The carnage! (broken shift and select lever shaft) - MR2 Owners Club Message Board
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post #1 of 41 (permalink) Old September 21st, 2019, 15:55 Thread Starter
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Thumbs down The carnage! (broken shift and select lever shaft)

My 93 Turbo lost the ability to shift gears a few weeks ago. Tracking down a replacement has proved to be extremely difficult. I'll let the pictures speak for themselves...
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post #2 of 41 (permalink) Old September 21st, 2019, 17:22
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You should be able to get everything you need here.

https://parts.lakelandtoyota.com/sho...rimLevel=18213

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post #3 of 41 (permalink) Old September 21st, 2019, 21:36 Thread Starter
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Thanks for the info, however, the part is discontinued from Toyota and every parts supplier I've tried has zero available. My buddy works for a local auto shop and has called around to all of his connections for parts supplies and transmission shops. Nada.
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post #4 of 41 (permalink) Old September 21st, 2019, 22:33
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Find a shop that can tig weld it back together?
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post #5 of 41 (permalink) Old September 22nd, 2019, 01:27
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Quote:
Originally Posted by DesertFox View Post
Thanks for the info, however, the part is discontinued from Toyota and every parts supplier I've tried has zero available. My buddy works for a local auto shop and has called around to all of his connections for parts supplies and transmission shops. Nada.
Make a list of parts you need and I'll see what I can do for you I have a direct connection to Japan.
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post #6 of 41 (permalink) Old September 23rd, 2019, 11:26 Thread Starter
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That's awesome, thank you!
The specific part that is broken (the shaft itself) is 33261-17070, so if anything, that's the part I need. The entire assembly is from a '93 Turbo E153 w/LSD, shown in the attachment, which I would be just fine if I could source the whole thing already assembled.

I am stopping by KO Racing this coming weekend to see if they've got anything in one of their spare transmissions so I'll let you know if I have any success there. Definitely don't want to waste your time if I'm able to source locally.
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post #7 of 41 (permalink) Old September 23rd, 2019, 14:40
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If OEM new parts are not available you can get an entire transmission from salvage and mine parts from it. I've done that for my vehicle manual tranny several times. A little more risky than OEM new but if no new is available it may be your only source.
Car-Part.com--Used Auto Parts Market
is a good resource to locate if none is in your area.
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post #8 of 41 (permalink) Old September 24th, 2019, 11:31
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post #9 of 41 (permalink) Old September 24th, 2019, 12:00
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Doesn’t look like it’s available from them either. Dunno if someone can fab/reproduce the original part?
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post #10 of 41 (permalink) Old September 24th, 2019, 17:23
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Doesnít look like itís available from them either. Dunno if someone can fab/reproduce the original part?
A machine shop would be able to. But it's going to cost some good money. Not talking an automotive machine shop but a true machine shop. Even better if you find one who does a lot with shafts and gears.
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post #11 of 41 (permalink) Old September 24th, 2019, 23:37 Thread Starter
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A machine shop would be able to. But it's going to cost some good money. Not talking an automotive machine shop but a true machine shop. Even better if you find one who does a lot with shafts and gears.
If I can't find a good used part, that is the next possible solution. Also throwing around the idea of going the CAD/3D printing route and having a company like this print it: https://i.materialise.com/en/3d-prin...terials/metals

Thinking if the quality has tight enough tolerances and has the long-term durability, it would be something anyone could download the design for and send off to have it printed. I don't have experience with 3D printing (yet) but have past experience in drafting and 3D modeling, so...heck...what's the worst that could happen?
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post #12 of 41 (permalink) Old September 25th, 2019, 14:15
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I may have what you need but I'm not 100%. I bought a 91 car that was suppose to have a 93+ LSD transmission. After I got the car up and running, found out the synchros were bad. Took it apart and ordered all the damaged parts for a 93. Turns out it had 91-92 gear set in it with the factory 93 LSD. So, I'm not sure what year the shift shaft is. I ended up buying another transmission.

After looking at the part #s, the 1992 seems to be the same as the 1993 but the 1991 has a different part #. Any way to tell the difference?
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post #13 of 41 (permalink) Old September 25th, 2019, 20:51 Thread Starter
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Originally Posted by NverEnf View Post
I may have what you need but I'm not 100%. I bought a 91 car that was suppose to have a 93+ LSD transmission. After I got the car up and running, found out the synchros were bad. Took it apart and ordered all the damaged parts for a 93. Turns out it had 91-92 gear set in it with the factory 93 LSD. So, I'm not sure what year the shift shaft is. I ended up buying another transmission.

After looking at the part #s, the 1992 seems to be the same as the 1993 but the 1991 has a different part #. Any way to tell the difference?
If you're able to snap a pic of the assembly I should be able to tell if it matches (I've been staring at enough parts diagrams recently...)

In case the shift is still in the transmission here's a link to a graphic for removal.

https://www.dropbox.com/s/5mvnssxkr6...0e153.JPG?dl=0

All the highlighted parts are what I had to unbolt in order to pull the assembly out of the transmission case.

The most difficult part for me was removing the lever lock pin (circled in blue). The nut and washer came off no problem, but I had to heat up the shift lever around the pin with a torch (careful not to melt the rubber gaskets) before I could get the pin out, which involved some wailing with a hammer and punch.
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post #14 of 41 (permalink) Old September 25th, 2019, 23:33
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If you can obtain that part and get a model of it that would be awesome. I assume at that point a machine/fab shop or as you said a metal 3D printer could make one. This is a little out of my knowledge range, but bringing this to market for owners would be awesome. I thankfully don't have this issue but I've read about it before...
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post #15 of 41 (permalink) Old September 26th, 2019, 02:04 Thread Starter
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That's the main reason why I would put the effort into creating a 3D drafting design of it, to help out other folks who run into this and offer a good (hopefully not overly expensive) solution. I should be able to model it from my existing part, since it was a very clean break. Just going to take a lot of time with a micrometer and CAD...and bugging my buddies who have 3D printers so I can print up prototypes in plastic before I spend the money to print in metal.
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post #16 of 41 (permalink) Old September 26th, 2019, 06:39
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Here it is. This is as far as I disassembled it when I pulled the transmission apart. I can take more pictures if need be.
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post #17 of 41 (permalink) Old September 26th, 2019, 12:31 Thread Starter
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Would you mind taking a few more photos from different angles? Maybe 45 degrees left and right of the current shot. Trying to see a few of the individual components, because I'm confused about a couple of things in comparison to all of the diagrams I'm looking at from various model years. Thanks!!
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post #18 of 41 (permalink) Old September 26th, 2019, 13:56
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Hopefully these help. I can disassemble it more and or take measurements if need be.
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File Type: jpg 818627B7-94E0-47B6-91C5-C8C1B560E37F_1569524161789.jpg (64.3 KB, 13 views)
File Type: jpg 79A9ED24-A392-489F-A74B-7F99A6B4DA61_1569524172375.jpg (65.0 KB, 11 views)
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post #19 of 41 (permalink) Old September 27th, 2019, 17:24
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Back on the 3D printing. Any thoughts on also making gears and synchros to fab? Is that even possible?
Can someone enlighten me as to what is needed? CAD drawings and detailed, preceise measurements of the parts?
Would a 3D printed metal be able to stand up to the forces?
Would a 3D print be able to be that precise on measurements?

Sorry to hi-jack.
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post #20 of 41 (permalink) Old September 30th, 2019, 22:29 Thread Starter
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So I sourced a shaft assembly from an open diff E153 from KO Racing this weekend in Portland. It looks like I'll only need a small bit of machining with a lathe to make it match my current part. I'll update this thread if/when I get the work done with (hopefully) very good results. The comparison photo shows the one component that needs to be adjusted which is just a small groove for a snap ring that holds the spring seat in place.

@NverEnf: I'm really confused with the part you have because every diagram and part I've looked at, it seems the shaft itself is longer, and the actual lever that bolts into the end of the shaft is at the other end and the "control shaft cover" doesn't have a hole at the end. I attached a couple pics to show what I mean.

@mr2_mike: This is not something I have experience with. I'm only considering going down the route of 3-D printing if I'm not able to fix the problem through more "conventional" means, but it would mean extra effort in drafting, lots of trial and error, and probably finding some folks who are more experienced than me to help answer those kinds of questions. Would be an adventure for sure!
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File Type: jpg control_shaft_cover_example.jpg (135.5 KB, 11 views)
File Type: jpg IMG_4213.JPG (198.5 KB, 8 views)
File Type: jpg Turbo-E153-shaft-comparisons.jpg (109.3 KB, 12 views)
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