K40 Gearbox Teardown

[mooseman426]

I'm in the process of pulling down 4 speed box from ke30. I want to get to all the synchro's. I've got the reverse gear and counter shaft out, as well as input shaft and gears/synchro's up to halfway along mainshaft.

 

Now I'm stuck. ;) Is there a trick to get the rest of the box apart? I'm thinking that I need to get the selector fork out of the way, but I can't see how this is done. Do I need to remove the pins holding them to the selector shaft, and if so how do I do it, and how will they go back in tight? Or is there another way to get the job done? I have also looked at the nut behind the rear bearing, but it is tight as hell, and I want to be sure about whether I need it off before I butcher it.

 

Thanks in advance

Edited July 4, 2010 by mooseman426

[Evan G]

prepare for a nightmare. Ive torn down a ke50 box and had a detent ball left over...

 

yes you have to remove the selector off the selector shaft. you have to take the rods out one at a time. the detent balls will fall out. draw a picture or take a pic to remember where they came from.

 

a roll pin have tension on them so you can reuse them. get a suitable punch and tap tap taparoo

 

gimme a pic and ill let you know more info

 

seriously it was a cunnnnnttttttt

Edited June 20, 2010 by Evan G

[mooseman426]

Thanks for the reply. I have grabbed a couple of pics

This is where I am up to, want to get the rest of the shaft out

I know it is hard to see in this photo, but this is one of the pins through selector shaft and fork. These are what I need to knock out to progress?

It looks like I will need to access one of the pins through this bolt hole. Does this look right?

 

Thanks heaps for the help. I've had fully sequential dog engagement motorbike gearboxes/engines apart heaps of times, and they have never been this hard! Thinking that if I get through this I might put a bit of a how to on the site

[rob83ke70]

seriously, gearboxes aren't that hard, if it doesn't come apart, find out why, don't force it, and pay really good attention to where everything goes so you can reassemble it. don't put anything in backwards, and after putting each thing into it make sure its right and works correctly. take your time, don't rush, you'll get there.

 

I haven't done a transmission rebuild for ages. I've done quite a few transaxles which are pretty easy, and a few subaru gearboxes which are interesting. can't wait till I get a k box pulled apart ;)

 

Robert.

[mooseman426]

I will be away from home for a week, apologies for no replies in that time. Cheers

[seabiscuit]

It looks like I will need to access one of the pins through this bolt hole. Does this look right?

Thanks heaps for the help. I've had fully sequential dog engagement motorbike gearboxes/engines apart heaps of times, and they have never been this hard! Thinking that if I get through this I might put a bit of a how to on the site

You shouldn't need to go through the bolt hole. As far as I know the gearbox I rebuilt in College was one of these and I was able to get all of the pins out through the big hole. It's MUCH easier to get all of the gears off once you get the shaft completely out!! Taking out the selector forks is what needs to be done to do this, though. Just keep undoing things, knocking pins out etc. until they come out.

 

For a bit of consolation, I took the longest to rebuild my gearbox in class. Everyone elses seemed to just fall apart, whereas mine was a puzzle :dance: Surely Toyota weren't going into "Toyota specialist" only repairs before the 90's! ;)

[mooseman426]

Friggin got it!! Thanks for the help.

Now to do the job I opened it up for.... then put it back together.....

Edited July 1, 2010 by mooseman426

[mooseman426]

I've been looking and looking for a bit that somebody wrote in the forum recently about these gearboxes. There was a link to some tech information and a couple of pics. I'm just chasing as much info as i can. Does anybody know/recall about this. I can't find it anywhere, starting to think i'm going mad.

[towe001]

This might be it

http://www.rollaclub.com/board/index.php?showtopic=42602

[mooseman426]

That is it exactly. Thanks heaps.

I must not have looked at it properly 1st time around though. I thought it had more k40 k50 stuff. But is handy information!

Edited July 5, 2010 by mooseman426

[jegankp]

Mate, recently i removed the K40 gearbox out of my KE20 also. and the problem with mine was a hollow tube slide up from where the drive shaft connects right to where the shifter is. this caused the shifter to get stuck on 3rd, which was engaged at the time. if I'm not mistaken, the first picture you posted was where the shifter sits, and if so, would you say it is possible for the hollow tube to get stuck there? and how was the condition of your box, at the drive shaft connection?!