Ruined Bell Housing on RA60F

Hi all! I just brought my 2005 Tacoma with the RA60F to my mechanic for a new clutch and throw-out bearing. As soon as he got the transmission out from under the truck he noticed that the clutch fork was very loose and upon further inspection found that the pivot ball stud had loosed from the bell housing and rounded out the hole...great! I called Toyota and $843 dollars later I have a new bell housing, or "front transmission case" as Toyota calls it. Now my question is, has anyone else experienced this? My truck does have 200k miles on it but how the hell does this pivot ball stud loosen from the bell housing and cost me nearly a grand!? Also, has anyone ever separated the bell housing from the rest of the transmission on one of these RA60F? It would be great to know how that's done so I can forward the information to my mechanic. Thanks!

 

You're already in for a new bellhousing - but I would have tried a fill, drill and tap with JB Weld.

But I'm a cheapskate like that...

 

A fab shops worst nightmare.....JB Weld haha But he does have a good idea of building up with a good clean weld then redrill and tap the hole. But you probably did the better option of replacing the part to preventing further issues.

 

In your first picture you can see the bolt heads that hold the Front Transmission Housing to the Middle Housing. I would be worried if my mechanic couldn't figure it out or know how to separate the housings.

Transmission components diagram:

http://www.customtacos.com/tech.old...6toyrm/06toypdf/06rmsrc/rm2006ta/03200510.pdf

 

Why cant a machine shop put in a steel threaded insert?

That would have been under 50 bucks to do

 

THIS. but maybe I'm a little biased because I'm a machinist lol... either way it would've been the easiest & cheapest route

 

That diagram is for a two wheel drive Tacoma. I have the same diagram for the RA60F and it still isn't exactly clear how they separate. Also, I believe there is a bearing pressed onto the input shaft which is held to the back side of the bell housing with a snap ring. Not as simple as unbolting it.

 

This was discussed briefly but I don't have quick access to a machine shop and was able to get a new bell housing from Toyota in 24 hours. If I had more time and/or a second vehicle to drive while my truck was in the shop I might have taken that route.

 

Sorry my mistake I posted the RA60 instead of the RA60F.

You have this drawing already?: http://www.customtacos.com/tech.old...6toyrm/06toypdf/06rmsrc/rm2006ta/03300410.pdf

It should be straight forward and obvious to a mechanic. I would consider a different shop...

 

Yes, I have that diagram already. I will vouch for my mechanic all day he knows what he's doing but does not claim to be a Toyota transmission specialist by any means. Based on the diagrams and what I have seen on the new bell housing I believe his questions are valid.

 

I've read up on it before, if I remember correctly you start from the tail end of the transmission and work you way forward. When the throwout bearing issue was still getting figured out they were changing bellhousings out and the dealerships were lacking the right tools to do it.

 

a manual trans is a manual trans. i would look into another shop to do the repair. look at this link it helped me when i had to replace 5th gear synchro
http://fjcruiser-club.com/docs/RM/RA61 Manual Transaxle.pdf

 

They are aluminum,and as such will wear a lot quicker than a cast iron housing will,so O.P dont feel bad,nothing is going too last forever.

 

Update: I was able to install a new pivot ball stud into the old bell housing. There were still good threads in the bottom of the hole and the stud was able to grab them and screw in 6-7 full turns. I added red loctite and cinched it down with a socket, she's toight like a tiger. New URD stage 2 clutch with bearing/repair sleeve kit is installed and working properly! Thanks for everyone's input.

 

Did Toyota return the bellhousing you purchased?

 

I intend to return it today. The receipt states that I have 10 days to make any returns and that they'll charge me a 20% handling fee but there's no reason that they shouldn't take it back. We took it out of the box to inspect it but never attempted to install it and the part is still in perfect condition. Heads are gonna roll if they don't take it back.

 

Congratulations and I hope you’re good for another 200K @1 loud trd ! Good info in this thread. Just a suggestion- add *Solved* or something similar to the thread title. It give people in a similar situation hope