I agreed to build our hero a special gearbox, one that combined the best of all worlds for his 2zz engine.
So he sent me a Corolla T sport box, the plan being to use the 1st-5th gears to keep his 2zz in lift all the time, if you use a 1zz box it falls out of lift during gearchanges. Then swap in a Mk3 LSD unit, and a Mk3 6th gear pair to give him extra long legs on the motorway.
So this is my gearbox building station with lots of custom made tools that enable me to build gearboxes and a bearing press for reassembly.
Here is the Corolla T sport box....
http://www.twobrutal.co.uk/forum/ima.../2015/05/2.jpg
With my special home made puller i stripped the 5th and 6th gear assemblies down...
http://www.twobrutal.co.uk/forum/ima.../2015/05/3.jpg
http://www.twobrutal.co.uk/forum/ima.../2015/05/4.jpg
Before too long we end up with a gearbox exploded out all over the place....
http://www.twobrutal.co.uk/forum/ima.../2015/05/5.jpg
Then i started work on this 30k 1zz 6 speed, we want this for the LSD, the cases and the 6th pair.
http://www.twobrutal.co.uk/forum/ima.../2015/05/6.jpg
That too got blitzed apart until i was just left with the lower case, which then got steam cleaned, immaculate.
http://www.twobrutal.co.uk/forum/ima.../2015/05/7.jpg
The crown wheel from the 2zz diff needs using on the LSD diff, they look very similar but if you used the 1zz diff with the 2zz internals very bad things would happen!
http://www.twobrutal.co.uk/forum/ima.../2015/05/8.jpg
Final assembly starts, LSD in, 2zz internal gears in, but lets use the shiney 30k 1zz selector stuff, why not.
http://www.twobrutal.co.uk/forum/ima.../2015/05/9.jpg
The cases built back up and the Mk3 6th set installed...
http://www.twobrutal.co.uk/forum/ima...2015/05/10.jpg
And there we have it, one 2zz/LSD/Mk3 longer 6th custom built gearbox.
http://www.twobrutal.co.uk/forum/ima...2015/05/11.jpg