Here comes my progress of the day. Engine/gearbox out, gearbox removed as well as the clutch and the turbo:



The surface of the flywheel and the clutch plate showing much signs of overheating:





and the clutch discs is nearby worn out even as it only have 70k km done:



As usual I found more things to repair than expected. Will have to get the Aussi downpipe welded as it is cracked:



Removed the turbo as I suspicious it to cause the oil consumtion the car shows since the last year. Will be replaced by a custom made upgrade turbo:



Also startet to overhaul the driveshafts as I´ve seen that they are aged:



What I didn´t expected was to found extremly aged greese. It´s so hard than I can cut it with a knife:



Good that I´ve bought the ultra expensive original Toyota boot sets for the front and rear driveshafts. Costs 446 € all together, but came with all the bits needed taht aftermarket boots most times miss.

Front:



Rear:

_________________

After having tried the usual 'Optifit' boot once, I am only buying Genuine Toyota boots (or other parts) ever since. They are really worth their price and will outlast the cheap thin Taiwan spec Opticrap. Good to see you're following the same principals.

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

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

Good to see you're making progress pulling the car apart. Nice write up and pics. Keep us posted on progress.

_________________
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

Hi Eric,

nice crack on the DP, what was the reason?
on my one i didnt used the lower support bracket, the aussie wasnt weldable (to much damaged) so the only one fast available was a cheap ebay one
.....last long until today

greetz

_________________
KEEP COOL UNDER PRESSURE

street legal?.....perhaps in tschibuti

Are you ordering the OEM parts through a dealership or buying them online? I'd be interested to know if the parts department at my local Toyota dealership would order parts for a GT-Four when I need them.

_________________
Matt
Currently planning an ST205 track & weekend build

I get many many parts from my local dealer so it shouldn't be a problem. Having the drawings from the parts catalogue is really helpful.

I find my local dealership excellent especially for things like bolts and clips, small stuff that TCB et al don't carry.

_________________
GT4DC Events Co-ordinator
1996 ST205 UK

If you use a Toyota dealer to order parts its helpful to print out the details for them from the EPC. If you haven't already sownloaded and installed it I would recommend you do so. I'd post the link but I'm on my mobile so it's too hard.

_________________
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

Snap!

_________________
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

I order my OEM parts at a local dealership. I´ve learned and worked as a car mechanic there in the past and still get a discount on all parts I order.
As my car is a *bleep* out of ST185 CS shell with a ST205 heart it´s a bit difficult to find the right parts. Mostly I search the part numbers at http://www.toyodiy.com/parts/q.html and tell my ex boss the numbers.

_________________

Don´t know why it cracked. I belief it´s more a ask of time until any DP cracks. Sooner or later they all will do. My Aussi DP is in the car since 2008 and done 30k km since install (including the support bracket) .Not a big thing to get it welded as it´s only one little crack.

_________________

Worked on the engine today and carryed the new gearbox from my shed to my mate´s garage I´m working on my car.

Replaced the crankshaft sealing and installed the new clutch including the new flywheel the Hyper Singel came with:



Than worked on the other end to replace the power steering pump after cleaning up the mess the old pump leaved behind. The pump is a used ST202 one I´ve bought cheap from a friend. Also replaced the crank and camshaft sealings and the timing belt. Used a timing belt from HKS I bought at the german MR2 board as it was a good deal and sure an upgrade, even as it isn´t necessary:



Finished with new OEM V belts:

_________________

I've heard and seen more cracked Aussie pipes than eBay ones by far. The two eBay pipes I've had ( one bought alone ) and one free with the xs stainless system are still fine after 140,000 miles over 7 years and the one I sold on has done 5years of service with no issues.

--
Darryl

_________________
--

Darryl

Could it be down to bad fitting and hitting the engine or sub frame?

Anything under stress will eventually give up.

Exhaust alignment is very important, so sticking an after market down pipe that is not exactly the same profile as the original CAT down pipe can cause problems?

Your answers.. For one Point>>>

_________________
[color=#000080]ST205 WRC 1994
Hybrid turbo
Apexi AVC-R
Apexi Power FC (Not being used ATM)
Apexi Power commander (Not being used ATM)

The downpipe is fitted without tension on it and don´t have contact to other parts. But the fronpipe is in permanent contact to the Cusco brace under the front axel:



There isn´t a way to avert this as the frontpipe is 3" thick.

_________________

_________________
GT Four Adovansu

"I want to enjoy the powerful and nimble agility behavior."