Transmission issues w/ 1981 2WD 22R

[RuralTowner]

Talk about a pain in the ass. :( Had to remove the line-up peg on the drivers side of the tranny since the engine already had one here...and drill out the hole to just oversize. Drilled out the peg hole in the top of the bell to make sure the top peg in the engine will go in...STILL not lining up even though all measurements. Mind you it took me an hour of trying before I noticed the first peg was causing a problem. Had to remove my seat and extend the notch in the floor board since the belly of the tranny extended several inches further back than the old one did I can get the tranny in except for the last 3/8th of an inch...goes in the clutch but not making it into the pilot bearing (yes the input shaft of the 5sp matches my old 4sp)...tomorrow though will be Round 2...I think the back of the engine is sagging a bit too much (to be expected w/o the tranny in place)...so will need to get a jack and piece of wood under it to raise it a bit and somehow work my way under to finish the lining up.

When I originally had my old tranny out it too was a pain in the arse...but not like this. At least I can take comfort in the fact that the problem would be identical with that replacement 4sp. <sigh>

[tbplus10]

Sounds like this swap is gonna fight you all the way to the finish line.
I wish I had a magical recomendation to make the job easier but it sounds like you covering all the bases already.

[RuralTowner]

Ok 1 problem: I cannot get the transmission to line up with the pilot bearing. The bell goes on just fine on its own. The input shaft at its narrowest and thickest is identical to the old transmission and pilot tool and it goes into the clutch disc fine...BUT!

The input shaft is 3 1/8th inch instead of 3 1/4 like the old tranny. The closest I can get the transmission installed is 1/8th an inch from flush...I do not have enough input shaft length it seems to make it to the pilot bearing to complete the lining up. NOTE: The input shaft of both the 5sp and spare 4sp are identical...so even if I was using the latter I'd still have the same problem. I've spent 2 afternoons so far trying to get it lined up.

Here's my question: Did flywheel thickness change at all between 81 and 88? It would seem that if it were even 1/16th an inch thinner I could jostle the tranny into place. I already eliminated the throwout bearing hitting the fingers as a culprit...there's a good inch or so of travel as it currently stands before the 2 touch when I move the fork. Or possible is the newer years pilot bearing thicker?

I'm at a loss to get things lined up.

[RuralTowner]

Managed to remove the alignment pegs in the engine to see if that will at all help...will know when I get back to it tomorrow after work. Got back too late today to try...particularly since the extra set of hands wasn't available to handle the rope at the rear of the tranny.

The replacement transmissions are 1/8th inch shorter in the splines. Okay what changed for them to do that? Was the center of the crankshaft where the pilot shaft is pressed in...extended back that much more in the later years?

[RuralTowner]

WOOT! Seems to shift in all gears fine! FINALLY OVERDRIVE so bye-bye(?) 28-30mpgs and hello 30-32(?). Now can risk the drive to near Phoenix to those Pick-A-Part places...though I'll still be driving in the slow lane even though the posted limit of 75 wouldn't be as BIG a deal anymore...much over 65mph and oil consumption starts to noticeably rise from the norm of about 1/2qt every 2 weeks-ish.

Just need to reroute the speedo cable now. Going to remove it completely then knock a hole in the tunnel so it runs from the speedo...through and down along the dash...then into the tunnel. As it stands its about 3 inches too short to work proper .

Drained what little oil was left in the tranny before doing the test run...had a bit more metal paste than the dead 4sp did...felt a couple slivers in there too but the test went fine. Going to run it for this next week using this oil batch which should be plenty of time to clear up any other loose metal grit. Then I'll put in a fresh load along with some STP.

Now the only problem is that my speedo won't work with the tranny. 45mph indicated is 60...my speedo is a 0-85...and I'm guessing I'd need a 100-110max...the head only. The one that originally came with the truck...the odo took a dump on me so I used the 0-110 from a parts Corolla I had...worked okay enough...though the odo stopped turning for it eventually...even though it still worked. The speed discrepancy was about the same as mine now reads...just opposite. At the start of May I Spent 50$ off eBay for a proper replacement but now that replacement wont read right

The 5sp is of a much newer year and the speedo drive gear is probably different enough from the one I pulled from my dead tranny to prevent re-using it...maybe? The 5sps gear is pretty well stuck...I'd have to take channel locks to the threads and thus ruining the ability to attach the speedo cable...just to get the gear out. I guess its time to follow up on that speedo out of that mid 70s Toyota pickup...thats literally next door to the guy I got the 5sp from.

[Dadstruck]

Glad to see that you got it fixed for the most part. Let us know on the other

[RuralTowner]

Haven't yet had the chance to look into that other truck's speedo...I know where the guy lives...but since I have to drive onto a large piece of private property first to get there I'd just as soon wait till I see him again. Going back for that transmission though was an another matter. In this case I don't have a phone # so can't call ahead.

Anywho...all's been good so far. Since the swap I've gotten 32 on the first fill-up...31+ on the second (both had some headwinds)...32.2 on the third....and today's fill up? Somewhere right between 33.5 and 34mpgs by using the approx miles I travel to/from work (I used to use this method for an extended period and is within a few miles of the real #) and the adjusted number of my odo (every 5 miles I need to add 2). ~425 miles on 12.5-6 gallons...TAKE THAT you current "economy cars". My car never gave this much after babying it (32.7 and it did that only once)...and even the 78 Corolla I have (all but given up hope on fixing proper) wouldnt reach that # unless factory new even with its own 5sp.

At this rate the truck's gas savings will pay for the transmissions in about 6 months...

[MD_Weems]

LOL - that is funny. Glad you got the tranny fixed, hope you find a speedo that works out.