How to fit a Toyota gearbox in a day These simple steps explain how to fit a Toyota gearbox and conversion kit to your car in a day. Please aslo take the time to look at this article also.
To do so successfully you will have to have some basic knowledge of car mechanics, especially clutch hydraulics, and the assistance of someone who is strong and doesn’t mind getting dirty to help you lift the Toyota box into place.
These steps are not meant to take the place of the instructions supplied with your conversion kit. If you are working from scratch, get the help of a trained mechanic or gifted amateur. It’s amazing how simple it all becomes once someone with a little knowledge is on the scene. You will also need the normal tools that any amateur mechanic should already have, plus a special tool to help you realign the clutch assembly. In all cases some minor welding will have to be carried out, so the appropriate tools will be needed.
The first job is to prepare the car for it’s new gearbox. Remove the old gearbox, the crossmember and any parts that are in the way. Clean the underfloor and the transmission tunnel of all dirt and grease so you can see where you are working. For an EJ or EH you will also find it easier if you remove the front seat. In any case you will have to remove any floor covering and console that will be in the way when it comes to making the hole for the shifter.
Unbolt the clutch and pressure plate and extract the bronze bushing out of the back of the crank. Inspect the flywheel and the pressure plate for damage. Our experience tells us to always fit a new or reconditioned pressure plate and to machine the flywheel, as there is nothing worse than having to do the whole job again because of clutch shudder which you will only find when you’ve finished the conversion. Also, most clutch plate suppliers will not honour any guarantee unless the flywheel and the pressure plate have been machined.
Fit the new spigot bush supplied with the kit, making sure to drive it right in without damaging it and reassemble the clutch using the plate and bearing supplied and your reconditioned pressure plate. Do this carefully making sure to install the spacer ring correctly. Tighten all bolts and for all FE to HK non synchro applications fit the supplied clutch bracket and slave cylinder on the driver side of the bellhousing. You will also have to check that the clutch pivot ball is in place.
You are now ready to bring on the muscle power and move the Toyota box into position. It’s now that you really learn how big and strong these boxes are. Locate the box correctly, using only a couple of the bolts to attach it to the motor. Remember to remove the shifter lever from the back of the box, and cover the opening with a rag to stop underbody dirt from entering the shift mechanism. Check out what modifications you will have to do to the floor and tunnel to ensure adequate clearance, mark those areas and the position of the shifter lever, and remove the gearbox again.
By now you probably have realised that some minor floor modifications will be necessary to fit the Toyota box successfully. If you have a factory manual body shell, these will include the removal of the tunnel section of the front floor crossmember. Make these modifications neatly, and reinforce the edges of the shifter hole with some steel plate 3mm thick and 30mm wide welded to the underfloor. Also weld plates over the cut crossmember ends to prevent water from entering the crossmember. From our experience, doing these things neatly, and well, will ensure you an easy passage through any engineers inspection.
If you decide to buy a kit, it will come with. Toyota 4 or 5 speed steel case gearbox, adapting bellhousing, clutch plate, spigot bush, clutch bearing, clutch fork, clutch slave cylinder, adapted speedo cable, Toyota tailshaft yoke from Holden Starfire four engined Toyota Corona (same uni’s as an early Holden), shortened tailshaft, universal joints, gearstick and floor boot, rear gearbox mount, and modified rear gearbox crossmember. There are some items you may wish to get yourself, but Dellow in Sydney, or Castlemaine Rod Shop have the other items as required.