How-to for K40/K50 gearbox strip

[greeneyes]

Hi Team- I have a 4spd & a 5spd for the KE70 and would like to strip both boxes and select the best bits.

Basically I need to take the speedo drive off the 4spd and transfer it to the 5spd (easily done) to correct the 20% speedo error, and see if I can stop the 5spd whining in the lower gears. (shim on the layshaft I expect)

Could some expert post up a couple of pics on how to remove the shafts from inside the casing please. We've removed the rear housing and the sump plate.

Ta

[greeneyes]

Ok- we've got the layshaft out, that was a drift job.

This is the tailshaft housing off and the sump on the way
http://www.ae86drivingclub.com.au/dcimages/3/5/6/14402.jpg

and this is the drift I knocked the countershaft out with, although I had to finish it with a steel tent peg as the drift wasn't quite long enough..
http://www.ae86drivingclub.com.au/dcimages/3/5/6/14403.jpg

and this is what we got when we lifted the layshaft out. Two spacers at one end and one at the other. Now.... can we get new spacers?
http://www.ae86drivingclub.com.au/dcimages/3/5/6/14404.jpg

[greeneyes]

OK, we've done the same with the K50 and found it has 15thou absolute gap at the thrust washer. (a 16thou won't fit at all)

Anyone know what the play should be in there? That washer is .0705 so I assume we can buy a thicker one somewhere...

Does anyone rebuild these boxes or does everyone just swap them?

[greeneyes]

haha! OK, don't worry... I have the 5speed half stripped. I was worried about the 15thou play in the layshaft endfloat, but the gearbox company here said thats fine, the endfloat won't make a noise it will be the two needle bearings. A mate at Toyota looked up the prices and one is $315 the other $220!!!

So I swapped the speedo drive, the other reason for stripping it, and will put it back together!