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I made an expensive mistake [Archive] - Toyota MR2 Message Board

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I made an expensive mistake [Archive] - Toyota MR2 Message Board Toyota MR2 Message Board > Toyota Engine Clubs > V6 Owners Group > I made an expensive mistake PDA

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Jason.MZW2007-11-2006, 01:15 PMThe 2001 S51 and 1990 S54 are manufactured a bit different on the inside. I was following the instructions of tranny disassembly for the S54 on the S51. Bad idea. I messed up the first time by breaking the head off of a bolt in the 5th gear synchro hub. So, I got my drill out, and pretty much demolished that hole. The funny thing is, I removed what was left of the bolt, and had about half of the threads remaining. Guess what? It still held enough torque to remove the synchro hub. It was amazing I didn't have to retap it.

So, with the S54, you use 3 case bolts each tightened down into the synchro hub until the hub starts to come up. That's not the case at all with the newer S51, and likely newer S54s as well. You're actually supposed to use a puller, similar to a steering wheel puller or pulley remover, bolt down the three bolts in the hub with the puller, and tighten the black pushrod. Let me tell you, that hub is on there compared to my S54. It seems a lot more reliable. Everything has extremely tight tolerances in the newer S series trannies. By the way, I demolished my 5th gear synchro when I was drilling and trying in vain to pry that thing off without the puller (remember, my 3rd bolt hole was unavailable before i resorted to drilling). The entire synchro needs to be replaced, and it's not cheap.

So, I tried removing the 5th driven gear with a gear puller. Guess what? A piece of the puller area of the gear broke off. With an unequal rotating mass, I'd better replace that too. Again, not cheap.

So, a lesson learned here. Don't follow old instructions. I have the new S51 disassembly instructions if anyone needs them. Straight from the BGB. canadam07-11-2006, 09:20 PMGood to know!

What had you decide to go to the S-series transmission? Weasy2k07-12-2006, 12:13 PMwhoa seems a lot more complicated then the E series trannys...

Good info tho.,, (insert mental note) JimKing07-12-2006, 01:02 PMWas this just part of removing the "guts" from the S51 tranny for reinstallation in your S54 case, or were you working on changing gears and/or synchros? I expect to be doing the same as you - namely using S51 internals with my existing 91na S54 case and shifter assy.

I have never disassmbled a tranny before, so excuse an ignorance.

-Jim Jason.MZW2007-12-2006, 04:24 PMWas this just part of removing the "guts" from the S51 tranny for reinstallation in your S54 case, or were you working on changing gears and/or synchros? I expect to be doing the same as you - namely using S51 internals with my existing 91na S54 case and shifter assy.

I have never disassmbled a tranny before, so excuse an ignorance.

-Jim

Yes, this was for tranny case swapping. I was thinking of using the longer 1st gear from my S54, but I'm not sure if they are compatible. I haven't removed the tranny case from my S51 yet because I need to find a gear puller small enough to fit the small 5th driven gear.

Also, for reassembly, the 5th gear synchro hub is supposed to be pressed back on. Right now, I'm waiting on all of my 5th gear parts. I ordered everything and it came out to about $354 at Partznet, but I had to go to my local dealer to get part numbers for certain things.

You also have to use a specific snap ring on the 5th gear synchro hub. One that allows the least amount of play. I'll post the instructions up for you Jim. The rest of the disassembly is the same as the MR2 BGB.

I went with the S series transmission for axle and hub compatibility, and also for less parasitic loss through the drivetrain. Because the internals of the transmission are lighter than the equivalent E153, more power can be transferred to the wheels without being lost turning heavier rotational mass. The downside is a weaker transmission and axle setup overall, but I'm not looking for big power. Brad Bedell07-12-2006, 04:45 PMDon't beat yourself up too much. :) We've all broken that gear from time to time, even with the correct tool.

-B Blitzo07-13-2006, 07:00 AMwhoa seems a lot more complicated then the E series trannys...

Good info tho.,, (insert mental note)

Actually, I think the S's are MUCH easier than the E's. Fewer shift rods, FAAAAAR easier differential shimming procedure, Less TORX bolts. I thought the 5th gear business was about the same.

Like Brad said, too. Sooner or later we all trash a #5. I trashed mine by munching the synchro with the bolts in the gear removal process. I use a puller now on all of 'em. Jason.MZW2007-13-2006, 08:56 AMThe sad thing is, the 5th gear parts cost as much as my whole transmission. I got my 2001 S51 with 21k on it for $350, and the 5th gear parts came out to $354. Powered by vBulletin® Version 4.2.5 Copyright © 2026 vBulletin Solutions Inc. All rights reserved.

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