Need help, no gears after motor rebuild - Toyota Nation Forum : Toyota Car and Truck Forums

wrenchdad · 01-01-2005, 10:00 PM

Hey Guys,

I just completed a motor rebuild on my son's 92 MR2 NA 2.2 while we had the motor/trans out we replaced the clutch assy, struts, back brakes, header and cold air intake. Now after getting everyting finished, the car will not go into any gear! I made sure when I removed the shifter cables not to get them swapped by leaving one still clipped to its mounting bracket and the other one I disconnected by removing the spring clip. And they will not reach to hook up to the wrong lever. It will just not go into any gear at all. I would think if I had them reversed I would at least get some gear even if it was it was not in the right shift pattern. But I do not even see the reverse lights come on. I checked the clutch and it is engaging and disengaging correctly. Is there anything I can do without having to pull the trans out again. I mean I will if thats what it takes but just was hoping I it might be something simple I could do from the outside. I made sure when I pulled the halfshafts out not to let the gears slip by inserting short pieces of PCV pipe the size of the shaft stubs and duct taping them in place.

The only other thing I can think of is when we were lower the motor/trans out of the car it did roll over on its side which was the side where the shift levers come out. Also we did move the trans around some to clean all the junk off it. Could that have made something fall out of place? If I have to go into the trans, what is the right way to start tearing it apart? I checked my repair manuals and none of them have a internal view of transmission for this car. I have rebuilt manual and auto trans before but I would like to have something to go by before I tear one apart.

Does anyone have any ideas? Thanks WD

JekylandHyde · 01-02-2005, 05:56 AM

Have you tried shifting the tranny manually? ~ without using the shifter & cables. Just try to move the levers around. If you can move the levers into gear, then you most likely have a broken shifter cable.

Unfortunately, I suspect that is not the case.

wrenchdad · 01-02-2005, 08:47 AM

Yes I have tried to move the levers by hand and the car is still like its not in gear also when you shift from 1st - N - 2nd it feels like you have five psoitions instead of three. When I watched the cables/levers on the trans it appears that the levers are overtraveling on both ends? That is on the lever that turns on the other lever, the one that moves the shaft in and out, it appears that it is not connected to anything. I can move it and I don't feel it touching anything in the trans. It sure looks like something has fell out of place. I mean, the motor/trans did roll over on its side it was not like it hit real hard but maybe that let a internal shift fork disengage? I would have thought that it would take more than that to do anything internally to a trans but I have never been into one of these types before. Been in and rebuilt a Ford toploader a couple of times but not one of these. But I may not be able to say that anymore after this next week!

Is there any place on the net where I can download a pdf file that would show me the internals of this trans?

thanks again WD

JekylandHyde · 01-03-2005, 05:28 AM

Happy reading:
http://www.mr2-tech.com/bgb/mechanic..._transaxle.htm

wrenchdad · 01-03-2005, 07:07 AM

Thanks JekylandHyde!

WD

wrenchdad · 01-03-2005, 01:12 PM

Thanks guys, I found the problem, the actuator on the "No. 1 shift inner lever" is broken off! I went to my local Toyota dealer and order the part it will be in on Friday. Cost = $75 + tax. The bad side is I did not find the missing piece, I ran a magnet down as far as I could and did not pick up anything. I am thinking about draining the fuild out and see it anything comes out with it.

here is the picture that shows the part , upper left corner of drawing.

http://www.mr2-tech.com/bgb/mechanic...ransaxle/6.htm

PS I did notice when I pulled the shift levers off that there is a small square bushing that had a great deal of wear on it. I ordered it too. cost=$11 + tax. You may want to check this on your own trans, looks like if it is worn that your netural gate may have some extra slack in it. This is a very easy fix that is external of the trans, could not find a picture that shows the lever breakdown but it goes on the pin that rides in the groove on the lever that turns.

thanks again, WD