5th gear pop-out on a MK1 NA is
one of those things that just about every MK1 owner will
experience at some point. Basically you put it into fifth and
either when trying to accelerate or lifting off the car will
pop-out of fifth gear leaving you with neutral and a screaming
engine! Obviously it becomes pretty annoying pretty quickly. You
can hold it in gear by resting your hand lightly on the gearstick
and holding it in, but this gets tiring on a long drive. Basically
the hub and fifth gear wear on the teeth in which they engage.
Over time you can tell if this is something you are going to see
because the gearstick will 'nod' as you accelerate or more
commonly when you lift off. As the wear increases it gets to the
point of where it will knock itself out of gear.
First job is to remove the gear case.
All that is under here is basically 5th gear. The other gears are
within the box itself.
Next job is to simply undo the nut
that holds the selector fork in place. Once undone this will allow
you to slide off the selector fork and the hub complete. It really
is that straightforward!
Here you can see the old fork and hub
assembly. Actually the fork was hardly worn though there was some
wear on the dog teeth on the hub and on 5th gear itself.
New 5th gear selector fork. £20 from
Other side of the new selector fork
New 5th gear hub £50 from Toyota
Side view of new hub. This bit is
where the selector fork sits.
Other side of the hub.
Installing the new fork and hub
really is dead easy and takes a minute or two. Basically just
slide it on altogether, taking a minute to line up the hub dog
teeth with those on 5th gear it will only go one way. Then simply
do up the nut that holds the fork on with a 10mm socket.
Here is a short
movie showing how 5th gear operates: images/fifthgear/5th_gear.wmv
After this it is
simply a matter of using some hermetite around the gearbox end
cover and doing up the 12mm bolts that hold it in position. None
of the bolts are particularly difficult to get at.
I should add that all
the wear is in the hub and the dog teeth on 5th gear. Obviously
here I haven't changed 5th gear so there is still wear here. But
by halving the wear so to speak I hope that the 5th gear ought to
be usable for another 20K miles or so. A thorough job would
involve using a puller and changing 5th gear, though I wasn't
exactly sure where the wear would be so I ordered the easy to
If you look closely at the dog teeth
you can see that the leading edge has had metal ground away from
it so the teeth are missing the top leading edge, this is where
the nodding gearstick comes from when you lift off.
In summary this is a
really easy fix for the sake of £75 inc. It takes an hour and a
half to do and really is a very straightforward job. I am not sure
of the costs of a new 5th gear but am expecting it wouldn't be