Hilux 4x4 Forum

Greetings all. I have a problem with my 4Y gearbox. The gear lever wont go into gear 5 and reverse unlesss you hold it in a certaiin position. it seems rather loose. any ideas?

Check the restrictor pin is not broken/damaged or loose. 5th and reverse both on the same side.
If not, then it points to the reverse/5th gear shift shaft assembly inside.

Pin could be worn or the nylon bushing inside is worn or collapsed. Put the box in neutral and pull upwards on the gear lever (it's spring loaded). If it moves more than about 5mm up and down the wear is excessive. Toyota supplied a complete gear lever with the assembly but a gearbox specialist should be able to replace the bushing and build up any wear / re-machine the pin bush in the turret housing.

Where in Pta can one find those 6mm pins in the gear shift lever retainer, the ones that the lever hinges on? Or do they have to be riveted/pressed in place with a special tool

Stef, it's not the pin that wears - its the bushing in the aluminium housing on the turret that wears and becomes elongated. IIRC the pin itself is a tight press fit into the lever shank.

Not the same model, but maybe this helps... https://www.youtube.com/watch?v=tcZusrWw2ao

In this case the pin more than the Alu:
Pins are actually pressed into the turret with slots machined into the sphere on lever.

Sifu-Lux wrote: ↑Mon Jul 10, 2017 9:34 am Not the same model, but maybe this helps... https://www.youtube.com/watch?v=tcZusrWw2ao

Pretty much the same as the w56...those pins in the turret, that's what need; don't want to buy the entire turret/retainer.

Yoh! That's badly worn! You won't get from the dealers - they only stock the complete assembly. You might have to have one made up.

Been to Gemini yesterday during lunch hour, they also don't have...(they did however have the infamous crank seal that no Toyota dealer in Gauteng had in stock, I'm talking Toyota OEM seals, not the R100 samples).

Anyhow, I thought I'd use the shank of a 6mm HSS drill bit, even 6.15 if I can find one. Existing holes are just over 5mm, so if I could drill it out to 6mm and press fit a 6.15mm shank it should be fairly tight....and still fit inside the slots in the sphere. Just not sure what to do ito a flange outside to prevent it from falling onto the box if they become worn out again

The < R50 fix:

2x 6mm HTS dowels - R4-40
1 x 5.9mm HSS drill bit R40

Nice tight fit with stud lock, nuts on the outside also tight fit with stud lock on the dowels and epoxy between the nuts
and the housing

Now that's what owning a Hilux is about :) Home made improvements better than factory! (at much lower cost)

Nicely done Stef. That should outlast the factory set-up by a long margin.

Thanks gents, I sincerely hope it lasts...I will have drive this bakkie until it takes size 13 rims...
I was tempted to weld the nuts onto the high tensile dowels, but that would make them soft again, hence the stud lock/epoxy approach.

Just on a sidenote, I needed a 4mm dowel on the propshaft of my little mercury outboard....R200 from the agents(who orders it from Durbs) vs R2-20 from the local fastener shop virtually on my doorstep. Long live DIY