Right, I did it, with a little help from a mate to hammer the new gears on.
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Bill was kind enough to post me his puller
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(the two half cup one) which he was also kind enough to let me grind another flat spot on so I didn't need to drop the gearbox.
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Putting the extra flat spot at around the 10-11 o'clock position allows the puller to be rotated slightly enough for the top slider arm to come under the inner wheel arch lip.
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Putting the new gears on was probably the hardest, they both took a fair bit of hammering with a socket and a lump of wood which is where it comes in real handy to have a friend because they can get some real swing on the hammer while you lay under the car holding the socket in place.
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I replaced both gears, the selector fork, the synchro ring and the sleeve that goes onto 5th.
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The synchro ring was a 96 corrola part and has far far fewer teeth on it than the one I took off and you do have to be very careful to line the correct bits up before smashing the hub back on.
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All parts were new from Toyota and it cost me a pretty penny as I replaced so much.
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The hub was the only bit I didn't change as it doesn't wear, but be careful when putting it back on because one of the three little sliding teeth fell out twice and the cir-clip came out and it didn't seem to have much tension in it when I put it back on and I was paranoid about it coming off again and one of them teeth falling out in the gearbox.
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Anyway, I put the oil back in this morning
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(made a filler neck from 2m of garden hose and a funnel) and took it on a test drive and it is all working, no nodding of the gear lever in 5th and nothing fell off.
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I do now unfortunately have a nod in 2nd.
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The lever comes forward when backing off.
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It hasn't jumped out and I don't think it will yet, but I don't know how long it will be before it does, but then you don't stay in 2nd long do you and when you back off it's cos you want it to come out of 2nd into 3rd, so I'm hoping it won't be a problem, but I an only assume that the damage was done while we were hammering the gears back on.
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We did actually wind the small gear back on with the lock nut for the last 1
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- 1.5 turns or so with about 3 extenders and a breaker bar as it was so tight but I just couldn't bring myself to keep hammering and I didn't want to bang it on too far and knew that the gear that came off had the end of the lock nut about flush with the end of the shaft.
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So the figures.
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70mph is now 3100rpm instead of 3600
22.581mph/1000rpm
So a theoretical max at 7500 of 171.6mph.
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I know that's unlikely and a bit crazy, but even so, a 150mph Mk1?
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Bonkers.
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Anyway, I only did it to drop the revs on the commute and improve mpg.
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I should be in the 40's now, the last couple of tanks full on the old gear returned 33mpg and 38mpg with different types of commute on B and A roads inc dual carriageway and 50mph contraflow.
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Anyway, that's enough from me.
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Thanks to all that have been involved in this mod, researching and attempting, especially Bill for doing it first and without buying new stuff from Toyota and to my mate Andy for lending me so many of his tools and his time and also especially to my wife for losing me under the car for days on end when things were not going my way.
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