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Location:
Sacramento, CA (USA)
Registered:
September 2004
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DIY: Transmission Rebuild *** No 56k ***
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Fri, 04 November 2005 19:28
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Brought this over from my club4ag post - though it'd be of interest for you guys.
Andrew
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Rebuilding (synchro's/bearings) t-50 toyota transmission.
Part #'s :
04331-14030 - Trans gasket kit (includes output shaft & input shaft seals)
90365-30020 BEARING, x 1 - Front - Input shaft bearing
90361-06047 ROLLER x 12 - Input/Output shaft roller/bearing
90363-25017 BEARING, x 1 - Rear - output shaft bearing
90369-30027 BEARING x 1 - Center - output shaft bearing
33365-14011 KEY, SYNC x 3 - 1/2 synchro hub keys
33368-20012 RING, SYN x 2 - 1/2 synchro's
33367-14010 RING, SYN x 2 - 3/4 synchro's
90365-30015 BEARING, x 1 - count shaft center bearing
More parts on the way
90365-20004 BEARING, x1 - front countershaft bearing
90365-20001 BEARING, x1 - rear countershaft bearing
33394-14010 KEY, 3&4 x3 3/4 synchro hub keys
33366-14010 KEY, 5&R x3 5/Rev synchro hub keys
33367-14010 RING, SYN x1 - 5th gear sychro
33363-14012 SLEEVE, T x1 - 1-2 shift collar/synchro hub
?????-????? x1 - 3-4 shift collar/synchro hub
90364-37002 BEARING, x2 - 1st & 2nd gear brgs
90364-37004 BEARING, x2 - reverse gear brgs
90364-27003 BEARING, x1 - 5th gear brg
Transmission pictures, steps and other useful info:
1. Transmission. (cleaned up, except for parts of the sr-5 bell housing which is going in the trash most likely)
2. Bell housing.
3. Bell housing removed: Pretty simple to do. Remove throw out bearing, clutch fork and intput shaft collar (4 - 12mm bolts inside bell housing). Then you simply unbolt the 7 (or maybe its  14mm bolts holding the bell housing onto the trans.
4. Extension housing.
5. Speedo gear removal/removed: Also relatively simple, but kind of delicate. Undo the 10mm bolt and remove the holding tab. Get some sort of penatrating lubricant (PB blaster in my case) and give a shot/drop where speedo gear goes into the Extension Housing. Get a flat tip screwdriver (med-large) and gently pry upwards while wiggling towards and away from the screw driver - be VERY careful as the aluminum housing for the speedo gear is pretty brittle/delicate and will chip if too much force used. Once it's part way out you won't be able to pry anymore, put the holding tab and bolt back in (facing away from speedo gear) and use it as a new pry point and continue. It'll come out - eventually.
Tip: if you have a spare speedo cable or a busted one its very easy to thread onto the end of the speedo gear and makes wiggling/tugging/removal much easier.
[Updated on: Mon, 14 November 2005 22:09]
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Fri, 04 November 2005 19:29
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6. Speedo gears and gt-s speedo gear p#
7. SR-5 speedo gear - note the #20 stamped on it, it's the # of teeth it has and determines how fast the cable spins - thereby how fast the speedo shows.
8. GT-S speedo gear - has a #19, spins the cable just a little slower. Since the differential ratio is lower in the gt-s than the sr-5 (ie more revolutions of motor required to make the vehicle move the same speed) it's necessary to install a different speedo gear to match the gt-s gearing.
9. Shift lever stops/pins: Remove both from extension housing, easy to do, weren't in there all that hard either. Just a quick tap with an open palm on a crescent wrench and they were loose and spun right out.
10. Reverse sensor: Remove, just use a 19mm deep socket. Behind/beneath the reverse sensor/switch is a ball bearing - remove it using a magnetic finger/wand/stick. (or flip the tranny over, it'll probably come out - just don't lose it!)
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Fri, 04 November 2005 19:29
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11. Remove extension housing: here's where the shifter stops/pins being removed helps, by rotating the shifter cup/bucket/intermediate shaft in the extension housing you can slide the extension housing back and off without much difficulty. (no need to knock out the spring pin/clip in the shifter socket/bucket and sliding the shaft out - too much work)
12. Remove shift shaft check ball's & springs: Roll transmission upside down, remove the two 10mm bolts and plate. The springs you can pick up with your fingers, but the check balls will be down lower and you'll need a magnetic finger/shaft to get them out (as with the reverse switch ball. you can flip it over - just don't lose them!).
13. Remove case half: Remove all 12mm bolts (11 total I think), tap case gently up and away from other half with a brass hammer or rubber mallet and it should come free.
14. Case removed - looks pretty cool, the input/output shaft and balance shaft will lift right out without having to do anything with the shift forks. Just remember, remove balance shaft first.
15. Case Cleaned.
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Fri, 04 November 2005 19:31
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16. Gears - input/output shaft & balance shaft removed.
17. 1st gear synchro
18. 2nd gear synchro. - see how the engagement is worn/damaged, I will probably replace this gear - and maybe the shift collar as well (if damaged)
19. 3rd gear synchro.
20. 4th gear synchro.
21. 5th gear synchro.
22. Reverse Gear - notice how chewed up the engagement for this gear is? That's because there is no synchronizer gear/ring for reverse and whoever drove on this trans before me was probably jamming it into reverse, possibly while still moving/rolling forward. But, since it is reverse, I'm not too worried about it and probably won't replace it.
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Fri, 04 November 2005 19:36
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29. Some of the parts needed have arrived. Of the bearings in the red boxes - only the three for the input/output shaft and the middle bearing (with dimple, for countershaft) have arrived, I will be ordering the two outer countershaft bearings.
30. Puller/Tool used to remove the outer bearings on the countershaft. On the front bearing the puller tool will slip right into the opening for the retaining bolt. So what I did was grab a spare stud from the side of a largeport block (the same studs that hold alt/ps/ac/motor mounts) and used that as a press point.
31. Front counter shaft bearing dissassembled (order of installation from left to right - washer/race goes down first, then bearing assy, then main bearing race - which is held in place by a bolt)
32. Front counter shaft bearing again - hopefully you can make out the part #, probably can pick 'em up aftermarket with a cross reference/guide.
33. Front counter shaft bearing again (shown in order of installation)
34. Rear counter shaft bearing. (order of installation - washer/race, bearing assy, main bearing race, then retaining c-clip)
35. Rear counter shaft bearing - part #.
36. Partially disassembled countershaft.
[Updated on: Fri, 04 November 2005 19:36]
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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I Supported Toymods
Location:
Sydney
Registered:
December 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 02:43
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Good work champ... most of us here are happy to pull down engines but there would only be a select few of us here that have ever pulled down a gearbox!
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Location:
tas
Registered:
June 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 02:58
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indeed thats excellent!
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Location:
Toronto, Downtown
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 03:06
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so true gearboxes are sooo complex im findind that the hard way atm..
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I supported Toymods
Location:
Frankston, Victoria
Registered:
April 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 04:32
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Amazing stuff man!! Good to see others sharing info for the greater Toyota modifying community 
Kev.
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I Supported Toymods
Location:
Sydney
Registered:
December 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 04:49
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| 4agte wrote on Sat, 05 November 2005 14:06 |
so true gearboxes are sooo complex im findind that the hard way atm..
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I think its the fact that the parts in a gearbox all look very similar that makes them look complex... mixing all the bits up could be a tragedy!
With an engine you can pretty much just chuck all the bits into a box and still know what goes where when it comes to putting it back together.
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Membership Secretary
Location:
Sydney
Registered:
June 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 06:58
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I am in total agree ance with Toobs I wopuld never pull down a box but have no issues what so ever doing an engine, having said that I have done some work on w58's and had them apart.
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 09:52
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| Toobs wrote on Sat, 05 November 2005 15:49 |
| 4agte wrote on Sat, 05 November 2005 14:06 |
so true gearboxes are sooo complex im findind that the hard way atm..
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I think its the fact that the parts in a gearbox all look very similar that makes them look complex... mixing all the bits up could be a tragedy!
With an engine you can pretty much just chuck all the bits into a box and still know what goes where when it comes to putting it back together.
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Definately that most of the parts look similar that makes it a little more complex - but it also has a LOT more moving parts than an engine does. I'm hoping this helps those that are considering tackling something like this in the future.
Also having it already laid out like this makes it seem a lot simpler, and you can always look at/reference the pictures if you mix up or confuse something.
I even took closer pictures of the individual bearings so that you can take the manufacturer of the bearing and part # down to the parts store and possibly see about purchasing them from the same manufacturer for less than it'd cost from toyota - or cross reference the bearing p#'s to a different manufacturer and use one with the same specs, just made elsewhere.
For instance the rear output shaft bearing (old) was a 'Koyo' bearing and the (new) one is a 'Nachi'...
Andrew
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I Supported Toymods
Location:
Sydney
Registered:
December 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 05 November 2005 14:23
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haha I don't think I'll ever be pulling mine apart... a T series box is one thing but an awd e series box with 2 differentials will most likely mean you'd need an acre of space to lay out all the bits in order!
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Location:
Perth
Registered:
July 2003
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sun, 06 November 2005 14:31
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That's an awesome write-up Andrew - excellent work.
How similar do you think it would be to a W58?
Thanks
Peter
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Location:
Melbourne
Registered:
November 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sun, 06 November 2005 14:41
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do you know the problem if your 5th gear comes out of gear while driving????????
which part would be need changing or worn????
its a W55
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Mon, 07 November 2005 00:59
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| 82MKII wrote on Mon, 07 November 2005 01:31 |
That's an awesome write-up Andrew - excellent work.
How similar do you think it would be to a W58?
Thanks
Peter
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Probably very similar - RWD manual transmissions are pretty similar afaik. Just different sizes/gears/lengths/ratios.
An easy way to tell would be to print out the picture of the t-50 break down from the documentation on this site and compare it to one of the w58, I'm sure you can find it somewhere (even if you have to go to a stealership and copy a couple pages)
| wolverine wrote on Mon, 07 November 2005 01:41 |
do you know the problem if your 5th gear comes out of gear while driving????????
which part would be need changing or worn????
its a W55
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Most likely a worn/damaged 5th gear and/or 5th gear synchro hub.
Andrew
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Location:
Rocky Mountains, Canada
Registered:
May 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Mon, 07 November 2005 05:21
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Someone (ie, forum mods) should mirror these photos on the toymods server or turn it into a tech article.
Dont want somthing this useful to dissapear.
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Mon, 07 November 2005 05:43
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| M.W.P. wrote on Mon, 07 November 2005 16:21 |
Someone (ie, forum mods) should mirror these photos on the toymods server or turn it into a tech article.
Dont want somthing this useful to dissapear.
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That'd be nice - I actually made the photo server account just for these pictures so they'd stay up and I wouldn't exceed any limits or have to delete them in the future.
I'm considering (once done) turning the post into a web page/tech article to have added to club4ag.com - if I do I'd be more than willing to send it to someone to have added. I would've loved to have something like this to look at/reference before I attempted it.
Andrew
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Location:
Rosanna, Melb
Registered:
June 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Mon, 07 November 2005 07:46
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There is a fair bit of difference between W5* and T50. T50 are split case, so you can just split the two sides and lay it down neatly and take the mainshaft and layshaft out (as shown in the writeup).
W58s dont have a splitcase and so you need to take the extension housing off, then the sandwich plate, and then take all the internals out through the back. The reverse arrangement also looks a little different, though I have never fully pulled down a W5* before.
Hen
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Location:
Brisbane
Registered:
May 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Mon, 07 November 2005 07:56
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| wolverine wrote on Mon, 07 November 2005 01:41 |
do you know the problem if your 5th gear comes out of gear while driving????????
which part would be need changing or worn????
its a W55
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I would suspect a worn shift fork / lock pin on the 5th / reverse shift fork...
As Henn said, W5X's are not split case so there is a fair difference
Still golly good write up / documentation! It would be good if it could makes its way into a pdf or word doc and into the tech docs.
Cheers
Wilbo
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Location:
Wollongong
Registered:
May 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Tue, 08 November 2005 00:13
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Damn this is great info. Keep going!
Any chance you know where I can get R154 info? My reverse gear is nearing end of life.
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Tue, 08 November 2005 00:29
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R154? Supra 6-speed then - I'd try supraforums.com, they seemed pretty helpful from what I was able to find on their site. I was lurking for injector information on a turbo build up for my 3rz. Which hit the backburner once I got my AE86...
Andrew
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Location:
Brisbane
Registered:
May 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Tue, 08 November 2005 01:33
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| assassin10000 wrote on Tue, 08 November 2005 11:29 |
R154? Supra 6-speed then - I'd try supraforums.com, they seemed pretty helpful from what I was able to find on their site. I was lurking for injector information on a turbo build up for my 3rz. Which hit the backburner once I got my AE86...
Andrew
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R154 is 5 Speed, as found behind 7M-GTE's and 1JZ-GTE's...the 6 speed is the V160/V161.
MA70 TSRM here
Cheers
Wilbo
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Tue, 08 November 2005 01:51
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| wilbo666 wrote on Tue, 08 November 2005 12:33 |
...the 6 speed is the V160/V161.
Cheers
Wilbo
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I stand corrected 
I'm not too well versed across all the toyota makes and models as far as engine/trans designations go...
Andrew
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Location:
Wollongong
Registered:
May 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Tue, 08 November 2005 04:16
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Excellent work guys. Thanks a heap
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Thu, 08 December 2005 16:18
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47 - more parts.
48 - Countershaft assembled w_new bearings.
49 - Assembling Outputshaft - 2nd gear _ synchro hub installed.
Here's where the fun starts, when reassembling the output shaft there are 3 small ball bearings which sink into the output shaft and hold certain pieces steady. When pressing it together you need to keep everything lined up and the locking balls in place. What I did was grease the cup on the output shaft to hold the balls in place, and when pressing everything together I held everything up in place with a finger or two - no worries about crushing a finger, it's fairly easy to do and there is enough room to get you're finger out well ahead of time...
50 - Assembling Outputshaft - 1st gear & center bearing installed.
51 - Almost assembled Outputshaft & Assembled Coutershaft.
Just need to put 3rd gear and the 3/4 sychnro hub together and on, and also the speedometer drive gear.
Still waiting on the new 3/4 shift collar/sleeve/synchro hub...
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Registered:
November 2005
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Re: DIY: Transmission Rebuild *** No 56k ***
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Thu, 08 December 2005 21:23
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good work!! the gearbox must be worth more than my car !!
good second hand parts would have been o.k for me, and buying the bearings from toyota is not a good idea.
but if you get stuck i'll help you out.
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Fri, 09 December 2005 00:18
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| evoX3 wrote on Fri, 09 December 2005 08:23 |
the gearbox must be worth more than my car !! good second hand parts would have been o.k for me, and buying the bearings from toyota is not a good idea.
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Actually I have paid more in parts for this than I bought my car for (over 800 us in parts, paid 650 us for the car)
The bearings probably were ok - but I decided if I was going to do this to go all the way.
Andrew
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Fri, 09 December 2005 02:43
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52 - Removing GT-S bellhousing.
53 - Removed GT-S bellhousing, degreasing.
54 - Removed SR-5 bellhousing, T-50 from the GT-S swap.
55 - The car, not driveable unfortunately
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Location:
VIC, Sth Frankston.
Registered:
July 2003
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Re: DIY: Transmission Rebuild *** No 56k ***
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Fri, 09 December 2005 06:27
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fantastic article!!
makes me feel a bit more confident about rebuilding my shagged w58 in the future...
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 10 December 2005 03:45
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56 - Cleaned bellhousing.
All pictures have been edited/shrunk to a lower resolution for faster loading... And to keep my photo account below 15 mb.
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Location:
Brisbane
Registered:
October 2002
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 10 December 2005 08:02
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what car is that in the background
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Location:
Sacramento, CA (USA)
Registered:
September 2004
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Re: DIY: Transmission Rebuild *** No 56k ***
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Sat, 10 December 2005 09:12
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My friends 92 NSX: Marga hills front headlight conversion/bumper. JDM carbon fiber side skirts (painted), JDM carbon fiber vented hood, JDM JGTC 7 layer dry carbon fiber wing, 03 nsx rear bumper/valence, Technomagnesio magnesium wheels, nsx type-r comptech gearset and final drive trans (usdm nsx's have crappy gear ratio's and drop out of vtech when shifting in the 5 speeds), intake/headers/exhaust and lots of other goodies.
Before pics:
After pics:
The bike to the left is what amounts to a world superbike - that's street driven. It's been through 3-4 photo shoots for a magazine but politics/management changes have kept it from having a full blown article - yet.
It will rev freely, its a kawasaki zx7r (last of the ones that had an R that actually stood for race model) with a ton of modifications, rev's freely to 16.5 and put down 169 rwhp on a dyno with a 'mild' tune. Sprocket has been changed to keep the top speed below 200 mph.
My friend and I are currently involved in getting ready to put together a 6-800 hp civic hatchback.
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