85 TK5 teardown/rebuild photos

[kishy]

I've just completed a mostly-full rebuild (bearings and seals only) on my '85 TK5 and figured some here might appreciate the photos.

Pics here:

https://imgur.com/a/wERNM9R

This was prompted by excessive fluid loss around the slip yoke, caused by a worn extension housing bushing. The extension housing bushing can be replaced without a full teardown, but there was also input shaft bearing wear which could be detected by letting off the clutch pedal in neutral and hearing a subtle whirring noise. With the trans removed, input shaft lateral wiggle was minor but obvious so a whole bearing kit made sense to do.

It hasn't gone back into the truck yet, but will be soon. Some corners were cut here but none that are likely to present any issues, at least not for a lot of mileage hopefully.

 

[JRR1285]

Thank you for posting this. Not sure if this is going to be above my level but I will need to rebuild my TK5 this spring.

 

[bluebroncoii]

If you still have it, would you be willing to sell the makeshift socket you used for this rebuild? I'm about to start a TK4 rebuild and finding some sort of speciality tool that you mentioned in your post seems to be impossible. I can only find the "FORD ROTUNDA T85T-1000-A Ranger Bronco II 4x4 Mitsubishi Transmission Tool Set" and I'm not sure any of the tools in that are for that nut specifically

 

[kishy]

If you still have it, would you be willing to sell the makeshift socket you used for this rebuild? I'm about to start a TK4 rebuild and finding some sort of speciality tool that you mentioned in your post seems to be impossible. I can only find the "FORD ROTUNDA T85T-1000-A Ranger Bronco II 4x4 Mitsubishi Transmission Tool Set" and I'm not sure any of the tools in that are for that nut specifically

I had left the special socket at my friend's machine shop which is in a different, but nearby city. I'll ask him and see if he wants to part with it. He was the one who cut and welded it for me.

Shown in photos but not really talked much about, the nut is a stake nut (locked in place by hammering part of it into a slot in the shaft), and when we removed it, we couldn't do a very good job "un-staking" it. It ended up taking a couple threads off the shaft and the nut was destroyed in the process. I was fortunate that a new nut was available on eBay at the time - D67Z-7045-A - and the shaft had enough threads left for it to grab.

So whatever you do to get that nut off, make sure you thoroughly un-stake it before you turn it, or your project could become scrap metal pretty quickly.

Do note the TK4/TK5 are not Mitsubishi transmissions so that tool set may or may not have any useful things in it. Toyo Kogyo is Mazda. These transmissions are siblings to ones found in Couriers/early B-series, and RX-7s. For example, I'm pretty sure (but not 100%) that this is the same locknut: https://www.atkinsrotary.com/87-95-...nsmission-5th-gear-lock-nut-3648-17-629-.html

I'll check back in about the socket soon.

 

[Shran]

Shown in photos but not really talked much about, the nut is a stake nut (locked in place by hammering part of it into a slot in the shaft), and when we removed it, we couldn't do a very good job "un-staking" it. It ended up taking a couple threads off the shaft and the nut was destroyed in the process.

I have a little chisel that I ground down for un-staking nuts like this - works great - way easier than using a screwdriver or similar tool.

 

[kishy]

If you still have it, would you be willing to sell the makeshift socket you used for this rebuild? I'm about to start a TK4 rebuild and finding some sort of speciality tool that you mentioned in your post seems to be impossible. I can only find the "FORD ROTUNDA T85T-1000-A Ranger Bronco II 4x4 Mitsubishi Transmission Tool Set" and I'm not sure any of the tools in that are for that nut specifically

I had left the special socket at my friend's machine shop which is in a different, but nearby city. I'll ask him and see if he wants to part with it. He was the one who cut and welded it for me.
...
I'll check back in about the socket soon.

I spoke with my friend. He is unwilling to sell the socket, on the basis that he owns and works on RX-7s (with some focus on the Turbo II which uses the sibling transmission of this one) and will therefore need it again at some point.

He is, however, willing to entertain renting it to you. e.g. you pay a large up-front deposit, maybe 100USD, we send you the socket, you use it for your project, and mail it back to receive a refund of $80 making your rental fee 20 bucks plus the return postage. Although we're in Canada, we both frequently cross the border so all mailing could be done inside the US, as long as your timeline is flexible enough to let one of us ship it on a date that we're already going to be going to Detroit, and between the two of us, that's roughly every 2 weeks.

If something along those lines would work for you, send me a PM and we can figure out the details. PayPal or mailing cash are the options we have available; most other options you might ask about (e.g. Venmo?) aren't available to us as Canadians.

I have a little chisel that I ground down for un-staking nuts like this - works great - way easier than using a screwdriver or similar tool.

Yeah, if I had paid it more thought, I would have tried to do a better job un-staking it, even if that meant maybe using a rotary tool to cut out the staked part of the nut. The mainshaft could easily have been totally ruined by that little screw-up (arguably, it technically was) and I'm lucky it only lost a thread or two so there was enough for the new nut to hold onto.

 

[Bugga390]

Im new to this group i have a 1986 ranger 2wd with the toyo kogyo 5 and am in the process of rebuilding it but can not figure out how to get the input shaft out, i have the counter shaft out and have pulled the mainshaft and input shaft apart but can figure out how the input shaft comes out any help would be great thank you