2ZZ Transmission Rebuild: Advice/Guidance Needed - Toyota Nation Forum : Toyota Car and Truck Forums

Evil Twin · 08-13-2008, 12:29 AM

Hi All,

I have a Lotus Elise with a Toyota 2ZZ motor -- I believe it's the same motor used in the Celica GT-S among other Toyota models -- which gets driven pretty hard (it's a track car). I need to rebuild the transaxle -- the second gear synchros seem to have worn to the point where it's hard to get shift into second gear after hard braking. When I first got the car, I could shift into second pretty much regardless of engine speed, then blip the throttle and let out the clutch. Now, I have to blip the throttle twice -- first to get into second gear (with the clutch in) and second when I let the clutch out (to rev match). I'm told that the transaxle is a bit of a pain to rebuild, as everything is press-fitted, but it's doable. My questions are:

1. Does anyone know where I can buy the mechanics manual so that I do muck this up?

2. Does anyone happen to know enough about the parts to tell me what I need to order for the rebuild? I'm told that the transaxle is no different that what is sold in the Toyota line but that the gear ratios are closer (and are only available in Japan -- but the gears seem fine, it's the synchros that are worn).

3. Does anyone have any suggestions for sourcing the parts? I'm new to the Toyota world, so I can't use any of my usual vendors for parts.

Thanks for your help,
Twin
Oregon

Elliot · 08-13-2008, 02:41 AM

trust me dude, a tranny rebuild isnt something you do in your garage. you need tons of special tools and guages and machines and stuff like that so its better to take it to a shop.

also are you sure its not just the clutch TOB?

***toyomoho*** · 08-13-2008, 09:56 AM

You would need to find out what US models used this trans, then find a service manual for one of those models. Start with Google, Wikipedia often has Toyota models and the trans listed. Do a search on specific model trans.

The Haynes and Chilton manuals do not cover trans rebuild, this leaves Toyota. Suggest a Google search, Ebay sells a lot of used OEM manuals or try used book stores such as Powell's in Portland.

If the part(s) are still available the Toyota dealer should be able to order them. You may have to bring the manual down and show them the part. If not, might look for racing part websites. Have not researched this thus don't know what you would find.

If you need bearings and seals and they are standard types a bearing house may be able to obtain them.

Elliot · 08-13-2008, 01:53 PM

Quote:

Originally Posted by toyomoho

You would need to find out what US models used this trans, then find a service manual for one of those models. Start with Google, Wikipedia often has Toyota models and the trans listed. Do a search on specific model trans.

The Haynes and Chilton manuals do not cover trans rebuild, this leaves Toyota. Suggest a Google search, Ebay sells a lot of used OEM manuals or try used book stores such as Powell's in Portland.

If the part(s) are still available the Toyota dealer should be able to order them. You may have to bring the manual down and show them the part. If not, might look for racing part websites. Have not researched this thus don't know what you would find.

If you need bearings and seals and they are standard types a bearing house may be able to obtain them.

yes getting ahold of the replacement parts is not a big deal, but while you are putting it back together if anything is mis-adjusted you will end up with a bigger problem than the one you are trying to fix, remember that there is a reason why haynes and chilton dont cover trans rebuild, it even says in the book that its reccomended that you take the car to a shop

Evil Twin · 08-20-2008, 01:37 PM

Thanks, all, for your help. It took me a while to get this information, but the gearbox on my Lotus is, I am told, a C64 box (which I believe is only available in Europe). My understanding is that the C64 box is identical to the C60 box (which is available here in the US) but has a longer 6th gear. Assuming that is true, does anyone know:

1. Where to get the mechanic's manual for the C60 box?

2. Whether Toyota sells a "rebuild" kit for the box or will I need to specify the parts individually?

Hope this helps. I appreciate any and all advice. While I do not have the skills to do this work myself, I will have help from someone who's rebuilt a dozen gearboxes (Hondas and Acuras, unfortunately, not Toyotas) whom I trust. My job is to collect the manual, parts, and all the information I can get to help with the job...

Best -- and thanks!
Twin