TURBO's L52 (rebuild in progress)

[TURBO]

5th / rev interlock

[TURBO]

5th gear detent ball and spring

[TURBO]

interlock pin order

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interlock and detent

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[TURBO]

baggies are handy

[TURBO]

this could have been done first, and probably should have been, but whatever... i waited... shoot me 

[TURBO]

this part could have waited till now because it was buried under all the shift rods

[TURBO]

[TURBO]

rear seal removal

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PART 3: CLEAN AND INSPECTION

[TURBO]

i recomend this stuff it works awesome
got it at OSH for $12.99

-$12.99

[TURBO]

this is where a FSM comes in real handy
You can buy the original Factory Service Manual (FSM) at:

    Toyota Material Distribution Center
    750 West Victoria St
    Rancho Dominguez/Compton, CA 90220-5538 USA
    1-800-622-2033
    (outside CA)(M-F: 7-5 PST)
    1-800-443-7656 (inside CA)
    1-310-818-4630 (in or outside CA)

or for 2004 and older go to http://www.helminc.com

i'm not gonna spend a whole lot of time on this part, but i'll throw out a few measurements i took... "max" is where there should have been no wear, and "min" is the thinnest measurement i took or the highest wear point for that part

                                            max        min
1st/2nd shift fork                     0.275"     0.2545"
3rd/4th shift fork                     0.2805"    0.250"
5th gear shift fork                    0.316"     0.311"
shift rails                                0.550"     0.550"
reverse idler shaft                    0.9445"   0.9445"
scyhchros                               N/A        0.030"


the FSM says the scyhchros  should have a minimum of 0.030" gap
mine were all pretty much right around there... so i'm going to replace them with new ones
this was kinda hard to measure because of the burr the factory leaves when they cut the gear...

*below are pics of measuring wear and non wear points

[TURBO]

here are my output shaft's measurements     

[TURBO]

other measurements will need to be taken during the assembly process.... so lets......

[TURBO]

PART 4: ASSEMBLY

[TURBO]

first i started off with a quick surface check

[TURBO]

i'm gonna call this the gear select rod...

[TURBO]

O-Ring grove

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gear selector rod seal

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I inserted what I'm calling the "gear selector rod" all the way just to check fitment, then I pulled it back out so i could install the "dangle-ly-do-hicky"

[TURBO]

i aligned the hole and put the bolt in finger tight.

[TURBO]

cycle test    

[TURBO]

tighten bolt

[TURBO]

got this "mechanic's wire" at harbor freight for $0.99

-$0.99

[TURBO]

safety wire the bolt

the point here is to wire it so the bolt cant back out or loosen... so do it in a way that if it starts to get loose, the wire will get tighter before it gets looser.

[TURBO]

[TURBO]

next thing i did was start with 5th gear shift rod and put the detent ball and spring in the top cover

[TURBO]

i bought some "HD springs" from Marlin's

they arnt on the web site, but they were pretty cheep just give'em a call 1 (559) 252-7295

[TURBO]

i was instructed to use only two (2) HD springs and to put them in place of 1st/2nd and 3rd/4th shift springs. 5th gear has two detent springs, and it wont ever pop out of reverse. it's pretty easy to tell'em apart...