Okay, christmas is over, got the use of a camera and got a break in the weather to do some work
happy New year to everyone. Some updates...
After getting the engine out, i gave the engine bay a bit of a scrub (not going to bother re-spraying it, just want the engine in now) Photos aren't great quality, some are mobile phone, the rest are a different camera.
Dirty engine bay
Clean(ish) engine bay
Finally got my drive shafts finished. Had to order a inner cv boot. Here's a run down of the hybrid shafts;
Driver side: ST202 driver side shaft with Corona outer cv joint (also fits a celica st182)
Passenger side: ST182 shaft, ST202 inner joint, Corona outer cv joint. The ST182 shaft is thicker and shorter than the ST202.
This is the ST202 shaft (top) and ST182 shaft (bottom) before cv joints are put on. The ST202 passenger side inner cv joint is top left.
What follows is step by step instructions on how to fit the outer cv joint and the inner cv joint.
First of all i'm gonna tell you what i was told i couldn't do by various mechanics and people that didn't bother to actually find out for themselves!! The ST202 inner cv joint was still on the ST202 passenger shaft, i needed it off and intact to put on the ST182 passenger shaft and i wasn't forking out for a new one as i already had one. I was told time time again that the joint would have to be "cut off" *cough bullshit cough*, I then went to the scrap yard to get one, but same story, "has to be cut off", and they wouldn't give it to me on it's own anyhow. So...i went to Toyota to price one. Same story, they only come intact with the drive shaft. I asked him how much, he told me to hang onto my balls!! "€600 for full shaft"!! Passport photo face ready, followed by hysterical laughter, a quick "good luck" and out the door!
So i brought the shaft to a Russian guy in Galway that owns SASHA MOTORS", he helped me out with an exhaust problem once when no-one else would touch it. I asked him if he could get the inner joint off intact, he took one look at it and said "yes very much. "20 meenits", charged me €20 and i now had a fully useable inner cv joint in one hand, and a banjaxed ST202 shaft in the other :thum: sound lad just saved me €580. How ever he got it off, he forced it off, cause the snap ring was still inside the joint, i later found out by a good friend thats a member here (and heres the good bit) that there is a "circlip" holding in the inner part of the joint that houses the bearings (photos below), and that all you need to do is remove it with a needle nose plyers and "walaa".. the whole thing slides off, then remove the snap ring on the end of the shaft and tap the rest off with a mallet. No cutting required
Happy frig'n days. You live and learn!!
So...on with it...
Here is the ST182 shaft against the old 1.3 Corolla shaft. Lined them up to see the length. They are roughly the same length!
Started putting the outer cv joint on the ST182 shaft first
Gave it a good clean first then on goes the boot
This cv joint was not pre-greased so filled it up with cv joint grease before fitting it.
Then lined up the cv joint (took a couple of goes to get the ring on the shaft to sit comfortably inside the joint), and tapped it on with a rubber mallet, put more grease inside the boot, fitted the boot over the cv joint and held it in place with the provided clips
One side done :thum:
Next up was the ST202 inner cv joint on the passenger side. The old boot i had for this was almost worn, so i picked up a universal boot which i later replaced with a proper ST202 inner cv boot that i ordered so here's the process anyways. Also important to not, that when i was looking at all these boots i had around the place, i noticed that there is no difference in the celica ST202 outer cv boots, and inner cv boots. They both have good thickness, they both are the same length, the only difference is the price and difficulty in getting one, so next time you're ordering an ST202 inner cv boot, order an outer ST202 boot, its quicker, less hassle and cheaper!
Worn boot
Inner ST202 cv joint
Pulled the battered snap ring out (before i learned about removing the circlip to get everything out)
Put the universal boot on (later changed it for the proper celica inner boot i ordered)
I had a inner cv joint kit i got from a friend, so i figured as i had the bearings out from the inner joint, i may as well swap the whole inner parts for the newer parts. Also i figured after pulling out the battered snap ring through the teeth of the cv joint, it may be wiser to replace it as it could be worn or damaged!!
So first, i put the outer ring over the shaft (narrow side first) then lined up the inner ring with the teeth and pushed it down as far as it would go, (one side of the inner ring has lines on it, thats the part that goes down first onto the shaft) then the snap ring at the end of the shaft to hold it in place.
Then after cleaning the housing of the inner cv joint, i put loads of grease in (not too much tho as it creates an air pocket which i later found out, and stops the shaft going in the whole way!!)
Then i cleaned all the bearings (six in total) making sure there is no dirt on them
Then (this is the tricky part) i put the bearings in the holes of the outer ring, which is lined up with the gaps on the inner ring. You have to hold these in place as you put the whole lot into the housing, cause they fall out easily (i developed a technique which i plan to patent some day called "the six finger floosy" haha. Then i lined it up with the gaps for the bearings on the housing and pushed the whole lot in to the very end.
This is the circlip, the thing that stops it all from coming back out, the hidden little bastard that is the cause for everyone i talked to, to say "it has to be cut off". It's a god damn conspiracy!! haha
That gets put around the shaft and fitted into the little gap at the very top of the housing, it hides right in there
Then i put extra grease in the boot, slid it over the cv joint and clamped it in place. Passenger side hybrid shaft complete
I lined up both hybrid shafts with both corolla shafts and they are the same length.
Top, ST182 shaft and bottom corolla shaft, both passenger side
Top, ST202 shaft and bottom corolla shaft, both driver side
Shafts done :thum:
Also, i went around the whole engine loom to see if all the wires were intact, good thing too cause one of the plugs was a mess. Who ever had this engine before me did a shit job on one of the plugs. It was spliced together with 6 different wires, no soldering, just twisted together and taped!! luckily when i bought the gearbox and intake, i was given a donor loom as well (Thanks Gary :thum: ) which came in well handy, just replace the wires and plug and soldered them up good!
The mess
Cleaned up, soldered and taped with new plug :thum:
I soldered one other plug that wasn't too bad too.
Today i replaced the front crash bar as the old one was rusted to shit and bent. photos of that up soon, with more updates!!
Heres a couple of pics of the engine as it is!! i desperately need a new camera. This old one im using doesn't focus as well as the one that was nicked!!
Wed Mar 27, 2024 12:39 am by jorpakko
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