05 Tacoma 6spd manual

I had some bolts back out on the inside of my transmission case and left me stuck in 5th gear. I’ve searched a few threads on here looking for a breakdown on the transmission so I can dissect and see how much damage is inside. Can someone point me in the right direction. A step by step break down would be nice. I’ve got the back of the case off and found a bolt and a small spring.

 

Here's from the FSM, not sure if your 2wd or 4wd so I included both, also some links and information in the thread below.
https://www.tacomaworld.com/threads...on-your-6-speed-transmissiom-write-up.338840/

 

Thank You!

 

OP, you have had the synco shift key, its spring and ball come out of the hub. This usually happens on the No. 3 hub. You may also likely find a bent shifting fork for that hub as the original were a cheap cast aluminum.

EDIT: here is some more information. See my Post #8 here and the included link will be especially useful for the pics.

 

Thanks for all the help! Taco’09 looking at the pictures in your post helped a lot! I got the truck couple years back and it was grinding going into 3rd every shift unless you slowed the shifter movement. Then one day it hung in gear on me 5 hours from home. The bolt that backed out on me was in the shift select lever and it came apart. I’ve got enough confidence now to go ahead and replace 3rd synchronizer and hopefully be on the road again soon!

 

If you are going to do the job yourself your life will be made easier if you acquire the large 60mm socket needed to take off the nut on the rear output shaft and get either the special tool or make something to counter hold the input shaft on the bell housing side so that the turning torque of the shaft can be properly set.

Klutch makes a 12pt. 60mm socket that is reasonable and I believe I got one at Northern Tool. That nut is actually a 6pt. and purchased a second one with 3/4" drive somewhere else.

For the special tool to counter hold the input shaft I made one from an old clutch disk and bolted a cross bar to it so that the bar would fit through the clutch fork opening on the bell housing and keep the shaft from turning.

There is an important "gotcha" you need to know about. That 60mm nut is used to compress a crush sleeve against a bearing for setting pre-load on that bearing. The bearing is on the 5th gear which is also the same as the output shaft.

The pre-load on that bearing sets the starting torque necessary to turn both the input and output shafts through the transmission. It also keeps the bearing from wearing out too soon from being too loose or wearing out too soon for being too tight.

There is thus no specific torque value per say for that 60mm nut. Make sure you get an extra nut and several of the crush sleeves. I think that on my first assembly I went through about 3 crush sleeves before I figured out how to set the preload.

You may find that that upon reassembly that nut has to be taken to very high torque value before the crush sleeve starts to yield. I was using a 3' long breaker bar with a 3/4" drive. Once the sleeve starts to yield it then becomes relatively easy to continue "crushing" the sleeve.