Hi - I have a 1994 Toyota 4WD with 5-speed manual transmission. I recently brought the transmission in to a Toyota dealer for a rebuild due to early stage shifting issues and popping out of first gear. They did a full rebuild and replaced all bearings, clutch forks, syncros and clutch.

After the repairs everything appeared to be working fine until I was driving at highway speed downhill. The transmission popped out of gear after releasing my foot from the accelerator. This problem is slowly getting worse with it popping out of fifth when decelerating.

The truck has 500,000 miles on it and I've never had a problem with popping out of fifth until this rebuild. Since it wasn't popping out of fifth when I brought it in for the rebuild it's obviously associated with something they did. Does anyone have any thoughts on what they might have done to cause this problem and what needs to be done to resolve it? The repair is still under warranty and I want to get it in before the warranty expires.

Thank you, ... Christopher

 

No answer yet?
I read this and just assumed it was the 3.0 liter R150.
I have a 94 like yours and rebuilt mine (about a year ago?). But I have yet to start the truck so I'm interested in what you find because there's yuugge odds I'll have an issue myself.

I can't think (thinking back) what might do that other than the clutch syncro might not be proper? Too loose or maybe those little grooves on the inside aren't there?
Wonder if you drive normal, release pedal, does it pop out repeatedly no matter accelerating, or just normal coasting?

 

I can't remember which gear my old 91 4runner used to pop out of, but it did it often. All I remember is replacing some plastic pieces on the top part of the transmission under the shifter boot for around $15, and it took about a half hour.

 

Here's what it was on mine.