AE86 from Portugal (restoring gearbox now...)

[Homem Bomba]

Hi guys,

I am a 25 year old Informatics Engineer from Portugal, with a taste for mechanical work on my free time, and of course, a proud AE86 owner. This post is a translation of the original post at ae86pt.com, the portuguese forum for hachis

This is my car:



It is currently just like I bought it, and the only extras it came with were the original wheels with a changed offset and Koni Sport adjustable shocks as well as Apex springs. Some time ago I went to a Koni representative here in Portugal to tune the shocks, as they were extremely stiff for my back! My first trip was from where the car was to my home town (approximately 60 miles/100km) and I woke up very sore the next morning!!!

This is the car at the tuner's workshop:



The car currently has some issues on the gearbox, namely reducing from 3rd to 2nd, so I am working on it to repair this.



I am following the workshop repair manual to work my way through the process. If you have done the same, I appreciate any input that you can provide

I am also filming the full overhaul and publishing the procedure on Youtube, as well as my full explanations of what I am doing. The explanations may be too detailed or not as "to-the-point" as a professional mechanic, but the videos are high-quality and may be useful for anyone trying to do the same thing.

Here's my youtube channel with all the videos (there are almost 20 videos by now, some in hd ):

http://www.youtube.com/user/MoleskineFan?feature=mhee

[Homem Bomba]

Gearbox disassembly, part 2:




Opened Gearbox... Overview:





Details of the main shaft:









Details of the Synchronizer Rings:








Details of the Counter-gear shaft:









Details of the Forks (some wear here...):
















Gear lever Shafts:













The shafts look excellent, no flaws or wear here I think:



Cleaning the inside of the casing, it looks like new thanks to a great Portuguese degreaser/detergent, Supergel.

[oldeskewltoy]

Homem Bomba Wrote:The car currently has some issues on the gearbox, namely reducing from 3rd to 2nd, so I am working on it to repair this.

This is a very common problem with the T50 transmission. There are a few options as to what to do.
1) rebuild as you are doing.
2) Find Supra transmission(W5, and find hard-to-find 4AG/W58 bellhousing
3) find Lexus IS200, or Altezza 6 speed and fit with LEEN adapter

[Homem Bomba]

Thanks, nice info! That LEEN conversion is sweet, but would be very expensive. I am also trying to keep the car as stock as possible, so my option is to rebuild

Cheers

[irishtwincam]

oldeskewltoy Wrote:2) Find Supra transmission(W5, and find hard-to-find 4AG/W58 bellhousing

Not hard to find, just expensive to ship around the world without making a profit.

http://skynet.ie/~eireae86/tech/4A-G_W_bel_housing/

[Homem Bomba]

Hi guys,

After a lot of time I'm back with the rebuild, now focusing on the more "delicate" aspects, namely diagnostic of the mainshaft, gears and bearings. During this time I have been sparing to buy some tools I needed:

->Bearing Puller + Extensions
->Feeler Gauge
->Dial Indicator + Base
->Vise

As always, I have posted some more videos of the rebuild, so that they can be of use to any others trying to repair their gearboxes. I have been doing this from the beginning, so check out the past videos to track the full rebuild process!

Here is an explanation of what is a bearing puller:

And also how to extend the reach of the tool without having to spend a lot of cash in extensions (believe me, they are costly!)

An explanation of what is a Feeler Gauge and how to use it:

Measuring the thrust clearances of the gears in the mainshaft, according to the technical manual:

Removing the rear bearing from the main shaft, using the bearing puller:

Removing the input shaft and the 4th Gear:

Removing the 5th Gear:

Removing Reverse Gear:

Removing Middle Bearing + 1st Gear

[Homem Bomba]

I got two more videos online, the main shaft is finally naked. Soon I'll place a video with detailed photos of all the bearings, including closeups of the engraved numbers and codes, as well as caliper measurements for reference purposes.

Removing 2nd and 3rd gears:

Removing input shaft bearing:

[zenki]

Nice work.

Subscribed on your youtube channel.

[Homem Bomba]

zenki Wrote:Nice work.

Subscribed on your youtube channel.

Thanks man, glad you like

After a day off work, I took out the remaining bearings, which were the ones from the countershaft.

The reason for going straight to the bearings in the countershaft is that the workshop manual follows the disassembly process in a methodical and ordered way. This assumes that you have bearings in stock and that they can be changed as the steps of the manual are followed. This is obviously not my case, so I had to take apart everything that has a bearing in it to order all the bearings at once from the store. Some inspection steps were therefore skipped, but I will perform them once I have the new bearings at home and start the reassembly of the transmission.

Now I have to look for the new bearings at quality OEMs such as Koyo or SKF, since in Toyota they are expensive as hell....

Here is a foreword video where I explain all this:

Removing the first end-bearing (it is held by a bolt):

Removing the bearing on the other end of the shaft (this one is held by a ring that you take out with the pliers) and also removing the center bearing:

Measuring procedure for the bearings:

Detailed pictures of all the bearings including dimensions and part numbers from ToyoDIY.com

[Homem Bomba]

Hi guys,

After a lot of time stopped in the garage, the gearbox rebuild is finally back on the road. I have been looking for the bearings forever, and I gave up.

I need the car on the road, and am starting to worry about the engine breaking down due to lack of use... Not to mention I am itching to drive my hachi again...

I explain my decisions in the first video:

Assembly of the input shaft bearing

Measurements of the main shaft:

Measuring gear oil clearances:

Diagnosing synchronizer rings (perhaps the most interesting video, this is general knowledge and can be used for any car)

Diagnosing hub sleeves:

Assembly of the secondary shaft

Assembling reverse idler gear:

Thanks!