Woodsport 6 speed gearbox conversion

[Woodsport]

Hi folks, we came up with a 6 speed upgrade a long time ago for the Mk1 but i haven't really offered it as a package before but now i can supply 6 speed gearbox packages for the Mk1 that will be a plug and play install.

What i'm offering is a C60 gearbox mated to a Mk1 bellhousing and comes with an optional LSD at extra cost if required, the gearbox i deliver to you will be a direct swap for your current 5 speed, it will not need any custom parts, your clutch assembly and everything else will just work.

If you go for the LSD option the only thing that will be different is the driveshafts, you will need to fit a pair of Mk2 NA shafts, these will work with your Mk1 hubs as normal, there are loads of those around or i can supply them at extra cost. If you go for a non LSD 6 speed i can build that to work with stock Mk1 driveshafts, so literally everything will be plug and play.

The labour on building a 6 speed transmission for a Mk1 is high, it takes me about 2-3 days to complete each one so it's not a cheap thing to do, but i'm offering it here anyway for those of you that have a popping out 5th or need to replace the original gearbox now could well be the time to upgrade to a nice 6 speed, possibly the coolest thing you can do to a stock Mk1. These gearboxes have the longer final drive and extended 6th gear set for lower cruising RPM and higher top speed.

A supplied 6 speed without LSD is £1050 delivered, that will come with brand new oil seals ready to install.

Add £250 for the LSD option

I can supply Mk2 driveshafts at £100 per pair delivered (i'm sure they can be bought cheaper yourself)

The only other company offering this for the Mk1 is in the USA and they are charging $4500 per gearbox.

There is a 2 week lead time on all orders, i need to source donor gearboxes, in total there are 3 gearboxes required to build one 6 speed with LSD. All of my gearboxes are backed up with 6 months warranty.

Any questions please ask. Thanks Paul.

[autobody]

Hi Paul, this 6 speed box sounds too good to be true. am defiantly interested in one of these for my sc. Once my car is running right (engine) then the next stage will be to replace the gearbox as currently its not a very smooth (crunches and gets stuck in gear etc...)

So since my car is a sc, will the below apply to me, will the the MK2 driveshafts work with the sc hubs?


The only thing that will be different is the driveshafts, you will need to fit a pair of Mk2 NA shafts, these will work with your Mk1 hubs as normal, there are loads of those around or i can supply them at extra cost.

I take it I would need a mk1 n/a gear cable too? anything else Paul?

[Woodsport]

Yes it will all work with your SC hubs, you will have nothing else to buy, it will all just plug and play.

[Woodsport]

Hi folks, i am gearing up (excuse the awful pun!) for a group run of 6 speed NON LSD gearboxes. There is a lot of interest in having a 6 speed option but the costs seem to put many off (i currently build them for £900, which is a quarter of the price they are sold for in the US) . I know that nobody in the UK would dream of spending £3500 on a 6 speed box, so £900 seems pretty realistic.

However i want to try and get the price down further on a group buy of them, which will mean me taking some time out to build 5 or 6 gearboxes in one go.

My question is what price would people be happy to pay for this? Obviously it can't be done for peanuts but if i can realistically offer a run of them at a reduced price please let me know what you would be happy to pay for a 6 speed and i will see what i can do, obviously based on number of takers as well.

Thankyou Paul.

[pistol pete]

this is a fantastic idea paul..
unfortunatly i dont have the money for one t the mo
i think 900 for one is a bargain, but after driving a mk1 with a LSD i would have to have one of them
maybee next year

[Woodsport]

Thanks Pete , I think I need a rough price guide people would be more inclined to pay, as it stands only the US owners buy them from me, I'm just wondering how cheap they need to be before UK owners want them or if there's just no interest here at all?

[pistol pete]

prob just a case of people dont' have any money, and just do them to order and leave at price you have as its still cheap enough, and you don't wanna do your self out of money, as you are great for helping people, but you still gotta make a living con't do everything for free

i know as soon as i can afford one i will be looking at it

[BARNEY]

I'm trying to decide whether i actually need one of these or just really want one. There is nothing wrong with my gearbox at the moment but i know this would be a very cool upgrade to have and i wouldn't want to miss the opportunity. Although the price is already reasonable, if a few mk1 owners were interested and the price was notched down to a mutually acceptable amount then this upgrade would be more justifiable, personally speaking. Any idea on a rough estimate for cost of labour to remove the old and fit the new box? Cheers. Rob

[Woodsport]

I'm in Florida right now on limited access, I'll reply better when I get home

[Woodsport]

Just thought i'd add to this by saying that i cannot make this any cheaper than £1000, but i can add value by saying each 6 speed gearbox will come with brand new diff bearings, new input bearing, new output bearing and a new input shaft oil seal along with two new diff output oil seals, this totals £350 worth of parts at the Toyota dealer. The Mk1 gearbox costs £100 and the Celica 6 speed i use costs £250, so that takes us to £700 worth of parts before any labour. My basic fee for rebuilding the whole unit is £300, that takes us to £1000, i am sorry i cannot do a 6 speed any cheaper than this, but like i said there's a guy in the states charging $4,500 for the same job.

That gives both you and i peace of mind that the bearings inside the gearbox are new, diff preload is also adjusted and set to the top end of factory spec.

So while i cannot do it cheaper i can provide a bearing and seal overhauled unit.

I hope that clears the costs up for those interested.

[jumpman33]

I think that's a fair price, if/when my gearbox needs replacing on my Mk1 i'll certainly be knocking on your door at that price.

[Woodsport]

Thanks, it's good to know the pricing is reasonable for what i'm actually offering.

This conversion seems a lot more popular in the US, i've built quite a few now for the US market but hardly any in the UK.

[Woodsport]

I thought i'd do a mini build thread showing what is involved. I haven't included the work stripping the 6 speed box or the Mk1 box down to their component parts, this is just the new 6 speed Mk1 gearbox build up.

So we start with our Mk1b bellhousing, this has to be a Mk1b item, a Mk1a housing is not compatable with this conversion, you can identify a Mk1b gearbox because it has two starter motor locations on it, a Mk1a only has one. So this has been steam cleaned and degreased with all bearings removed.

http://www.mr2mk1club.com/images/imported/2013/01/mk1bell-1.jpg

This is all of the 6 speed internal parts from the donor C60 gearbox...

http://www.mr2mk1club.com/images/imported/2013/01/6spdstripped-1.jpg

Here are all of the new bearings and seals from Toyota, nearly £400 worth, not a lot for the money but essential if this is to be done right.

http://www.mr2mk1club.com/images/imported/2013/01/newbearingsandseals-1.jpg

This gearbox is getting the Mk3 LSD unit, so the first step is to remove the old bearings from the Mk3 LSD...

http://www.mr2mk1club.com/images/imported/2013/01/LSDoldbearingsremoved-1.jpg

The Mk3 speedo cog is the same as a Mk1 cog, so the speedo will work as before.

Now install the new bearings onto the diff...

http://www.mr2mk1club.com/images/imported/2013/01/newbearingsonLSD-1.jpg

Now fit the 6 speed crownwheel onto the LSD, for the non LSD version you use the MK1 diff and Mk1 crownwheel which is also the same gear size but a different bolt PCD...

http://www.mr2mk1club.com/images/imported/2013/01/6spdcrownwheelfitted-1.jpg

Now we fit the original diff washer into the case, this one is a fixed 2mm width, we adjust the preload on the diff by changing the thickness of the opposing shim in the other half of the case....

http://www.mr2mk1club.com/images/imported/2013/01/newdiffcasewasher-1.jpg

The new bearing race is then fitted...

http://www.mr2mk1club.com/images/imported/2013/01/newdiffcaserace-1.jpg

Now we install the new output shaft bearing...

http://www.mr2mk1club.com/images/imported/2013/01/outputbearingfitted-1.jpg

Not forgetting the retainer and bolt...

http://www.mr2mk1club.com/images/imported/2013/01/outputbearingretainer-1.jpg

Now we fit the new input shaft bearing...

http://www.mr2mk1club.com/images/imported/2013/01/inputshaftbearing-1.jpg

The adjustment shim is fitted to the middle case, this shim is what affects the load on the diff...

http://www.mr2mk1club.com/images/imported/2013/01/EEshimfitted-1.jpg

And the new race fitted over that...

http://www.mr2mk1club.com/images/imported/2013/01/midcaseracefitted-1.jpg

This shim will need to come back out if the preload is not correct.

Now to adjust the preload we need to install both the diff and output shaft into the case...

http://www.mr2mk1club.com/images/imported/2013/01/difffitted-1.jpg

http://www.mr2mk1club.com/images/imported/2013/01/outputshaftfitted-1.jpg

The mid case is then dummy fitted and all bolts torqued down as it would be on the finished box, the top snap ring is also fitted...

http://www.mr2mk1club.com/images/imported/2013/01/midcaseandsnapring-1.jpg

A 14mm headed M10x1.25 bolt is screwed into the top of the output shaft so my torque meter can be used...

http://www.mr2mk1club.com/images/imported/2013/01/preloadchecking-1.jpg

Rotating the meter reveals how much resistance there is on the new diff bearings, if it is too much then the case comes apart again, top shim replaced for a slightly thinner one and the case refitted again, this process is repeated until the correct diff preload is obtained. For info, 0.05 shim thickness results in 3.5 in/lbs of difference to the preload, the shims are available from Toyota in 0.05 increments.

Now that the preload is correct we can start to build the gearbox up properly starting with the input shaft and one of the selectors...

http://www.mr2mk1club.com/images/imported/2013/01/inputshaftandselector-1.jpg

The rest of the selectors are then refitted...

http://www.mr2mk1club.com/images/imported/2013/01/otherselectors-1.jpg

Then three selector retaining bolts are fitted...

http://www.mr2mk1club.com/images/imported/2013/01/selectorbolt1-1.jpg

http://www.mr2mk1club.com/images/imported/2013/01/selectorbolt2-1.jpg

http://www.mr2mk1club.com/images/imported/2013/01/selectorbolt3-1.jpg

The lower selector detent ball and spring are now fitted....

http://www.mr2mk1club.com/images/imported/2013/01/selectordetent-1.jpg

http://www.mr2mk1club.com/images/imported/2013/01/selectordetent2-1.jpg

[Woodsport]

Fit the case magnet...

http://www.mr2mk1club.com/images/imported/2013/01/casemagnet-1.jpg

Now time for the reverse selector...

http://www.mr2mk1club.com/images/imported/2013/01/reverseidlerselector-1.jpg

http://www.mr2mk1club.com/images/imported/2013/01/reverseselectorbolts-1.jpg

The reverse idler is now added...

http://www.mr2mk1club.com/images/imported/2013/01/reverseidler-1.jpg

The shaft on this needs to be orientated correctly to the case or the retaining bolt on the outside won't line up...

http://www.mr2mk1club.com/images/imported/2013/01/reverseidlermark-1.jpg

Now the case is ready for sealant...

http://www.mr2mk1club.com/images/imported/2013/01/casesealant-1.jpg

With the middle case fitted and all bolts torqued down for the final time, the reverse idler bolt can be fitted...

http://www.mr2mk1club.com/images/imported/2013/01/reverseidlerbolt-1.jpg

Now both snap rings are fitted to input and output shafts...

http://www.mr2mk1club.com/images/imported/2013/01/snaprings-1.jpg

Add the shaft retainer plate and bolts..

http://www.mr2mk1club.com/images/imported/2013/01/shaftretainerbolts-1.jpg

Fit the selector circlip...

http://www.mr2mk1club.com/images/imported/2013/01/selectorsnapring-1.jpg

Install both upper selector detent balls/springs...

http://www.mr2mk1club.com/images/imported/2013/01/upperdetents-1.jpg

http://www.mr2mk1club.com/images/imported/2013/01/upperdetents2-1.jpg

Now add 5th driven gear...

http://www.mr2mk1club.com/images/imported/2013/01/5thgear1-1.jpg

The roller bearing for 5th....

http://www.mr2mk1club.com/images/imported/2013/01/5throller-1.jpg

Refit the 5th/6th selector fork and synchro hub along with circlip....

http://www.mr2mk1club.com/images/imported/2013/01/synchrohubsnapring-1.jpg

Fit selector fork bolt...

http://www.mr2mk1club.com/images/imported/2013/01/5th6thselectorbolt-1.jpg

Fit roller bearing and synchro ring....

http://www.mr2mk1club.com/images/imported/2013/01/synchro-1.jpg

Refit 6th gears, top bearings and circlips....

http://www.mr2mk1club.com/images/imported/2013/01/topsnaprings-1.jpg

Refit end casing...

http://www.mr2mk1club.com/images/imported/2013/01/uppercasebolts-1.jpg

Turn the gearbox over and install the inner bellhousing bolts, input shaft oil seal and release bearing trumpet...

http://www.mr2mk1club.com/images/imported/2013/01/insidecasebolts-1.jpg

The outer selector assembly then slides back in, add the Mk1 reverse light switch and that's it!

[coverco]

That is a fantastic write up Paul, considering the amount of work involved the price seems very reasonable. Good luck with the sales. If I did more than 200 miles a year in my car I would have one. I have a six speed in my van and that is great.

[Woodsport]

Thankyou Tommy.

[Woodsport]

I'm doing a special one off run of three 6 speed gearboxes at a reduced price in the next month, instead of £1050 delivered per unit i am doing them for £850 delivered per unit.

These three will all get the same new bearings etc that the full price version gets, after these three the price will return to £1050.

A 6 speed Mk1 gearbox will never get this cheap, so if you want one of the three please register interest below, thanks Paul.

[Woodsport]

One already taken, two left.

[Woodsport]

Two gone, only one left, then it's back to full price chaps.

[Woodsport]

Due to the popularity of this new lower price i am extending the special run to 6 gearboxes, 4 now gone straight away to the USA, two left.

Anyone know the reason why US owners want this and not UK people? US sales have always outsold UK by 10:1. They really go mad for this upgrade over there.

[superwhite90]

We're all skint!

[b4wrc]

I think the American market offers more options to modify the 4age engine in ways not available over here. There are specialists that offer stroker kits over size pistons and higher lift cams. Also the American market seems to have more access to the Japanese tuning specialists and parts are much cheaper than here.

All these high performance engine options mean that the standard gearbox begins to be the weak link in terms of power delivery and your 6 speed box overcomes this. I think this is the reason that American market likes your conversion

[Deadly_smell]

There are more than 10 times more Americans than British !!!

[Woodsport]

LOL there aren't 10 times more American Mk1 owners than british though.

[Woodsport]

I have now extended this run of 6 speed Mk1 gearboxes to 9 at this price, 5 are going to the US and one to France, 3 left.

[Woodsport]

2 left now.

[Woodsport]

One 6 speed left in this current run, after that it's back to full price.

[IanC]

More going to the US as their road network is a lot more high speed continuous driving than we ever get in the UK? Just a thought, not many twisty A roads in the USA... All long straight freeways

[Woodsport]

You're probably right Ian, although i did install one of my 6 speeds into a local Mk1 yesterday, pretty mint white over silver Mk1a.

[Woodsport]

I'm doing another cut price run of 6 speed gearboxes very soon if anyone wants one, the last batch sold out pretty quickly but most as usual went to the USA.

[Woodsport]

Another 6 speed production run underway now, this is "the" must have mod for Mk1 owners, totally transforms the car.

Rebuilt C60/52 Woodsport hybrid with new bearings/seals £950
As above but with LSD installed £1250 (requires Mk2 NA driveshafts which are all plug and play with this option, I can supply at £80/pair)

All Woodsport 6 speed gearboxes are fully plug and play, no modifications to do whatsoever, take the old worn 5 speed out and fit the 6 speed, it's a straight change.

If you're interested let me know, thanks.

[BIGBOYZJUNK]

^ as Paul says[emoji1303]

[autobody]

Hi Paul, I was interested in 6 speed box when you had your original special one off run. At the time my car was having its engine build. I have in the last few months got the car back and would like to know if you will be doing another special run.

Also are you able to fit, if so please do PM me cost to a fitting service. the car is an original SC.

regards Imran

[Woodsport]

Hi Imran, if your car is an original SC then the driveshafts won't work with the 6 speed, as your gearbox is currently an E series and the 6 speed is a C series.

I would need to fit a pair of Mk1 NA shafts with the 6 speed, or if you want the LSD including, a pair of Mk2 NA shafts.

The price I am currently offering this conversion at is the lowest I can possibly do it for I'm afraid. I also cannot offer fitting at the moment due to my massive workload, it would be at least 6 months away.

Many thanks Paul.

[Woodsport]

I'm going to be doing another production run of my 6 speed gearbox conversions if anyone is interested, thanks Paul.

[MylesHSG]

I'm going to be doing another production run of my 6 speed gearbox conversions if anyone is interested, thanks Paul.

God dam it Paul I'm meant to be saving for a mortgage. Your 6 speed gearbox is top of my list for my next mod.

[Adi64gt]

Is the price on exchange of a 5 speed or is it an outright buy Paul?
When would the next run of gearboxes be available?
Cheers Adrian

[Woodsport]

Hi Myles, just live in the Mr2 :)

Hi Adrian, I can allow a little off for a 5 speed in exchange, which would be used for its bellhousing on the next 6 speed, I buy Mk1b gearboxes in for £50 for that purpose, the only part I use is the bellhousing from the 5 speed.

[MylesHSG]

Paul, what would be the price for the 6 speed and LSD if you fit it as well?

[Woodsport]

Hi Myles, the LSD version is £1250, thanks Paul.

[MylesHSG]

Is that labour included?

[Woodsport]

Hi Myles, that is an all in price, thanks Paul.

[cchrysos]

Hi Paul. Is that £1250 for the LSD gearbox fitted to the car or £1250 for the gearbox with LSD fitted. I sense there could be some confusion here?

[Woodsport]

Hi, it's £1250 for me to build a 6 speed with LSD, plus shipping if you want it delivered to your door, roughly £70 nationwide.

Fitting into the car would be £200 extra at my garage, plus the option of having a new clutch installed at the same time (silly not to) , but is subject to my workload and booking.

[Woodsport]

Paul, what would be the price for the 6 speed and LSD if you fit it as well?

Sorry for the confusion, I read this to mean how much extra is the LSD if I fit that as well, not how much is the gearbox fitted as well to the car.

[MylesHSG]

Cheers for clearing that up Paul. I'll have to have a little think about it, plus find someone down here to fit it!

[Woodsport]

Well it's a straight gearbox change, no modifications, it just swaps over as if you were fitting another gearbox, so any decent garage should be able to do it.

[MylesHSG]

Ah ok, I thought with it changing from a 5 to a 6 speed it would need work doing with linkages and be a bit more specialised.

[Woodsport]

No that's the beauty of my 6 speed, it's just a straight swap, the gearbox looks identical too with only a slightly longer end casing for 6th.

All gearboxes come fully painted (apart from starter motor flange/earth points) and new driveshaft oil seals installed too.

[superwhite90]

Hi Paul,

When are you doing the production run and how long does it take? The LSD option.

[Woodsport]

In about a fortnight, I plan on building three of them, one is already spoken for.

[superwhite90]

When would you be doing the run again? I am interested in the LSD box and someone else I know is interested as well.

[Woodsport]

I sold one of the three in this run, so I will leave it open ended, basically I will build them as I take the order.

[superwhite90]

Ah okay fair enough. I would be able to donate my gearbox as well.

[superwhite90]

Are the mk2 shafts for the LSD option, just basic N/A for any REV? or are they specific?

[Woodsport]

The Mk2 shafts are needed for the LSD option, buy any NA Mk2 ones and any revision will do, they plug and play into the LSD and Mk1 hub with no mods, much stronger shafts than Mk1 and do away with the bolt on flange.

[superwhite90]

thanks Paul.

[superwhite90]

Paul, stupid question, these are to suit the 212mm or 200mm flywheel/clutch combo yes?

[BIGBOYZJUNK]

I'm running a 212mm with mine

[Woodsport]

It will work with whatever flywheel/clutch you currently have.

[superwhite90]

Hi Paul, sorry to keep banging on with questions, do this have any issues mating up to a 4AGZE? I.e. would a driveshaft clash with anything?

[Woodsport]

There are no issues with fitting, you do need to use the 4a-ge flywheel and clutch, the GZE one is too big to fit inside the C52 bellhousing, also you need to use your original 4a-ge starter motor, but yes it will all work.

[superwhite90]

That's all fine then as I'll be running my 4age fidanza flywheel with my current and any future gearboxes.

[Woodsport]

I have a ready to go 6 speed with LSD fitted in my workshop complete with a pair of Mk2 NA driveshafts (so a complete 6 speed LSD install package), looking for £1400 delivered anywhere in the UK.

[Shaner]

Hi Paul, hope you're well.

Am I right in saying that to fit this complete 6 speed to a Supercharger, you would need to fit a smaller 4A-GE flywheel (and clutch), as well as a 4A-GE starter motor to the GZE engine? Will the Mk2 NA driveshafts therefore fit the Supercharger hubs?

I would still love to get a 6 speed for my Supercharger, but have you (or anybody else), ever fitted one to a Supercharger? Does it work as well as with the 4A-GE engine?

Shane.

[Woodsport]

Hi Shane, yes they have been fitted to a supercharger engine before, in fact I have one in my workshop right now bolted to a 4a-gze, I could send you everything needed to make it fully plug and play onto a 4a-gze.

Mk2 NA shafts fit the SC hubs, they are the same as NA ones.

It works really well with both engines.

[Woodsport]

Another one of our famous 6 speed conversion gearboxes bolted to its plinth just before it gets boxed, this one has our LSD mod too and is going to Australia. http://www.mr2mk1club.com/images/imported/2017/07/52775379ef5a1287ca7da77a5bf17541-1.jpg

Sent from my SM-G950F using Tapatalk

[john Oswald]

Just recently had the 6 speed box and normally asperated clutch fitted to F561OVU by Paul.
Drove down to Cornwall from Durham and returned home covering 1422miles the the whole car was faultless.
Makes a world of difference on the motor ways.
Gear change slick and smooth.
Back in 1985 I purchased one of the first MR2's into the country we toured Europe with it.
We followed that one in 87 with the Tbar which we had for another 2 years.
Loved the car then and still do.
Slowly having F261OVU brought up to as new as spec as possible through Paul of Woodsport,

[Woodsport]

Hi John, thank you for the kind feedback and welcome to the Mk1 club.

[Woodsport]

Revised prices for 2018....

6 speed gearbox without LSD, new diff bearings, new input and output shaft bearings and all new seals £1195 delivered UK wide.

As above but with LSD fitted £1495.

These 6 speed conversions are my own invention and we have supplied dozens world wide with a 100% success rate on both fitment and reliability, some have now covered over 30k on boosted engines without issue.

Fully plug and play, take out your old gearbox and fit the new 6 speed without anything to modify or adapt, get rid of that tired old C50/52 unit with worn synchros and jumping out of gear. A Woodsport 6 speed is a modern upgrade for your Mk1 with longer gear ratios and final drive.

*Note that the LSD version requires Mk2 Mr2 NA driveshafts, which are again fully plug and play on a Mk1 with our 6 speed conversion.

[Robin Davies]

Had the PW 6 speed box in for 9 months now- It's brilliant!
It saves fuel and much is quieter on a long run, makes it a different car!
My old box was sound incl 5th gear, but the new one changes better too despite that. Car would actually pull a higher 6th gear still, but can't have everything.
Brings car into 21st century.
robin
PS, Anyone want a good MK1b 5 speed box and shafts 99,00 miles?

[Woodsport]

Great to hear you are enjoying it Robin, they really do transform the Mk1, the C60 is such a nice unit.

[Woodsport]

I have a fully built spare 6 speed conversion in stock if anyone wants one of my marvellous gearboxes :)

[b4wrc]

Is it possible to fit the 6 speed gearbox with a supported shaft so that equal length drive shafts can be used?

[Woodsport]

It is possible yes, because Mk3 Mr2 shafts fit the gearbox and also fit the hubs, the only issue is the supported bearing bracket, which on the 1zz has somewhere to bolt to, on a 4a-ge it does not directly bolt up to anywhere with the 1zz bracket, but i have made adaptors in the past to hold the Mk3 supported shaft onto the 4a-ge block, now i don't have jigs for that part, it was so rare that anyone asked me to do that that i just did it in situ on the day.

Unless there is a Corolla or something which uses a C series gearbox and a 4a engine with a supported shaft setup (from memory i think there is but will need to research it), then that would provide a plug and play supported shaft setup.

I will look into it and get back to you, but yes it is possible to do it anyway with a little but of bracketry and Mk3 shafts.