Toyota
5 Speed Into Zephyr 6
By Peter Lukeis
and Jim Flegg.
The
below swap was done to fit a Toyota 5-speed Box to a Mkl
Zephyr, however the swap is perfect for the Mkll and Mklll cars as well.
The box shown above
(A) is a 1982-84 Toyota Celica box.
The 1982-84 Celica
box (B) puts the gear lever too far back for a Bench seat in a
Mk1 Zephyr and (C) shows where the gear lever should be. Note: 1982-84 is the
wrong box as it has the incorrect shifter position.
Dellow in
Australia make a conversion kit that brings the gearstick forward so it fits in
front of the bench seat in a Mkl
car,
DELLOW contact details :
Email: www.dellowauto.com.au
Tel: +61 2 9774 4419
+61 2 9774 3873
Fax: +61 2 9774 4783
(D) See how far back
the mounting for the gearlever is out of the 1982-84 Toyota Celica &
Corona.
(E) This gearbox is
from a later model.
(F) This area is
best suited for the gearshift and would be from an early model 1976-79 Toyota Celica.
(G) Inner of the
spacer ring (shown
below) fits over this shoulder.
(H) Spacer ring
fitted to the inside of a Mklll
Zephyr Bell housing.
(I) The Spacer ring used
for the Mklll Bell housing to Toyota gearbox
mounting.
Note:
Not required if adapting to a Mkll
bell housing as there is almost no space.
(J) Spacer ring fitted to locate and centre the Mklll bell housing to the Toyota Gearbox.
(K) The Adaptor
plate is 5mm thick, use 4 holes only to mount the bell housing to the gearbox.
(L)
5mm thick steel plate.
(M) Note: Cut out is
IMPORTANT so that the plate can sit flush on the gearbox front.
Use a gasket between
the Toyota gearbox front and the 5mm-plate rear face.
(N) 1, Spigot
bearing to go in the stock Zephyr flywheel,
2, Reducer
spacer/bush for the Toyota gearbox front shaft,
3, Spigot thrust
bearing pivot for the clutch fork/lever.
(O) Be careful not to lose either of
the two holding springs.
(P) Here you
reposition the clutch fork/lever pivot point. NOTE: Drill and tap it, DON’T use
rivets as shown.
(Q) Shorten the
lever/fork in this area to suit.
(R) Use the clutch
thrust bearing and thrust fork/lever from the Toyota Celica box.
NOTE: Early Toyota
thrust lever/fork is cast steel, the later thrust
fork/lever is cast iron.
(S) Spacer/locating
ring fitted, (T)
Mklll Zephyr Bell housing, with clutch thrust
fork/lever fitted up.
(U)
Toyota Clutch Plate Part Number R8593W
215mm Diameter.
(V) Machine 5mm off
the shown inside edge off the Mklll Clutch pressure
plate so the Toyota clutch plates spring area will
easily clear the Mklll Zephyr pressure plate inner
area.
(W)
Mklll Zephyr Pressure plate.
(X) 5mm machined
groove.
Notes:
Modification
to floor trans tunnel top:
The
top of the trans tunnel needs trimmed here and then a
tight cover seated and fastened over the opening because the topside of the
Toyota box is higher than the Zephyr box and fouls with the tunnel.
Gearbox cross member,
Modification to the
Zephyr gearbox cross member will be needed to mount the Toyota box. Before
removing the stock Zephyr cross member or the standard Zephyr gearbox, measure
to make sure where the centre line of the Zephyrs gearbox rear tail shaft end
is. This measurement is used to make sure the Toyota gearbox rear end sits
close to where the Zephyr gearbox end did. This measurement helps keep the
front universal joint operating angle close to standard.
Driveshaft,
When
measuring for the new drive shaft, insert the Toyota front yoke fully
(carefully) into the rear of the 5-speed gearbox, then back it out one inch.
Now measure between the front universal joint cup centre
to the rear universal joint cup centre at the diff, to get the new drive shaft
length.
The one-inch free end gap at the gearbox end
allows for the rear travel of the back axle as it moves the drive shaft in and
out of the gearbox while in use. On completion of the drive shaft make sure the
gearbox is filled with the correct oil.
Speedo,
A
new speedo cable will need to be made with the Toyota end on a Zephyr cable.
Make sure on installing the new cable that the cable has no sharp curves and is
not resting on the hot exhaust anywhere.
Clutch
line,
Swapping
certain Zephyr bell housings will swap the clutch slave cylinder from one side
of the car to the other. A new line either matched up from a parts store may
fit or take your clutch line ends to a Brake shop with your clutch line length
measurements, (allow for some engine movement too) and run the line clear of
the hot exhaust as well.
GaleforceZephyrs.com
wish to extend a big thanks to Peter Lukeis and fabricator Jim Flegg
for compiling this article to help other Car owners
Disclaimer: The advice and guidelines given in these articles are given in
good faith. The owners and managers of the Galeforce
Zephyr site will take no responsibility for any injuries or
loss sustained while carrying out the described tasks and procedures or
any consequences arising. Please read the Safety First Article