C60 Transmission rebuild / helical LSD install process with pics

[billybrun]

I'm doing this after an unfortunate incident. My transmission decided to give up after 8 years of demanding driving, not abuse. The transmission started making this awful clunking noises and what seemed like skipping.

Took the transmission out of the car and opened it to find the output shaft pinion gear along with the differential ring gear totally messed up. Now, since second gear was grinding really bad for a while now, I was planning on doing a syncro job and transmission rebuild anyways. This was my perfect excuse.
I'll try and help those after me that want to tackle this project by listing parts and procedures that were a little hard to get, especially since some procedures are different when installing and LSD into the C60 transmission.

Parts list with part numbers:

- Toyota MR-S Spyder JDM helical LSD (limited slip differential) 41301-20230
- Throwout bearing 31230-12191 (new part number)
- Ring gear 41221-12490 (new part number)
- Output shaft 33321-20180
- Second gear 33332-12150 (new part number)
- Second gear syncro 33038-20010
- Differential front bearing 90366-40097
- Differential back bearing 90366-40094
- Differential speedo gear 33481-20160
- Shift fork, 1st, 2nd and reverse 33212-10013
- Transaxle overhaul gasket kit 04331-20080
- First gear syncro 33367-20070
- Reverse gear (1st and 2nd shift sleeve) 33331-12060 (new part number)
- Output shaft front bearing 90365-33006
- Input shaft front bearing 90365-25021
- 3rd Gear: 33034-20071 (new part number)
- 3rd Gear Syncro: 33368-20080 (new part number)
- 4th Gear: 33035-20181 (new part number)
- 4th Gear Syncro: 33368-12210 (new part number)
- 3rd and 4th shift Sleeve: 33364-12030 (new part number)

Now, when it came down to special tools needed to remove the bearings and gears, the recommended by toyota cost a pretty penny and people always break gears while taking them out, so it's not that good anyways. I found a $29 Harbor Freight bearing puller kit that worked perfectly without damaging any gears.


http://i529.photobucket.com/albums/dd333/billybrun/07-31-08_0019.jpg


Since I'm installing a helical type LSD, a different procedure is required to set the differential bearings preload. As per MR-S Spyder and Lotus service manuals, instead of just closing and torquing the transmission housing only with the differential inside like you would do it for an open differential, you have to close and torque the transmission housing with the fully assembled output shaft and the fully assembled differential (LSD) and ring gear, then check the torque it takes to start to move the output shaft as opposed to the differential on an open one. Oh, also the torque on the ring gear is different when installing it on an LSD, instead of 57 ft/lbs is 74 ft/lbs.

Bearing preload (at starting):

New bearings: 0.17-0.35 Nm (1.7-3.6 kgf.cm) (1.5-3.09 in/lbs)
Used bearings: 0.11-0.22 Nm (1.1-2.2 kgf.cm) (0.97-1.94 in/lbs)
Adjustments made are the same as for non lsd, there is no special oil requirement for the lsd.

If you need to make adjustments to the preload, you'll need shims, the ones that go under the differential bearing race on the transmission side. My tranny was out of specs by 2 in/lbs, it came with the DD shim, which is 2.25mm so I'll go with a 2.30mm. Every 0.05mm adjustment should bring the torque up or down 2 to 3 in/lbs. Here is a list of shims:

AA 2.10mm 90564-41014
BB 2.15mm 90564-41015
CC 2.20mm 90564-41016
DD 2.25mm 90564-41017
EE 2.30mm 90564-41018
FF 2.35mm 90564-41019
GG 2.40mm 90564-41020
HH 2.45mm 90564-41021
JJ 2.50mm 90564-41022
KK 2.55mm 90564-41023
LL 2.60mm 90564-41024
MM 2.65mm 90564-41025

There're more, let me know if you need any more part numbers.

Correct procedure to check preload on LSD differential bearings.
http://i529.photobucket.com/albums/dd333/billybrun/08-15-08_0507.jpg


Some parts came in.
http://i529.photobucket.com/albums/dd333/billybrun/08-15-08_1913.jpg


JDM Toyota helical LSD.
http://i529.photobucket.com/albums/dd333/billybrun/08-15-08_0401.jpg


Stock open differential with 8 years old Phantom Grip LSD.
http://i529.photobucket.com/albums/dd333/billybrun/08-15-08_1917.jpg


Damaged output shaft.
http://i529.photobucket.com/albums/dd333/billybrun/08-15-08_1916.jpg


Stock flywheel resurfaced. I don't like lighter than stock flywheels.
http://i529.photobucket.com/albums/dd333/billybrun/08-15-08_1915.jpg


Removing gears from damaged output shaft.
http://i529.photobucket.com/albums/dd333/billybrun/07-31-08_0017.jpg


Input shaft waiting to be disassembled.
http://i529.photobucket.com/albums/dd333/billybrun/07-31-08_0020.jpg


Bell housing with new bearings installed.
http://i529.photobucket.com/albums/dd333/billybrun/08-15-08_0400.jpg

[DooM]

Good write up. I will be tackling this project pretty soon and theres some good info in here for those that are looking to install an LSD.

Also just to clarify: the Mr-s helical LSD is basically the TRD 1.5 way LSD right?

[billybrun]

Also just to clarify: the Mr-s helical LSD is basically the TRD 1.5 way LSD right?

If I remember correctly, TRD 1.5 LSD is clutch type. The one I'm installing is the helical that came stock on the Spyder. People say it's the same as the discontinued TRD helical. If you ask me, they look that same, and I prefer helical over clutch any day. They are quiet, maintenance free and last longer.

[Entranced]

good write up! too bad there aren't any updated syncro's that help with the hard shifting we have in our cars. It'd be nice to throw them in while your doing all of this.

How much did this all cost you, not including the tools?

[kortik]

nice that's a lot of work

[billybrun]

How much did this all cost you, not including the tools?

You can do it for about $872 which was only damaged parts, but I decided to replaced 3rd and 4th gear along with sleeve and syncro to the new improved ones for peace of mind. My total was $1200 plus the LSD $740. I see it as a new transmission with LSD cheaper than new one with out.
I thought of just buying a new transmission from Toyota, but after I opened it, I saw that I could have a better than new for cheaper. That's me doing the work, which is fun and not hard if you get the right tools.

[Vroom_Vroom]

hey whats up man?? I havent seen you post in a lifetime. If I remember correctly you had the black celica and posted vids of you running that 14.1 against a white prelude?? Glad to see your still pimpin the celica, are you still taking it to the strip? new numbers? whp? mods? I believe I still have your vids floating around my comp some where. Thanks for the write up and pics.

[billybrun]

Yeap, I know. I still use the Celica as a backup and daily driver. I have a G35 Coupe too that I kind of rotate around.

[MFChop]

Hey where did you get that info about the torque and preload... ie the service manuals....

I need copies to give to the tranny shop on how to do it right... they screwed up the shimming on mine the first time thus ruining the ring gear and output gear/shaft....ps good write up kinda wish I had the time to do mine myself...

[celicajonz]

go0d write up

[Punkers7465]

Awesome write up, it's really nice that you included the part numbers.

Thank you!!!

edit: why isn't this in the install guide section?

[gndude]

Looking at buying a used C60 with damage - anyone know what these bolt holes are used for - is it a transmission mount?

http://i357.photobucket.com/albums/oo18/todda2026/Picture022.jpg

[Celicasaur]

.

[Entranced]

looks like the front engine mount... no? isn't that the clutch fork in the pic? or am i mistaken?

[Celicasaur]

.

[SuperDave]

A question for Billybrun. At any stage of this rebuild did you need the services of a press to remove the input shaft bearing or press the gears back onto the shafts or for anything else?

[MFChop]

yeah you need a press to put the gears back on....and a puller to remove

[Celicasaur]

.

[monkeywrench]

Looking at buying a used C60 with damage - anyone know what these bolt holes are used for - is it a transmission mount?

http://i357.photobucket.com/albums/oo18/todda2026/Picture022.jpg

Yes, those are for the mount. They break in a lot of crashes. Pretty difficult to weld or you can get a new trans case segment from Toyota for $700 :eek:

Edit: also, what exploded inside that bellhousing??

[shadytunerGTS]

Is Billybrun still around? I wanted to ask him how the ol' Phantom Grip held up and if it worked out well.

[Throttle]

What is the part number for the Harbor Freight Gear puller set?

No problems with pulling the gears with the puller? Does it seem like good enough quality to use it a few times before it would break?

[gndude]

Yes, good question - can you really tear down the transmission with the puller listed? I've rebuilt all sorts of motors, removed transmissions but never opened them up. I assumed it would be too difficult to rebuild a manual but from what I've found out it does not look that difficult? Am I missing something here?

[billybrun]

Is Billybrun still around? I wanted to ask him how the ol' Phantom Grip held up and if it worked out well.

I'm still around, but I left the country once again. I'm back in the sand box...

About the Phantom grip LSD, it looked ok, I guess, when I pulled it out. I sold the old differential with it in it. It still had tension, but I wanted a Helical LSD this time, they work a lot better.

[billybrun]

A question for Billybrun. At any stage of this rebuild did you need the services of a press to remove the input shaft bearing or press the gears back onto the shafts or for anything else?

YES, I really don't see how I would've done it without a press. I used the press at work, it was fast and easy to install and remove the gears and bearings.
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I just noticed the date on the last reply, lol I've been busy over here, lost track of time.