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So if you want to have a crack at building your own 6 speed gearbox with LSD this will be a pretty good guide for you.
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This gearbox will be a direct replacement for your 5 speed, there is nothing to modify on the car itself, but you will need to use Mk2 NA driveshafts with the LSD, but don't worry it's still all plug and play.
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Hope some of you find it useful, enjoy!
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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.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/mk1bell.jpg)
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This is all of the 6 speed internal parts from the donor C60 gearbox.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/6spdstripped.jpg)
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Here are all of the new bearings and seals from Toyota, nearly
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/newbearingsandseals.jpg)
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This gearbox is getting the Mk3 LSD unit, so the first step is to remove the old bearings from the Mk3 LSD.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/LSDoldbearingsremoved.jpg)
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The Mk3 speedo cog is the same as a Mk1 cog, so the speedo will work as before.
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Now install the new bearings onto the diff.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/newbearingsonLSD.jpg)
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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.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/6spdcrownwheelfitted.jpg)
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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.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/newdiffcasewasher.jpg)
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The new bearing race is then fitted.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/newdiffcaserace.jpg)
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Now we install the new output shaft bearing.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/outputbearingfitted.jpg)
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Not forgetting the retainer and bolt.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/outputbearingretainer.jpg)
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Now we fit the new input shaft bearing.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/inputshaftbearing.jpg)
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The adjustment shim is fitted to the middle case, this shim is what affects the load on the diff.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/EEshimfitted.jpg)
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And the new race fitted over that.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/midcaseracefitted.jpg)
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This shim will need to come back out if the preload is not correct.
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Now to adjust the preload we need to install both the diff and output shaft into the case.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/difffitted.jpg)
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/outputshaftfitted.jpg)
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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.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/midcaseandsnapring.jpg)
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A 14mm headed M10x1.25 bolt is screwed into the top of the output shaft so my torque meter can be used.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/preloadchecking.jpg)
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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.
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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.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/inputshaftandselector.jpg)
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The rest of the selectors are then refitted.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/otherselectors.jpg)
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Then three selector retaining bolts are fitted.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/selectorbolt1.jpg)
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/selectorbolt2.jpg)
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/selectorbolt3.jpg)
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The lower selector detent ball and spring are now fitted.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/selectordetent.jpg)
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/selectordetent2.jpg)
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Fit the case magnet.
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Now time for the reverse selector.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/reverseidlerselector.jpg)
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/reverseselectorbolts.jpg)
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The reverse idler is now added.
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The shaft on this needs to be orientated correctly to the case or the retaining bolt on the outside won't line up.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/reverseidlermark.jpg)
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Now the case is ready for sealant.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/casesealant.jpg)
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With the middle case fitted and all bolts torqued down for the final time, the reverse idler bolt can be fitted.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/reverseidlerbolt.jpg)
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Now both snap rings are fitted to input and output shafts.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/snaprings.jpg)
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Add the shaft retainer plate and bolts.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/shaftretainerbolts.jpg)
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Fit the selector circlip.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/selectorsnapring.jpg)
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Install both upper selector detent balls/springs.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/upperdetents.jpg)
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/upperdetents2.jpg)
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Now add 5th driven gear.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/5thgear1.jpg)
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The roller bearing for 5th.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/5throller.jpg)
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Refit the 5th/6th selector fork and synchro hub along with circlip.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/synchrohubsnapring.jpg)
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Fit selector fork bolt.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/5th6thselectorbolt.jpg)
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Fit roller bearing and synchro ring.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/synchro.jpg)
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Refit 6th gears, top bearings and circlips.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/topsnaprings.jpg)
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Refit end casing.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/uppercasebolts.jpg)
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Turn the gearbox over and install the inner bellhousing bolts, input shaft oil seal and release bearing trumpet.
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![Image](http://img.photobucket.com/albums/v624/paddy1970/Woodsport7/insidecasebolts.jpg)
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The outer selector assembly then slides back in, add the Mk1 reverse light switch and that's it!