Rev 3 Turbo Gearbox rebuild

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MR2madlad
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Rev 3 Turbo Gearbox rebuild

Post by MR2madlad » 29/05/18 22:30

Hi fellow MR 2 owners
New to the forums but have owned my mr2 turbo for 16 years racking up 130K miles on her.
I am after some help with regards to gearbox rebuild, I'm planning to have a go and do it myself as 1st and 2nd gear are a real pain to select, even worse when hot, wondering if selector folk if bent or something??
Things I have checked / changed so far, new master and slave cylinder, (slave the spring inside was in 5 bits) bled right through, new gear linkage bushes (solid brass I made at work) and on the actual gearbox there is an arm that swivels and slides with a almost cube block of metal with hole in it that a circular pin sits in this was worn from square 1/4 diagonal, made new one at work during work tut tut !
All did improve it slightly as did the MT-90 gear oil but its never really gone away and always been an issue.
Anyway I have dropped the lot, done a complete engine strip down and rebuild with new parts and gaskets, seals etc as water pump housing to block seal was leaking and clutch slipping + cambelt was overdue for a change, engine is all clean inside and out, painted, new hoses from hell, turbo technics are working on the turbo but engine is ready to go back in so now I though I would tackle the gearbox while I wait for some parts to come in / back.
Anyone have any tips or tricks on how to service the E153 box ? i've stripped most of the bolts off the outer casing and 5th gear cover but can't shift the cover its stuck on tight, resorted to the precision realignment tool (big hammer) in a few safe places with chisel but it won't shift, don't want to damage it so thinking of using my gas torch to warm it up and see if this will help?????
Is there a BGB on the E153 or anyone done a rebuild and have the part numbers and know if Toyota UK even supply the syncros, gears etc.
I have contacted 5 gearbox rebuild people but they never reply or phone back so they obviously either are really busy or this box is a right pain in the butt.

Not wanting to find a replacement used box as its probably worn so would prefer to rebuild it myself as then I know its good (or should be if put back together right)
Thanks
John



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abovetherim
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Re: Rev 3 Turbo Gearbox rebuild

Post by abovetherim » 29/05/18 23:26

If you know how to rebuild a box and have the specific tools for the Toyota box then go for it.
Paul Woods is the man with the knowledge.

If it were me I would just ship it to him and have him do the rebuild and extended 5th gear mod.
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Re: Rev 3 Turbo Gearbox rebuild

Post by notroubleclubber » 30/05/18 8:26

Where are u based?
I know tes transmissions in westbury wiltshire will do it as i had a quote from them myself....

Wasnt cheap though


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Re: Rev 3 Turbo Gearbox rebuild

Post by MR2madlad » 30/05/18 20:58

Hi

Thanks for the reply's thus far.

Got the covers off, heat worked wonders got 5th gear off made a tool at work again, the countersunk torx bots were a pain thou as was the output shaft lock nut.

There is a lot of very very very fine brass bits in there, gonna go to mr Toyota and see what they can still get, if they can't source the parts, I'll stick it back together (nothing ells touched apart from covers off & 5th) and possibly contact Paul who was mentioned.

I'm in Burgess Hill, West Sussex.

Lets see what happens, does not look to be a complicated rebuild, will need to buy a low force torque wrench for the preload and maybe a puller, parts are gonna be the issue I thinks

Not sure how to upload photos, am I able to?

Thanks

John


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Re: Rev 3 Turbo Gearbox rebuild

Post by rgb » 30/05/18 22:06

I had mine fully rebuilt for 1700 quid . everyone recons I got ripped of but that's the price genuine Toyota parts and a specialist .make you own mind up.


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Re: Rev 3 Turbo Gearbox rebuild

Post by MR2madlad » 12/06/18 22:40

Hi everybody

Got the box totally stripped down to component parts except dif, pretty easy with a decent puller.

Ordered all the bits I think need replacing from Toyota, gonna cost a kidney - 20% discount.

Just washed the whole lot in dishwasher, came up lovely, got rid of all the horrible grey black residue all over the inside, cleaned oil pump and pipes etc

Been wire brushing the ali castings with stainless steel wire brushes and scotchbright to remove as mush of the ali oxide as possible, been hell but finally its back to shiny metal ready for quick rub over with fine pad and wipe then spray paint.

Waiting for the bits to arrive from Japan at end of month.

Will reply with my progress once all the bits arrive.

Cheers


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Re: Rev 3 Turbo Gearbox rebuild

Post by MR2madlad » 12/09/18 20:10

Hi

Been a long time but I did manage to rebuild my E153 box successfully, all new syncho rings and all obtainable from Toyota, 2nd and 3rd come as a 3 peice set and do cost a bit, 5th / reverse can buy the bits individually.

I had an accident with 4th driven and 2nd gear pressing it off (broke several teath) so had to get 2 new gears, toyota stocked these at £140 for 4th driven and £200 odd for second but they gave me a date of a month, i waited a month, they never arrived, they gave me another date but that was 6 weeks away and I really needed car rebuilt and out of garage.

After alot of research i found 90% of the 1995 Celica ST205 E154F box uses same parts, input shaft 1st gear driven and -1st gear are differant ratio the rest are identical, picked up a good low milage uses box and stripped it for the 2 gears for less than the price of new ones from toyota and have sold alot of the remaining good parts on the well known auction site so effectively selling the parts has paid for 1/3 of the rebuild.

I also weighed the ali castings in for scrap so got money back on scrap ali.

Sold all the syncho rings as they had minimal wear, in fact had i not of ordered and fitted new ones I would of happily used the used ones out of the Celica box as they were near mint (with minor de-burring) when compaired to new.

Gears went back on easy as pie when stuck in oven for 10 mins at 150°c tapped down nicely with wooden block and hammer.

Gearbox is fantastic, all gears shift smoth and positive and after removing and using the Celica diff bearings its lovely and quiet.

Was well worth the effort and saved me alot on rebuild by a company.

Just thought I would let you know it was sucessfull, looks brilliant all painted up, even cleaned and painted the bolts gloss black.

Just use a good hydraulic press and supports and it will go fine.


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Re: Rev 3 Turbo Gearbox rebuild

Post by Snorkie » 12/09/18 21:14

Its very impressive to see some one who can rebuild a engine and gearbox these days, but what is more
impressive is how you are allowed to put gearbox parts in the dish washer and oven?.

Do you have any pics of the casings after they came out the dish washer.

Are you married? and if so does she know what you did.

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Re: Rev 3 Turbo Gearbox rebuild

Post by MR2Jay » 12/09/18 21:59

Fair play - can't say I'd like to tackle a gearbox rebuild myself :blink:

I tip my hat sir :th:
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Re: Rev 3 Turbo Gearbox rebuild

Post by MR2madlad » 11/08/19 21:28

Snorkie wrote:
12/09/18 21:14
Its very impressive to see some one who can rebuild a engine and gearbox these days, but what is more
impressive is how you are allowed to put gearbox parts in the dish washer and oven?.

Do you have any pics of the casings after they came out the dish washer.

Are you married? and if so does she know what you did.
Hi Sorry for very late reply.

Am not married fortunately (girlfriend has own house but stays over mine a lot) so I can do what must be done when she is not here :laughing

Thanks for the compliments, I do have photos but how do you actually upload them to the forum, anyone help ?

Trick with Ali is to get it out as soon as dishwasher finishes and when dry and still warm (before oxide forms) get a good couple of coats of etch primer on it.

Its all still nice and clean at the moment, she hasn't got wet in rain since.

Cheers

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Re: Rev 3 Turbo Gearbox rebuild

Post by jimi » 12/08/19 1:46

MR2madlad wrote:
11/08/19 21:28

Thanks for the compliments, I do have photos but how do you actually upload them to the forum, anyone help ?


https://www.mr2oc.co.uk/forum/92/167439 ... 9#p1772660

https://www.mr2oc.co.uk/forum/92/165916.html
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Re: Rev 3 Turbo Gearbox rebuild

Post by MR2DI4 » 12/08/19 6:29

Dishwasher ? Just wait until you put your car parts that have been UHT painted into the oven to cure ! :laughing

I thought I could get away with it, those brake rotors look like pies.

Busted when she opened the oven door.........they really don't smell like pies.


Signed,

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Re: Rev 3 Turbo Gearbox rebuild

Post by jimi » 12/08/19 17:20

Great thread, be excellent if you can add some pictures. I'm sure other members will find this useful so I'll move this thread to MK2 Useful Info for now, it may end up in KY2 when/if I get time. :th:
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Re: Rev 3 Turbo Gearbox rebuild

Post by MR2madlad » 12/08/19 22:05

Hi All

These are some pictures of the E153 gearbox rebuild, I have more but not on this PC.

As you can see I got a bit involved.

Will add the others when I track them down.

Cheers

John
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