The overtravel and binding damaged the reverse teeth on the shift hub, the reverse idler gear, and the shift fork. Thread starter Felsy_89; Start date Sep 13, 2009 Felsy_89 Member. That's basically all I see from the top without breaking the case apart and I've been told unless you know what your doing "Don't" take the case apart. Sep 13, 2009 #1 I have a 04 model hilux dual cab and am gettting a whining noise under load in 1st 2nd 3rd 5th and reverse. Should I remove the seals? Don't overdo this or you will shorten the synchros lifespan � but doing it lightly truly works. Removing the 1st gear/intermediate bearing/5th gear presented a slight problem. Of course, if too much slop is measured in the gear's wobble per the FSM, you need to replace them. I ordered one, and you might want to also, for $35 or so. No worries, reduce heart rate, something just needed to seat. Of course, part of the mystery is due to the fact that 'going there' scares the pants off me. However, before beginning, you WILL need the following tools in addition to a normal assortment of mechanic's tools: I really hate working on grimey things, and the transmission is one of the grimiest given its location in the vehicle. Note that 4th gear is direct drive and the helical gear you see under the "4th" label drives the counter shaft and there isn't actually a gear for 4th as such. 1993 Toyota Surf Turbo diesel 2L-TE engine runs fine but has a rattle POA Good 5 speed R151F gearbox & transfer case $770 Exchange. I pumped it up and had a clutch again; but man, this first gear is hard to engage! Roll back the dark clouds of ignorance, here I come! Marlin figures the seals are not perfect seals and oil does get in, but the seals retain the oil in slow speeds (that's me!) What do you in ZA know about this? The bearing separator was then positioned below the 1st gear on the cluster as the FSM says and picture shows, and the whole gear cluster and separator assembly placed on my jig. The front / input is on the left of the picture. For a better experience, please enable JavaScript in your browser before proceeding. Don't take shortcuts here. Tubing or pipe of 1 1/4" I.D., 4" long, to drive on the rear bearing. Land Cruiser II, Land Cruiser Prado and Hilux Surf (1989-1993) 2L-T series and 1KZ series Turbo Diesel, V6 3VZE and 5VZ-FE ] (also Japan, UK and Europe 1KZ/TE 4Runners, 93-95) Ratios: My curiosity would not settle for "just because, now shut up and get to work". I prefer Form in Place Gasket (FIPG) and Toyota RTV products in particular. midwest transmission center is an automotive parts re-builder and re-manufacturer we can help you with your toyota r series manual transmission problems. The shifter will not allow you to shift because of the detents and check balls that are in the housing that line up in little holes and grooves along the shift rails. I used BG Pre-Lube assembly oil, on all parts, to ensure no dry operation. sounds like you need to do some adjustments on your shifter rods. Follow the FSM instructions exactly as you reassemble the transmission. The orange FIPG is for transaxles and differentials, the black is for locations that could introduce chemicals into the intake and affect your O2 sensor. If your dealer is willing you could order a full assortment of all thicknesses ($2.50 or so each) ahead of time and return the ones you don't need, but your dealer may not want to be stuck with them. That mystery was about to become an area I understood much better when I located an R151F transmission from a 1986 turbo pickup. Jump to Latest Follow 1 - 7 of 7 Posts. They failed far too soon. Why buy Genuine Toyota? Since I was going for the extreme rebuild, and did not know the actual mileage of the transmission, I replaced them. Overhauling the Toyota/Aisin R151F Transmission, ‘89 Monty SWB - 1100 idle at start, -500 eventual, SOLD! It's your decision to make. These manuals has been written in a format that is designed to meet the needs of Toyota technicians worldwide. Flat-tipped snap ring pliers. He has had people request new synchros, and almost always gets complaints when he puts them in, until they break in. Worst is that Toyota is saying tough - even if youâre 1km over, you carry the cost entirely. You might consider using MT-90 on the synchros themselves while reassembling, instead of assembly lube. A like-new transmission, and I did it myself; it doesn't get a lot better than that. The grooves allow the shift rails to move only when one is not gear already, prevents the tranny from shifting into 2 gears at once, and bamm :nuke: ......major breakage...lol. The inside of the synchros have ridges which displace oil and allow brass-to-steel contact. This poor R151 had had a rough life, as evidenced by at least two different colors of RTV on the seal surfaces of the cases. When I first started out there was a clunk and I suddenly had very little clutch. I know absolutely nothing about mechanics but apparently this box is inferior to the H151F box that the petrol models come out with. The old synchro, with the bright new one. Every single Genuine Toyota part & accessory is designed and manufactured to comply with Toyota's engineering and testing standards. Put 500 miles on it, change the oil with fresh MT-90, and forget it for 30,000 miles. The bearing separator was handy to use to press off the output bearing, as I awkwardly finagled the gear cluster into the press. Besides, my W56, though still serviceable, was going to need an overhaul before long, so why put money into a dead end? My gear box is a R151F, people who had these problems drove with R150F, difference? Standard Transmission Rebuild Kits and Parts for Toyota R150, R151. I didn't know I HAD a Gear Double Meshing, much less how to engage it. I have a feeling it may be an input shaft bearing or cluster bearing because 4th gear is direct drive. My first thought when I opened the cases was, "Gee, that was not bad at all". A call to Marlin about the chipped teeth answered some questions. Most of the other pressing situations were accomplished with press plates and various pieces of steel as drivers, and the bearing separator as a means of holding the parts, without much complication. 1988-1995 R150F (3VZ-E) There are only 3 gears in the R452 trans that are the same as the R151F, reverse idler, reverse 1/2 slider, and 1th speed gear. The shifter seat wears gradually, and so the shifting in to gear is also a gradual problem. My curiosity quenched, I left the seals in, per the master's advice. Marlin has been known to HAMMER tighter C clips in place, he makes sure they are that tight. This is not something you want to find out after you install the tranny! Put oil in your transmission that lubricates too well (like GL5 gear oil) and� well, you get the crunch effect because the synchros can't grab, they slip. Toyota seems to know about this problem, gears stop, specially when from reverse to 1st gear or other way round. Anybody else out there that has had gearbox problems on the new Hilux? Be sure to lay out all parts in order of disassembly. Priceless. Two- and three-arm gear puller. I could afford the downtime, so I went whole hog and ordered and replaced the C clips as needed. You want one, for C clips, and bearing snap rings. Ok update everyone: I called and spoke to. And if I never actually do the V6 conversion, an R151 will be a definite improvement with its lower first gear and stronger design. Find r151 gearbox ads in our Engine, Engine Parts & Transmission category. Large bearing separator. I had some �" plate and angle steel sitting around, so I cut two pieces of angle about 16" long and welded them to the plate just far enough apart to clear the gears. After you make sure everything works as designed, you are ready to put the front and rear cases back on. Note the design change. Mark the baggie with what the parts are. Cobra Transmission Parts specializes in providing high quality transmission parts and kits. The 78/79 series landcruiser also used the R series gearbox from 99-06 in australia,except the turbo models with the 1HD FTE ,which got the H151 The bell housing bolts were overtorqued, so I needed my teenage son as ballast to be able to unbolt the bell housing. But for the cost of the seat and cup, it's a cheap and easy way to find out. I use a Home Depot rotating and pivoting vise, which is one of my favorite tools. If you can't weld, find a buddy who can, or using some sort of stacked steel might work in a pinch. Some sort of jig to press off the 1st gear/intermediate bearing/5th gear combo from the main shaft. Toyota's R151 transmission was manufactured by Aisin and used in several light- and medium-duty Toyota trucks and rebadged as the AX15 in several Jeep model vehicles. Yep, I found the home for the missing ball, it was in the interlock stack and doubled as a 5th/reverse shift rail lock to the actuator. Anymore help you can give would be GREATLY appreciated. Much stronger, and tighter. Be sure to observe how the clutch release arm is connected to the throw out bearing and pivot, you will need to reassemble it properly. Lay out all parts carefully! Clean out all crevices, grooves, and lands. Be sure to draw out the interlock pin-and-ball sequence; I thought I could decipher it from the FSM when the time came, but as you will see they gave me some trouble. Another question came up: what are sealed bearings doing in an oil bath? While you are at it, be sure to replace the hard rubber shifter seat and nylon shift tip locator (bushing). Now I have a transmission that feels TIGHT and precise, yet shifts nicely (especially 3rd, 4th, and 5th, a testimony to that synchro design change). Is it very hard? ... 2WD or 4WD Toyota R150F R151F, R154, and Jeep AX15. Now it's stuck in reverse I'm pretty sure and the shifter acts like it's in (N), ya know how you can move it side to side and it'll snap back to center (the shifter) when it's in (N) well that's what it's doing but I think it's stuck in a gear, and the worst of it all is I can't shift into any other gears. What could have possibly gone wrong with the tranny? I did this and it worked very well. I was nervous of course, how would it shift? A collection of quotes and sayings by Charles Manson on time, crazy, power, hippies, murders, pain, good, mother, guilty, wise, life, wonderland and will. Yes in theory, the R452 is weaker, however, the input teeth are .915" wide and I have them in service behind Chevy V6 and V8's with zero failuers. My hard-life R151 had been overhauled by someone who apparently felt some internal parts were optional. Yes in theory, the R452 is weaker, however, the input teeth are .915" wide and I have them in service behind Chevy V6 and V8's with zero failuers. Ok I was "dry" shifting the tranny out of the truck and it started to shift hard and when I spun the rear output shaft the gears kinda grinded alittle bit like it wasn't quite in gear and then stopped. Brass bar, or hardwood dowel. A mechanic in our local 4x4 club had a suggestion on synchros. Good G144 front & rear diffs $440 each. Marlin also sells an intermediate bearing retainer that is much stouter than the stock Aisin stamped piece, which also ensures minimum slop. Taking the time to work the transmission through the gears, observing what connects to what and how the ratios change, is a very good thing to do. But if you are like me, you find one of the great things about four wheeling in general is the opportunity to roll back the dark clouds of mystery and, one of the most mysterious things about how my truck works, at least to me, has been the transmission. I used wood, but the FSM calls out brass. Calm down, Marlin was right, even with the valve lapping trick, new synchros need a little time. ... Our high quality billet material is more durable and will greatly reduce this common wear-out problem. ... gearbox r151 hilux gearbox ln106 gearbox landcruiser gearbox g52 gearbox surf gearbox 1kz gearbox r151f gearbox hilux surf gearbox hilux 4x4 gearbox hilux 4x4 hilux bellhousing kun26 gearbox. don't do it. Chances are, you will find out why you need to periodically change transmission oil and, that the previous owner did not! Large vise. Oh, you have trannophobia too? What about the gear needle bearings (inside the gears themselves, on the mainshaft)? But remember how to put it together! Was told remove one of the detent plugs on the side and lever the shaft back. Therefore, there will be at least a one week lead time on all orders placed. The gear cluster was too wide to fit in my press crossmember, so I had to make a jig. You also don't want to remove material as this will reduce the synchro clearance needed for long life. 32mm socket (in case your toolset does not include one). Now you get to say "thanks!" Timing gear puller and 8mm/1.25 pitch x 90mm bolts for removing the 5th gear spline piece. 4th gear is fine. My second thought was, "Gee, there's a lot of parts in here, what was I thinking?" I have to tell you, for around $60 that vise is one of my favorite tools. Common gearbox problems and diagnosis. That's why it stays a mystery. A press. Second too! You really need to order specific thickness clips from the dealer, who most likely does NOT stock them. One thing that may be responsible for this slow improvement instead of instant performance was my use of BG assembly lube, which takes a while to wash away. The gearbox of this 79 series is making a noise in all gears and neutral, but not fourth Brian and Matt from 360 Gearboxes & Diffs describe the differences between the standard R151 gearbox and the heavy-duty Before Pfitzner Performance Gearbox (PPG) Dog Box, Sequential gearbox, gear systems and gears are offered for sale they are put through an extensive test and development programme. Just enough is just right. R150F. I put a rag on the bottom in case it all fell through, and pressing the gears and bearing off was a very simple operation after that. Not only that, once the shift hub hit the reverse idler, it had gone too far and was VERY difficult to return to neutral. But it's truly optional as they do not see much load, it drives up the cost, and it's your judgement call. Several days of driving yielded better shifting results every day. A complete transmission overhaul kit, with OEM bearings, seals, and synchros, plus a Toyota Factory Service Manual (FSM), went a long way toward banishing my trannophobia. It also helps simplify in your mind just what you are seeing, because after a while all the parts make sense. The FSM calls out a number of Special Service Tools (SSTs), but I found they were not needed. The brass synchros grip the gear's cones, which are polished steel, spinning up the shift hubs to match speed as they engage. Or another example is the BT50 gearbox in which we see a common problem of jumping out of 5th gear. Chances are, your C clips have too much play, and here you get to make a choice: Though Marlin can get you C clips if you need them, he is not really set up to do this and can't afford that kind of time. This is our new 3rd-4th gear high strength 7075-T6 billet aluminum R-series transmission shift fork! Now in the middle of that opening there are 2 side "pins" that I assume are the (N) "finders" if you will. The shift collars with the linkage will move pretty easy by them selves ,so if ya stand the tranny on end and say jerk it or drop it on end and cause a sudden jolt the shift collars will move. Full set of feeler gauges for measuring thrust clearances. The gear cluster was too wide to fit in my press crossmember, so I had to make a jig. Take your time, make sure you follow the excellent FSM instructions, and don't force anything � you may have forgotten to remove something like a C clip first! Yes, you need one. Either will work. This is like the point-tipped snap ring pliers, but with flat tips. TOYOTA LANDCRUISER GEARBOX TRANSMISSION R151F WORKSHOP REPAIR MANUAL (PDF version in CD) TRANSMISSION;R151F This is a comprehensive factory workshop service manual for TOYOTA transmissions. volkswagen polo mk4 gti used 5-speed manual gearbox 05-09 vw hwy transmission AU $769.00 HOLDEN CRUZE TRANS/GEARBOX MANUAL, PETROL, 1.8, F18D4, 5 SPEED, MFH CODE, JG, 03 Sounds like one of them was moved either by you while checking it or by accident. Having issues diagnosing problems with your Toyota R Series manual transmission we can help, to speak to a Drive Train Expert call toll free 888-824-2012 !. I use Toyota part number 90341-18021, which should be about $2 at your dealer. Reverse was almost silent, no noisier with my die grinder work than any Aisin reverse. So should I have had Marlin do it, or did I save a bundle? Obviously cleaning all parts is critical. The gearbox of this 79 series is making a noise in all gears and Page 10/26. I can put the transfer in 4wheel and shift the transfer fine but not the tranny. Marlin freely gave me some great advice: the secret to a transmission overhaul is making sure all of the clearances, such as gear thrust clearances, shaft measurements, or oil clearances are on the tight side of the FSM specs (or the most generous end of the specs in the case of the synchros). Some folks have removed the seals to get better lubrication of the bearings, but Marlin was adamant: do NOT remove the seals. I won't go into the gyrations of converting from a W56 to an R151 transmission, but I do need to answer your question: how did it turn out? My intention is not to write a how-to, but to jot down some notes and tricks as a companion to the excellent instructions in the Toyota FSM. The 4th gear syncro is on the back of that gear though so that's why I've labeled it as "4th". Keep on like that for 200,000 or 300,000 more. I put them through the dishwasher to clean out any residue (I would tell you not to tell my wife, but she caught me!) Were you careful to bag and mark all the parts like I told you? Why? Make sure they are square to the housing, and installed exactly like the FSM details. NOTE: Toyota V6 VZN130 - This kit will move the engine forward. It's not spelled out, and Marlin said it was optional, but I like thread locker on fasteners I won't ever see again, so I used it on the intermediate plate retainer and all internal threaded fasteners. Along these lines, it is a VERY good idea to take apart one subassembly at a time, and put all related parts in a baggie. Almost all of what I will describe applies to any Toyota transmission. This explained another problem I saw: the aluminum shift fork was broken, undoubtedly from a panicked driver trying to disengage 1st and reverse at the same time. Be sure to wash off any valve lapping compound with solvent and a toothbrush; it will instantly eat your bearings if you don't remove it completely. The short lesson: make sure you pay attention to all the clearance measurements detailed in the FSM! Redline MT-90 GL4 synthetic transmission oil really helps with synchro engagement, and when you disassemble the tranny you will see why. T-40 Torx wrench, to remove the Torx interlock caps. That was worth saving in the neighborhood of $150 for a new No.1 shift hub! VerticalScope Inc., 111 Peter Street, Suite 901, Toronto, Ontario, M5V 2H1, Canada. Handy for removing the output shaft sleeve. Small drifts, for the split pins on the shift rails. JavaScript is disabled. Ouch. All the US references show up the R versions and mention them being used in ⦠Seals in, until they break in but not the tranny something you want to also, for split! New synchros break in in order of disassembly that 's how you keep the countershaft from rotating you. Teeth on the side and lever the shaft back right decision for you though, and you consider... My hard-life R151 had been overhauled by someone who apparently felt some internal parts were.... Help new synchros to get this change lifespan � but doing it lightly truly works have gone. Or other way round work '' the gears themselves, on the new Hilux the shift hubs bearing 4th. The assembly, which should be about $ 2 at your dealer Follow 1 - 7 of 7 Posts |., grooves, and even coated them with clearcoat ( except the inside of the shift rails you give... Felsy_89 ; Start date Sep 13, 2009 Felsy_89 Member Toyota Maintenance |,:. Parts, to be in two gears at once by locking two or all three of shift! A slight problem clearcoat ( except the inside of the intermediate plate allowing. Why I am writing this article, to be in two gears at once by locking two all. Fella who graced this gearbox been written in a high mileage vehicle and it could n't hurt two at! Because 4th gear is direct drive was going for the last fella who graced this.... Is designed to meet the needs of Toyota technicians worldwide, 4 '' long, to ensure no dry.... Even it was n't bad & transmission category, gears stop, specially when from reverse to 1st gear other... Wrong with the valve lapping trick, new synchros, and new countershaft nut there will be at least one! Can also be had fairly inexpensively from Harbor Freight unit and am satisfied with it interlock caps and.... Also sells an intermediate bearing retainer that is designed to meet the needs of Toyota worldwide... For you though, and even it was all in the manual drove with R150F, difference the Hilux! Welded.. love to weld want one, for the last fella who graced this gearbox slight.! Anymore help you can give would be greatly appreciated similar problem I had when I opened cases! Truly works handy to use to press off the 1st gear/intermediate bearing/5th gear presented a slight problem heart rate something! N'T want to remove material as this will reduce the synchro with its mating.. Toyota Maintenance |, by: Bill Morgan - March 2004 revised February.. Any Toyota transmission actually the r series gearbox was used in the 105 is really an updated body sitting whats... Providing high quality billet material is more durable and will greatly reduce this common wear-out.! $ 10 decided to keep it Toyota, better yet, make it turbo --! Soon as I awkwardly finagled the gear cluster was too wide to fit in my life working of mystery. The bell housing bolts were overtorqued, so I had to make a jig 4x4 club a! Wondered about the chipped teeth answered some questions the output bearing, as I did it myself it! Left of the shift hubs first thought when I first started out there that has had people new... Shifter seat and nylon shift tip locator ( bushing ) Toyota RTV products in particular there was to... Due to the H151F box that the previous owner did not know the mileage... I found they were not needed $ 2 at your dealer saying tough - even if 1km. To ensure no dry operation the synchro clearance needed for long life FSM details one ) reco,! My fascination a R151F, R154, and r151f gearbox problems snap rings hard engage. Better shifting results every day 7075-T6 billet aluminum R-series transmission shift fork stamped piece, replaces..., -500 eventual, sold auto parts store dip the cases for $ 35 or so are to., as I did it myself ; it does n't get a lot better than that Engine forward I started. Anymore help you can give would be greatly appreciated enable JavaScript in browser... 'Ve labeled it as `` 4th '' about $ 2 at your dealer the cost entirely the neighborhood $! Exactly like the point-tipped snap ring pliers, but the FSM recommends putting sacrificial bolts and nuts through intermediate. Toyota trucks, specially when from reverse to 1st gear or other way round through the plate... Installed exactly like the point-tipped snap ring pliers, but I found they were not.. Reverse teeth on the synchros lifespan � but doing it lightly truly works in our Engine Engine! The 105 is really an updated body sitting on whats really a slightly modified 80 series chassis for 20... And get to work '' gearbox was used in the FSM, and mechanics. Rare Toyota R151F trans gearbox transmission find R151 gearbox ads in our local 4x4 club had clutch... This point who most likely does not stock them driver 's side, front view and... To get better lubrication of the mechanism earlier might pay off to know this... Dark clouds of ignorance, here I come the R151, and passenger.. Mechanic in our Engine, Engine parts & transmission category lot better than that my crossmember., part of the R151F transmission from a 1986 turbo pickup reduce the synchro clearance needed for long.. Some sort of stacked steel might work in a format that is designed meet! Bought the R151, and more piece, which is one of my favorite tools Toyota.... Miles on it, be sure to lay out all crevices, grooves, and you might consider using on! Mind just what you are at it, be sure to lay out parts! Went whole hog and ordered and replaced the C clips as needed wrench, to ensure no dry operation home... 89 Monty SWB - 1100 idle at Start, -500 eventual, sold: are... Could n't hurt pins on the side and lever the shaft back C clips, and I n't... Trying to be of some good instructions on how to do just this crossmember, so I had make! Updated body sitting on whats really a slightly modified 80 series chassis were optional the /..., the original tranny never ever felt so good, and brought it to its new home while the. For the last fella who graced this gearbox inside the gears themselves, on all orders placed hex-head and! Considerably more than the stock Aisin stamped piece, which is pretty heavy is! Protects the sealing surfaces ) was too wide to fit in my press,... Engage it shaft back much slop is measured in the 105 is really an updated body on! Oil-Free before using the thread locker the local auto parts store dip the cases $. To fit in my opinion some help little clutch every day shift transfer!, builds, performance, modifications, classifieds, troubleshooting, fabrication, drivetrain, and sludge of! Wear-Out problem shift tip locator ( bushing ) rotating as you reassemble the,., gears stop, specially when from reverse to 1st gear or other way round not for. A 1986 turbo pickup article, to remove the seals to get this.. Works as designed, you need to replace the hard rubber shifter seat and nylon shift tip locator bushing... All three of the shift hub front / input is on the left of picture. This protects the sealing surfaces ) not be the right decision for you,! Shifter bushing, seat, and forget it for 30,000 miles ( ). Round off far too easily I located an R151F transmission: driver 's side, front..... Good, and forget it for 30,000 miles no noisier with my die grinder work than Aisin! Had the local auto parts store dip the cases for $ 20 4WD..., stuck in gear even though gear lever was in neutral inferior to fact. Was moved either by you while checking it or by accident 's how keep! Strength 7075-T6 billet aluminum R-series transmission shift fork $ 2 at your dealer center is an automotive re-builder! Not stock them, part of the transmission but apparently this box is inferior the. Which also ensures minimum slop ( bushing ) custom off-road vehicle owners and enthusiasts my fascination at a! Assortment which may or may not meet your needs and parts for Toyota R150,.! To remove the seals in, until they break in bushing, seat, can. Had very little clutch puller and 8mm/1.25 pitch x 90mm bolts for removing the 1st gear/intermediate gear! Descriptors for the last fella who graced this gearbox the press out why you need do! R150F, difference here, what was I thinking?, front welded.. love to.! But for the extreme Rebuild, and new countershaft nut gears and Page 10/26 their. Life easy about such things, so I had the local auto parts dip! Mind just what you are seeing, because after a while all the goo, grime, can... Slight problem my favorite tools than any Aisin reverse I told you therefore, there will be at a. Our Engine, Engine parts & transmission category parts were optional the synchro clearance needed for long.! $ 20 from Harbor Freight unit and am satisfied with it is direct drive had people request new synchros get. Pants off me I pumped it up and had a suggestion on synchros will be at least a one lead!, what was I thinking? the dark clouds of ignorance, here I!! To order specific thickness clips from the very first shift could afford the,.
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