Darell Staniforth Motorsport re-built mine,
a new 5th gear syncro from Toyota was used.

He was the gearbox re-build man for Toyotas.

Not sure what tools were used,
but he could re-build yours if you posted it?

Stephen

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1993 Carlos Sainz 2939, Forged, Apexi RX6B turbo with external wastegate. MOTEC M4, AFPR and 800cc injects. 3" exhaust, +1mm valves.ST205 cams. Rays 8.5" x 17". 205 rear subframe. Bilstein coilovers. 205 brakes.TRD diff

The RM399E repair manual for the transaxle is available from the Swiss Drivers club here
http://www.gtfour.ch/info/buecher/st205 ... rm399e.pdf

Tools wise I'd expect you will need a DTI gauge and a set of feeler gauges over and above the usual fully socked tool cabinet. Probably an array of bearing pullers too

I have to say that I wouldn't want to touch a gearbox build myself. You're likely to see lots of damage when you pull the end of the gearbox off. I suspect the "usual" broken selector fork and a bunch of shrapnel. If swapping obvious bits doesn't fix the issue then I'd sooner swap the whole gearbox

I´ve got a education as a car mechanic. So even as I don´t work in this job since 15 years I´m not afraid to do a bit more difficult jobs on my cars myself. Up to that I can always ask the master of the garage I´ve learned and borrow repair manuels and special service tools from there. I wouln´t go so far to do a full gearbox rebuild myself, but I think I can replace the 5th gear sycro myself.

Opened the box today:





Looks like it will be done by replacing the 5th gear syncro. Hope the car will be running again soon.

A full rebuild of the old box woulnd´t be an option anyway as the swap to an already bought ST205 gearbox was planed for the next winter. Would prefer to do the swap now, but I don´t have the money for a nice clutch, a lightweight flywheel and the swap of the TTE lockdiff from the old to the new gearbox now as this burns all my money at the moment: http://www.imoc.co.uk/forums/viewtopic.php?t=168603

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Ouch

Hopefully just replacing the hub will fix

I was expecting a broken fork, not a smashed hub. Interesting this is the second in a short time we have seen. I wonder if this is just coincidence

Checked the Prices for the parts that would be needed to repair the old gearbox yesterday. Much more Money than I will so stick into the old gearbox. So I decided to go for the big solution.

The car will get out of use for the next month or two so i will have the time to buy the parts bit for bit. Bought the most expensive one today:



I will also replace the Timing belt, cam driveshaft and crankshaft sealins, driveschaft boots, the Turbo and the Radiator.

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Cool retro build man! I remember you telling about it during the Swiss meet in 2008, but never seen it before.

I've shot a few pics of the Fritzinger AW11 in Slowly Sideways during Rallye Deutschland 2010. You want them?

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René - Carlos Sainz 2433•5000
Turbocelica.nl | ST185 CS restoration and full rebuild

If it ain't broken.. it soon will be

Sure !!!

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Just had look at your AW11 build thread on IMOC. Looks like a huge amount of work. Car looks stunning. Well done!

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Thank You for the warm words to my MR2 !

Was able to set the next hook after a point of my shopping list:

- ST205 gearbox 440 € *done
- Exedy Hyper Singel clutch 1050 € *done
- Used waterpump für the intercooler system 70 € *done
- All eight driveshaft boots, original Toyota parts 446 € *done
- Used powersteering pump 30 € *done
- Damaged CT20 turbo 150 € *done
- Rebuild and upgrade turbo 360 € *done

- Timing belt
- Cam-, crank-, driveshaft sealings
- LSD oil for gearbox and rear diff
- Alu radiator
- Two Spal fans for radiator

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Drove the car to a mates garage today as he has a car lift. Also ordered the engine and gearbox sealings and the v belts. All the other missing parts arrived over the last weeks.

Took two weeks off from work and so the project engine/drivetrain rebuild will start tomorrow.

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Good luck and happy spannering

+1 and take pics ftw.

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René - Carlos Sainz 2433•5000
Turbocelica.nl | ST185 CS restoration and full rebuild

If it ain't broken.. it soon will be

First day is gone. Engine is disconnected, braces are out, frontpipe is removed as well as the probshaft. Driveshafts are bolted off and just have to be took out.



Also testfitted the alu rad but it is so thick that there is no chance so get a fan between the rad and the Aussi downpipe:



I´ve bought two Spal fans, but because of this I only can use one of them:

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I thought the ST185CS/RC used 'push' fans mounted in front of the rad, or was that just the TTE ST185's? I'm an ST205 jockey so not familiar with 185's

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Only the TTE ST185 hat two push type rads with kevlar shrouds. The street ST185 Turbo/RC/CS had a singel pull type fan plus a 2nd smaller pull type one if they was fitted with aircondition. The radiator setup is the same as on the ST205 with the rad for the intercooler system a few centimeters in front of the main rad.

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