

out put shaft,,,,,,,, the first part which goes in is the second gear ,, followed by 2nd gear synchronizer ring , clutch hub hub sleeve as one unit , 1st gear synchronizer ring and then the 1st gear it self ,,,,,,,roller bearings goes in between the 2 gears ,,,,,,

[agoodfriend]

the next part is this main bearing,,,,, i have replaced this bearing ,,,,,, do not hammer it in ,,,, cone heater is needed to heat the bearing inner cone but unfortunately i dont have that ,,,,, i do have a hot plate but unfortunately did not find it at this time as it may be buried some where in home store,,, so i use an electric iron to heat the bearing ,,,,,, it will go on shaft without even pressing ,,,,, slide in on its own weight ,,,,,

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[agoodfriend]

next is the 3rd gear with synchronizer ring , clutch hub with hub sleeve ,,,,,,,,,,heat up the 3rd and 4th gear clutch hub and slide it in ,,,,,,,,also slide in the main bearing on input shaft , again heat it and slide in ,,,,,

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[agoodfriend]

fully assembled output shaft along with input shaft and counter shaft ,,,,,, all will slide in the main plate in same position and as one unit ,,,,,,,

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[agoodfriend]

input shaft , output shaft and counter shaft goes in the main plate ,,,,,,,, rear bearing retainer will lock the bearing on it snap ring ,,,,,,,,

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