Back on track.

Well, as should be readily apparent, my work on the Corolla has been sidelined for a bit.  A big factor was work, but the other was a lack of hardware.  Since I’ve gotten the differential back, I have been wanting to install the rear end and rear suspension.  One thing that I wanted to do though was to use all new hardware for the multitude of nuts and bolts.  I had previously ordered the lower spring cushions, but I needed to order the upper ones.  So, I placed an order with Herb at Cabe Toyota out in Long Beach for everything.  Unfortunately, quite a few bits needed to be special ordered.  So, I had been waiting for about three weeks until they came in last week.  Thus, I set about working.

Now, I didn’t look at the proper order for installation (despite having the manual), I just did what came logically to me.  The first step was to install the differential in the axle housing.  I had painted the differential housing previously to ensure a uniform look.

Next, I started installing suspension components.  First were the three bumpers that attach to the chassis.  One on each spring perch and one in the center for the driveshaft/differential.

After those two pieces came the shocks.  I did a bit of research and from what I’ve read, Bilstein shocks aren’t quite as stiff as the more traditional Japanese manufacturers, so I decided to give them a shot:

I left the shocks free hanging until I could get them on the rear end.   I wanted a bit of wiggle room to work.  Besides, the suspension isn’t supposed to be tightened until there is a bit of load on it, so I will wait until she’s on all four wheels for that.

Next was the control and lateral arms (with their new TRD bushings):

The lateral arms took a bit of wiggling to get in place, but aside from that, it went smoothly.  Finally, the hard part, manuevering the rear end underneath the car to get linked up with everything.  It was incredibly difficult, but after about an hour, everything was installed:

I did notice the scrape in the paint on the rear housing.  I may have to touch that up with some paint.  The springs are Tanabe GF210 springs that I got for a good deal.  I didn’t want to pay for new OEM springs and I wanted something reasonably close to stock, which is why I went with them.  I don’t have much experience driving/racing a rear wheel drive car, so I don’t want to go too extreme yet.

The other projects that I’ve been working on right now:

1. The steering rack is painted, but the outer links are seized to the inner links, making installing the new boots difficult.  The hardware order I placed with Herb included bolts for installing the rack in the front suspension crossmember.  My Techno Toy Tuning delrin steering rack bushing also arrived.  Once I replace the boots and relube the rack, it’ll be ready.
2. The front suspension is a work in progress.  There are two main parts to the front suspension: the suspension crossmember and lower control arm mounting and the MacPherson strut assembly.  The strut assembly is in the process of being disassembled and seperated from the brake components, but I am having an issue removing the gland nut on one of the strut casings.  The lower control arms are a problem, as I am trying to replace the bushings with TRD bushings.  One bushing is removed and the other has not been, then I need to figure out how to press the new bushings in.  Then I’ll be able to reassemble everything.

The engine has not made progress, but once the suspension is installed, that’ll be at the top of the list.  I’m anxiously awaiting the timing belt and intake manifold install, if for no other reason than to be able to clear off my work bench.  Once the engine is done, the brake and fuel systems will get some attention.

It is great to be able to bolt some parts onto the car, though.  Every time something goes on, the garage looks cleaner and cleaner!

An update to the lazy update.

Here are the pictures from my latest update.  Work has been difficult lately with a great deal of travel and obligations outside of normal work hours.  I was planning on uploading these pictures while I was out of town, but I forgot the charger for the laptop, making work impossible.

Anyway, here are the pictures:

First is the manual rack that I picked up.  I’ve been working on stripping and repainting it.  I’m also planning on replacing the boots.

Here is the differential I rebuilt with the Techno Toy Tuning kit that I had installed in the old housing.  The other picture is the old open differential.  I may put this up on club4AG for cheap to help someone out.

A lazy update

First, I want to apologize, it should not have taken me this long to update the log.  I have been in and out of town a considerable amount in the past month, but that does not excuse my laziness in posting an update.  Right now, here is where I stand.  I picked up the differential from the shop and it is in great shape.  I am waiting to install the differential into the rear axle housing until I can get the housing attached to the car.

I am waiting on new hardware from Toyota in order to install the rear suspension and housing onto the chassis.  I have ordered it, but it is taking quite a while to be delivered, as some items needed to be special ordered.  Once those parts have arrived, the installation should go pretty smoothly (famous last words, I know).

In the meantime, I have been working on installing the TRD bushing kit on the front suspension.  Unfortunately, I ran into a snag.  When I attempted to press the lower control arm bushings out, it bent the arm.  In order to correct that, I am going to rebend it and then strengthen the arm with some reinforcement.   I’ll post some pictures when I get that task completed.

I did finally receive my steering rack, which was in good shape aside from being a bit dirty.  I cleaned it up with a wire brush and painted it.  Once I replace the boots on it, I’ll take some pictures.  I may want to replace the outer tie rods in the future, but I’m going to wait to evaluate that.

That’s all for now.  I’ll write a bit more and post some pictures when I have a bit more time.

Steering Rack Update

Well, after I placed my order for the steering rack about 10 days ago, I hadn’t heard anything from the shop, so I gave them a quick call this morning, only to find out that they cancelled my order and didn’t bother to tell me about it, so I am now without a steering rack.  Given the fact that MR2s and AE86s are in short supply at junkyards around here, I may have to order the rack from someone else or find it on eBay.  We’ll see how it works out, but it may delay the installation of the front subframe.

<edit> I think I have some good karma from the car gods, because I found a steering rack for $82 shipped on MR2 Owner’s Club.  I don’t know when it will get here, but I’m not in any rush, as I don’t have the rack bushings yet.  I was kind of angry about the retailer not telling me about my cancelled order, but when one door closes, another one opens!  The previous rack was over $150 between shipping and core charge! </edit>

Two weeks of misery with a flash of brilliance at the end

I have to say that the last two weeks have been maddening.  Unfortunately, two things have limited the amount of work that I’ve been doing to the car.  First, I’ve been out of town, which has left me short on leisure time.  Second, the sheer frustration I was feeling while trying to install the end link TRD bushings was incredible and causing an extreme lack of motivation.

Last weekend, I tried numerous things to get the bushings to into the end links, including using the hydraulic press as well as a bolt, washers, a nut and my wrenches.  The main issue was the incredibly tight fit of the bushings into the end links, which made applying pressure difficult.  The problem with the second method was the fact that I could not find proper hardware to do the job, despite looking at Ace Hardware, Lowe’s and Home Depot.   I tried for hours to get those bushings in place, but the only thing that resulted was frustration.

Being out of town the past week, I did place a few orders for some necessary parts.  I ordered my manual steering rack as well as manual steering rack bushings from Techno Toy Tuning.  Once I got back into town, I spent Friday morning on car tasks, as I took the newly rebuilt limited slip differential and housing to a local shop for installation along with new bearings.  I also stopped by Toyota to pick up a timing belt tensioner spring to complete the new timing belt.

However, feeling dejected and upset, I did a bit of research and came upon an idea that seemed very obvious after reading it:  Heating up the end links and chilling the bushings to open up the tolerances a little bit.  Well, in the past week, I had managed to put a grand total of ONE bushing in the links and after I tried freezing and heating things, I completed the remaining seven bushings in about two hours.   Frankly, I was overjoyed.

So, I’ve now got the end links and the sway bar bushings completed.  The differential should be ready for pickup by next weekend, so my goal for next weekend is to do the following:

1. Install the remaining bushings in the front suspension.
2. Install the differential into the rear axle housing.
3. Finish the timing belt installation (if I have time)

Once the manual rack and rack bushings arrive, I’ll be able to install the front suspension and engine mounts, but I do not have an ETA on that.

An interesting turn of events

Sorry for no update last week, but I’ll explain in this post what happened.  I’m traveling this week (once again), but should be back on Friday for some more progress.  The past two weekends have some great (and not so great work) being done.

The first weekend, I installed the proper oil pan on the new engine:

The plug obviously isn’t the stock oil drain plug.  It is a plug that I bought from a company called SuperPlug.  It has an extra long magnet on the end along with the nylon washer, which doesn’t need replacement.  I’ll retain the old one just in case, but I think this one will work well.

The other thing that happened this week was that I received my water pump.  I was standing in my garage talking to a neighbor when UPS delivered it.  The odd thing about it was that when I walked up to my door, there was another box sitting next to it.  I wasn’t expecting any packages (outside of the original water pump), but it was my birthday, so I figured it was something a relative sent.  I opened the first package and sure enough, it was the water pump.  Upon opening the second package, I discovered ANOTHER water pump!  I checked my account and there was only one entry for the billing on the part.  After calling the company, they basically told me that they only billed me once for it and to just leave it at that.  I guess I pulled the chance card labeled “Computer error in your favor: Collect free water pump.”  I’ll probably throw it up on Club4AG for free just to keep the good karma going.

Being that I now had the required water pump, I installed it into the block with no problems:

With that completed, I attempted to install the timing belt and tensioner when I ran into snags.  I was planning on reusing the old tensioner, but after installing the belt twice and trying to turn the motor to ensure proper tension and alignment, the belt kept slipping at the crank.  I took a second look at the tensioner and it was rusted on one side, preventing a good fit between the tensioner and the belt.  So, I could not install the timing belt and pulleys.  However, a new tensioner has been ordered and should arrive by Friday (the 20th) for installation this weekend.

With my hopes of progress on the engine dashed, I turned to the brake and clutch hydraulic systems.  The clutch master cylinder turned out well after painting, so I installed the clutch master cylinder and clutch pedal as well as the brake booster and brake pedal:

I am not really concerned about the rust on the pedals, as that should not be visible due to the dash, but if I get bored one weekend, I will remove them and clean them off.  I did find a very helpful guide for this project at www.toyodiy.com, though.  They have a full parts listing of this car, which shows you how everything goes together as well as part numbers for the entire car.  This has been an invaluable resource so far and I’m sure it’ll continue to be.  In looking at the parts reference, I did discover that there is a gasket between the body of the car and the clutch master cylinder as well as a bracket that sits on both sides of the firewall between the brake booster and the pedal.  I am compiling a list of small parts and hardware that I need and place a massive order at Toyota one of these days.

That work wrapped up the previous weekend.  Disregarding the work with the timing belt, I’m pretty happy with the progress.

The next week started out interestingly.  I was in town this week, so I took Thursday off and drove down to Jacksonville to pick up the hydraulic press and vise that my Dad left at a friend’s place.  The girlfriend and I took the evening and camped out by the beach at a nice little park in Jacksonville, which was nice.  On Friday, we drove back to Atlanta, but that took a while given the distance, construction and traffic.  Friday, I set up the press as well as bolted the vise to the bench:

On Saturday, I set to work on fixing one of the problems that had been plaguing me for a long time.  One of the bolts was seized to a link in the rear axle housing.  I was thinking that the bolt just became seized to the mounting plate on the housing.  Unfortunately, I never had anything that could hold the rear axle housing firm enough to add enough torque to break it loose.  The vise certainly solved that part of the problem!  Unfortunately, after getting the housing secured and turning the bolt a few times with a breaker bar, my initial assessment proved wrong.  In reality, the bolt had become seized to the metal center sleeve of the bushing, meaning that I could not remove it in any traditional fashion.

So, I set about cutting the bolt out, but it was a very slow process.  The first hour saw me cut the one side of the bolt (as you can see it resting on the housing in the above picture).  The other side of the bolt was very difficult however.  It took a total of three hours to get that bolt out, with a combination of a hacksaw, a sawzall, a drill and a screwdriver.  But, it DID come out.

After that, I got to work pressing out all the bushings which went very quickly.  One suspension bushing did come out with some force, but aside from that, it was pretty normal.

I will be replacing the bushings on the suspension with the holy grail of AE86 suspension bushings, the TRD Kit:

Next week, my goal is to replace the entire bushing set with the TRD bushings (including the front suspension bushings) as well as install the new tensioner and timing belt.

Slow going.

Unfortunately, I am on the road once again this week, so my work time has been shortened.  The other item that slowed progress was the weather.  Sunday was a mess of snowfall, believe it or not.  Atlanta received over four inches of snow, so that puts the kibosh on painting pretty quickly!  Nonetheless, I did get some work completed.

First, the cleaning of the oil pan was completed and it was sprayed with a few coats of paint.  By the time I return on Friday, I’ll assess whether I need any additional paint, but I doubt it.  (For the record, no I did not paint in the garage next to the pristine paint on the car.   That is just the best place to hang the pan while it was drying.)

The clutch master and slave were also cleaned and painted:

As you can see, these are much cleaner than the previous rust-covered pictures show!

The brake booster also came out well:

I took a quick trip to the auto parts store with my new brake master cylinder, but they had left early due to the snow, so my hopes of bench bleeding the master cylinder were dashed.

My new waterpump should be waiting for me when I arrive home on Friday, so my goals for the weekend are the following:

1. Finish cleaning the new engine.
2. Install the new water pump (including finding the water pump pulley, which is somewhere unknown)
3. Install the new timing belt and covers.
4. Reinstall crankshaft pulley.
5. Install clutch hydraulics and pedal.
6. Bench bleed the brake master cylinder.
7. Install brake booster, pedal, master cylinder and slave cylinder.

If I get all of those accomplished, I would call it an incredibly productive weekend.

The weekend after next, I’m heading down to Jacksonville to pick up a hydraulic press and a vise.  That should make changing the suspension bushings much easier.  Once the suspension bushings and the differentials are changed, I can install the rear axle in the chassis.

Engine work and other misc. tasks.

Once again, I am out of town for this week, putting a damper on work around the garage.  However, I did get some work done last weekend.  Unfortunately, I didn’t take pictures of everything.

First, I finished cleaning the brake booster of rust and then painted with two coats of glossy black.  I’ll post pictures next week of that.

Second, I started cleaning up the oil pan from my old Corolla engine (which has since been disassembled).  This oil pan is different than the MR2 oil pan in that it has a return fitting for the oil cooler, which MR2s do not have.  The older pan was somewhat rusty, so I am cleaning it up with a wire brush and then I will be repainting it, hopefully that will be done this upcoming weekend.

Next, I did some work on the engine, as I finally have my pulley puller.  After marking the timing belt for proper orientation, I removed the tensioner and belt and got to work removing the water pump for replacement.  I had a new water pump from Summit Racing that I picked up for cheap, but it turned out to be the wrong part, so I’ll have to return it.  I’ve learned an important lesson when purchasing parts for this car and that is to always specify coupe, even if you have a hatchback like I do.   Apparently all parts companies have the GT-S in their computers as coupes and if you specify a hatchback, it will pull parts for an FX-16 model, which has next to nothing in common with the performance model.

So, I ended up removing the water pump and all the water hard lines running to the heater core.  One thing I’m not 100% certain of is what the routing is for the water, given the fact that the car no longer has a heater core.   I’ve done quite a bit of research on this subject, but I haven’t been able to glean any answers.  It isn’t important at this stage, but I’d like to figure it out at some point.

Anyway, here are pictures of the engine before and after:

One of the most time consuming parts of this project has been finding and cleaning all the parts that are going onto this car.  For instance, the housing for the water pump is different between the MR2 engine and the AE86 engine, so I had to find that part and then work on cleaning it.  I’ve got wire wheels for my drill and Dremel tool as well as a 10 gallon liquid parts cleaner, but it is still tedious and timeconsuming.

Finally, the last thing I started working on was to clean up the clutch master cylinder as well as the clutch slave cylinder.   Here are the before pictures:

My goals for the upcoming weekend:

1. Have the clutch master and slave cleaned, painted and installed.
2. Have the brake master cylinder bench bled and installed along with the brake booster.
3. Have the oil pan cleaned, painted and installed.

Interior taping and painting.

The initial sections of using the Rustoleum to repaint the interior turned out rather well, but not perfect.  After consultations with my dad, I have decided to do the full interior, but with a dilution of the paint with mineral spirits.  Thursday night was spent taping the lines for the bottom of the interior:

Friday night was spent painting the interior, which went rather well.  I’m very pleased with the results:

As you can see from comparisons with previous posts, this is a much better finish and consistency of color.

I also ran over to Sears on Friday and picked up a crankshaft pulley puller, which will allow me to do further work on the new engine (timing belt, water pump and some optimization to the oil pump).  I’ll try to take a crack at that tomorrow.

Interior Progress

Unfortunately, I was out of town once again this week, so my normal weekend schedule was compromised.  Other activities also stood in the way of spending a lot of time working on the car, but I did make some progress.  The primary thing that I accomplished was to clean the entire interior of the car, which took a while.  Unfortunately, what I thought was dirt and dust in some cases turned out to be overspray, so any color other than glossy black that you see on the interior pictures was paint.  This being the case, I started painting a few test spots with Rustoleum Gloss Black paint to see how it looked and also to evaluate brush technique and paint thickness.  Given a few early looks,  I think it will work out fine.

A bit of really good news, though.  I managed to find another Corolla in the junkyard for another right door handle.  I cannot say for certain that it will work, but I think that it’ll be just fine.

That’s about all I did this past weekend, but I did make a few key steps forward in suppliers, as I found a shop that can replace the open differential currently in the differential housing with my newly rebuilt limited slip differential.  I would love to learn how to replace the differential on my own, but right now, I do not have the tools nor the knowhow to do so.  When I called the shop (which normally specializes in off road trucks), they immediately knew exactly what I wanted and how long it would take, so I was quite impressed.  They’ll get my business when I’m ready to take that step.

Next weekend (being Valentine’s Day as well as keeping up with household chores) may not see as much work as I like, but I’ll do my best to be out in the garage as much as possible.