Tamiya Bruiser/Mountaineer Transmission Service Manual
Contents
1. 1 3 20 Shift Spring B 21 Shift Spring C 22 2 5 Bushing 23 5mm Bronze Bearings 25 Dust Protector 28 laxi 8mm Cap Screw 5 Ball Bearings Retrofit If you plan to install ball bearings you ll need e Eight 8 850 5x8mm Flanged bearings e g Duratrax DTXC1527 e Five 5 1150 5x11mm bearings e Shims This be a package of Calandra 5mm Axle Shims can be difficult to find or Traxxas 5x8mm Fiber Washers 1985 available at Tower Hobbies or your local hobby shop You might see in various parts of this document See notes below e 2 5mm hex wrench 2 3 4 5 C2 Notes 1 The shims are necessary because the there is a difference in the flange thickness between the original bronze bushings and the ball bearings We need to preserve that clearance otherwise the transmission won t shift properly Also the flanged bearings are Version 1 03 Page 7 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual typically adjacent to some non spinning surface and without some kind of spacer to keep the flange from rubbing that surface you re not totally reducing friction Ideally the shims should have an inside diameter of 5mm and outside diameter of 6 to 6 5mm smaller than the outer ballrace of the bearing Figure 4 850 Flanged Bushing and 850 Flanged Ball Bearing e Each 850 flanged bushing is about 4 05mm thick The flange is about 12. You should retrofit all bushings with ball bearings There is a little more driveline drag friction in 4WD mode so it is advisable to run with ball bearings inside the transmission Version 1 03 Page 23 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Figure 30 shows the modified Shift Rail arrangement Ideally when Low gear is engaged the spring between the two Shift Forks should not be fully compressed as shown in the picture there should have a little more slack available to aid gear engagement If you want to experiment and need a donor spring you may find a suitable one from a retractable ballpoint pen Figure 30 Modified Shift Rail arrangement for full time 4WD Low gear engaged End Version 1 03 Page 24 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Document History Date 10 5 1999 3 17 2003 Version 1 01 updated email address 4 15 2003 Version 1 02 Fixed missing picture in Fig 7 malformed email link 7 11 2007 Version 1 03 Updated copyright info Copyright 1999 2007 Ko ping Hu All rights reserved No part of this document may be reproduced in any form or by any means without permission in writing from the author Other product and company names mentioned herein may be the trademarks of their respective owners This version of the document is free for personal use Please contact the auth
3. Plastic Gear Figure 14 Version 1 03 Page 14 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Disassembly of Transmission Case B Part 1 Remove Transmission Case by loosening three 3x15mm hex screws Be careful the cover is under spring tension Do not lose that spring Figure 15 Here is the side view of the transmission with Transmission Case removed I ve replaced the Plastic spur Gear to show the relationship of the gears Figure 16 Version 1 03 Page 15 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Disassembly of Transmission Case B Part 2 Picture shows Transmission Case B removed Parts are shown with the correct orientation Don t lose that Shift Spring A 15mm spring The 2 Speed Countershaft the shaft with gears on each end is supported by two 2 850 flanged bushings If retrofitting with ball bearings use 5 shims between the gear and the bearing flange Disassembly is now complete with this end Re assemble if desired before continuing on The Output Side of the Transmission Transmission Case E Figure 18 Version 1 03 Page 16 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Transmission Case E End Plate Removal Remove Transmission Case E by loosening three 3x15mm hex screws The Transmission Case E is under spring ten
4. need to remove 3 hex screws two 3x10mm and one 3x15mm Note the orientation of the Dust Protector the white plastic crescent shaped piece The side with 4 protrusions faces the screws There is an 1150 bushing in the cover The Plastic spur Gear can now be exposed Figure 9 Transmission with Motor Housing removed Version 1 03 Page 11 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Figure 10 Detail photo of the Plastic Gear and Dust Protector This is the Plastic spur Gear This is Tamiya part number 4265002 no longer available from Tamiya I ve found Kyosho s one piece transmission gear from part 4BBOO6 Big Brute USA 1 can be adapted to fit check Tower Hobbies The Kyosho part does not have a slipper clutch Tu BIN Figure 11 The Plastic Gear is supported by two 850 flanged bushings Version 1 03 Page 12 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual soar Mw bruni PESE P Lan ly Figure 12 Plastic spur Gear This side faces the motor This is the other side of the Plastic Gear Note the non adjustable slipper mechanism If you are retrofitting with bearings recommend 2 shims on either side of the flange Version 1 03 Page 13 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Figure 13 Transmission Case B This is what s underneath the
5. 05mm thick e Each Duratrax 850 flanged ball bearing is about 2 48mm thick The flange is about 0 59mm thick e There is a difference of 0 46mm between the flange thicknesses You can round this up to 0 50mm for convenience We are not worried about the thickness of the bearing itself e Each of the Calandra shims is about 12mm thick To make up for the difference in flange thickness you need about 4 shims You may have to measure the flange thickness difference and adjust the number of shims as required in your case 2 There will be some areas where it won t be possible to retrofit the bushings without modifications or specialized presses so you ll just have to lubricate those bronze bushings well used Slick 50 a PTFE additive used in automobiles and motorcycles You can also use BreakFree CLP available in hardware stores and gun shops Tamiya s instruction manual advises against using grease Version 1 03 Page 8 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual 6 Naming Conventions follow the naming conventions found in the exploded diagram of the transmission The transmission can be divided into 5 sections Starting from the motor we have the Motor Housing Transmission Case A then Transmission Case B Transmission Case C Transmission Case D Transmission Case E Transmission Case C is the one that looks like 2 sections fused together Figure 6 Right side of transm
6. 2mm spring See picture below for correct orientation Note the Low Speed Countershaft and Gear Unit the one with 2 gears and a metal tube is oriented with the long shaft pointing out Version 1 03 Page 18 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Another picture of the internal parts and their orientation Er eem E E 51 Figure 23 There couple of bushings here If retrofitting with ball bearings for each 850 flanged bearing use 5 shims between the flange and its adjacent surface J E IB Figure 24 Transmission Case D can be unbolted from Transmission Case C by removing three 3x10mm hex screws Version 1 03 Page 19 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual This is what an empty Transmission Case C looks like after removing everything inside Transmission Case D looking from the output end E hy 14 2 T 1 t ILL T oak We WES T m 4 73 v zn te Eu d FART igt raa a A BA Figure 25 Version 1 03 Page 20 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual This is the other end looking from the input motor side of an empty Transmission Case C While it ma
7. L RI i gt bU OW Sy ce LP AC BP5 17 24 hif arm ars FEIN buie Eonar E CES ee ee 1 B ee A Ed loan 4 Thread shirk ioe vee tan FAHS ii TAS WX Fa ees Mises parta Temporary secure shii nem ms Shawn tor amocth Bake ne PC TE A 1 Se Eo A Ope sors rm p Feii VIERTE Plizber pars hal cap ATS PARTS USED 3 eA road Screw bag ir L di og Pr me tte in BP5 507 i Sws Propolis shah short Figure 1 Attaching transmission parts Version 1 03 Page 4 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual GHIFT GATE E R o4Le RBXAE Gas shit 3 FTA FR SH Im LEdg4 5 TF eu Second gear os make a shiti giie paslit sham mot in kit and atach on the left sha of ranmi Foslar bes balie ou oe AA oF e Am Top gear TE Bark Langer Fian JA ee Pb Fae dr
8. Maen att gale unire plastic heed air PE a RIL TR oe Porth Fy oS LPH Ute Fry ete a FECE gt oe FROME FE WHEN 2 CHAN RAT LIT You angay driving this modal us ww 2 chan ursi alsi this A shite pervs nol umm andi you must change gear Gear position 5 homi while ranning 1 35 a AT yJ a esa a a Fak Stick opera on were sram he sbck i Ys change gear Proper aperabon should bo done is shown i dae RE irae ine eH J a mem ux raw v Jamais rd deos E34 z Ady UD Lal Lans Epid conos adjustment ie qti 48ESGktUO LTLATEA and hid tha hinein wath rati l i NA hearer LEY ame Fors acria RN it e vr uh pari n i and ponilion 2 ma tha fisco cam gae loma Firearer mht u j rn T4lo te Pha de Bde Lio X Led dies V Fully uii and postion the clade TUM ven eie Tor al dern 13 Sadi MOR TARE EA Figure 2 Gear shift operation and adjustment Version 1 03
9. Page 5 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual You should waterproof your transmission by applying silicone sealant to the gaps between each section This also keeps dirt out and lubricants in Note do not know of any easy way to remove dried silicone sealant from a used transmission It seems to be impervious to most household thinners and solvents such as paint thinner lacquer thinner kerosene etc Apply silicone sealant to joints of transmis sion for waterproofing y LO Transmission fi 7 PRO ROY a E A m3 EON CK Figure 3 Sealing the transmission Version 1 03 Page 6 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual 4 Parts List Tamiya included an exploded diagram in some of their kits If you need a copy of one you can get it from this URL http Awww kope com bruiser Exploded pdf PartNo Name Quantity 1 Motor Housing Transmission Case A 1 Transmission Case B Transmission Case C Transmission Case D Transmission Case E 6 JRS 750SHMotor withPinon 7 Plastic Idler Gear Counter Gear Main Gear Cluster 9 pnd Speed Countershaft and Gear Unit 11 12 FrontDrive Countergear 13 FrontDrive Countershaft 01 14 Front Drive ShaftandGear Unit 1 15 Shift Fork A Shift ForkA 16 ShftFokB Y Y 2 17 18 gShifingRings
10. Tamiya Bruiser Mountaineer Transmission Service Manual Ko ping Hu Version 1 03 First published October 5 1999 Revised April 15 2003 Table of Contents OO Oe C ES Introduction Background oetup and Operation Parts amp Ball Bearings Retrofit Naming Conventions Disassembly Modifying the Transmission for Full Time 4 0 22 Tamiya Bruiser Mountaineer Transmission Service Manual 1 Introduction This is all original research done by myself with my own transmissions decided to write this document to benefit other Tamiya Bruiser Mountaineer enthusiasts In the past used my own handwritten notes and pictures for my personal use and realized that there aren t any good reference material of this kind This can be a good reference material if you decide to rebuild modify your transmission or retrofit with ball bearings Although this was based on the Bruiser Mountaineer transmission it is also applicable to the Toyota 4x4 HiLux and Blazing Blazer A note of caution Try not to lose anything inside the transmission Aside from the Plastic Gear and some common bearings none of the internal parts are available separately You ll have to scavenge from another transmission or make your own Use this document at your own risk Although l ve checked the instructions your results may vary and I m not responsible fo
11. is 15 to modify the arrangements of the elements on the Shift Rail a bit A little fine tuning may be required but will give you the general idea 1 You need the outer Shift Fork B fixed in place so that it always connects the 18T Idler Gear with the Main Gear Cluster If you take Shift Spring C out and just leave the 5x12 5mm Bushing the hollow metal tube in place you re pretty close You need to push the inner Shift Fork B away from the outer Shift Fork B In other words you need a longer spring between the two Shift Forks than the original Shift Spring B This spring will 1 Keep the outer Shift Fork B against the Bushing 2 Keep the inner Shift Fork B away so that it does not stay in Low or Medium gear if you push the Shift Rail in to select High gear 3 Compress enough between the two Shift Forks so that you can still shift into Low gear They two Shift Forks are about 16 to 17mm apart depending on the slop in the transmission This spring should probably be about twice as long as the Shift Spring B You might find that Shift Spring C will work in its place Reassemble and manually test the transmission turn by hand and shift by hand If the spring is too long to work properly then you will have to find a suitably shorter one You will lose the ability to shift from 2WD to 4WD It may be possible to devise a shifter mechanism to operate the 2 Shift Forks independently but lIl leave it up to you to experiment
12. ission Version 1 03 Page 9 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual 7 Disassembly Here is a typical Bruiser transmission The gap between each of the transmission sections is usually sealed with silicone sealant to 1 keep lubricant in and 2 keep dirt out There are 3 oil holes in the transmission New Tamiya replacement rubber caps are no longer available but similar aftermarket replacements are available you ll have to be resourceful and find what works You may find suitable rubber neoprene feet in electronics supply stores or rubber caps in auto parts stores to plug seal those 8mm diameter holes You can even use duct tape Occasionally you may find people selling these parts on eBay Figure 7 A typical used transmission Version 1 03 Page 10 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Disassembly of the Motor Housing Side Start by removing the motor Picture below is with the motor removed This is the Motor Housing Transmission Case A This is the side that the motor pinion goes into v TE E iu aig m eur yy 4 MIT LL hi i x i ry s 1 a 4 11 a L E i j Vel ammi ri dA nomen Rc iaa d Figure 8 Front of transmission the Motor Housing motor input side Removal of the Motor Housing You
13. or at khu financier com if you plan to use it for commercial purposes This document is provided AS IS and without any warranty or condition expressed implied or statutory By using this document at all you re agreeing to abide by these terms Distribution Please provide a hyperlink back to the original document in case update the document people can always get the latest The document may be found on http www kope com bruiser You may store a copy locally for your own use In cases where hyperlinking is not feasible freely authorize the distribution of copies of this version of the document as long as the following conditions are met 1 Nofee is charged for the document 2 document is only distributed in its original form and is not altered in any way Itis not included as part of another commercial offering Version 1 03 Page 25 of 25 Copyright 1999 2007 Ko ping Hu
14. r any damage you may cause to your transmission or your truck due to the use of this material 2 Background This is a Tamiya 3 speed transmission with integral transfer case made for certain vehicles in Tamiya s line of 1 10 scale radio controlled 4WD vehicles For the Bruiser Mountaineer it uses a Mabuchi RS750SH electric motor for power For the Toyota 4x4 Pickup HiLux and Blazing Blazer it uses a RS540 electric motor Shifting can be done manually or via a servo acting upon the shift rail protruding from the end The basic transmission mated to either RS540 or RS750 motors have been used in the following Tamiya vehicles e Toyota 4x4 Pickup RA 1028 1982 1985 e Blazing Blazer RA 1029 1982 1984 e Bruiser 58048 1986 1992 e Mountaineer 58111 1993 1996 3 Setup and Operation have included the relevant sections from a Mountaineer Manual for reference To summarize Shift arm e Pulled out 4WD Low Neutral 2WD Medium e Pushed in 2WD High Initially a space of 8 10mm is left between the shift arm and the transmission Version 1 03 Page 3 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual JA M PARTS USED Eule EA EUOU Dx iHa amp ttaching tranamisaicei paris BLI s Piri ee ERE egg vizio me IF Le Flange a oS gt y top d tA AY Fi 2
15. sion Don t lose that spring The Other Side of the Transmission Case E End Plate The bushings are either stuck here or on the shafts below There are recesses for two 2 1150 and one 1 850F bushings When you reassemble this part you might find it easier to mount the 3 bearings bushings back in the Transmission Case E End Plate Figure 19 Disassembly of Transmission Case D Carefully remove the Front Drive Shaft and Gear Unit from Transmission Case D You may directly replace the 1150 bushings with 1150 ball bearings would use rubber sealed ball bearings at least on the output side of the shaft Figure 20 Version 1 03 Page 17 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual The Front Drive Countergear Assembly Exploded view of the Front Drive Countergear the screwed the End Plate do not know of any ball bearings that replaces the Plastic bushing Figure 21 Disassembly of the Transmission Case D Continued Remove the following parts Main Gear Cluster Shift Rail assembly lift out the entire thing Low Speed Countershaft and Gear Unit Parts are shown in the correct orientation below Figure 22 Figure 22 The Shift Rail assembly is assembled in the following manner Shift Rail pointed side in Shift Fork B flat side against the stop Shift Spring B 9mm spring Shift Fork B flat side out 5x12 5mm Bushing Shift Spring C 3
16. t Drive Countergear which meshes with the 18T Idler Gear Since the 18T Idler Gear is decoupled from the Main Gear Cluster except in Low Gear no power is transmitted to the front output shaft When you shift into Low gear by pulling out the Shift Rail the outer Shift Fork B slides the outer Shifting Ring between the Main Gear Cluster and the 18T Idler Gear thereby connecting the two Once this connection is made power is transmitted to the front output shaft Obviously shifting into Low gear does more than just that it also engages the Low Speed Countershaft and Gear Unit Assembly It would be helpful to study Figure 24 specifically the arrangement of the Shift Rail Assembly You will note that the two Shift Forks basically move in unison the Shift Springs B and C are there to maintain the required distance between the Shift Forks and to provide a little give if the gears do not engage Please see Figure 28 and 29 for a better idea of gear engagements Figure 28 Medium Gear unmodified Version 1 03 Page 22 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual Figure 29 Low Gear unmodified key is to keep the outer Shift Fork B fixed relation to the 18T idler Gear and the Main Gear Cluster so that the associated Shifting Ring connects the two while at the same time allow the Shift Rail to move in and out to engage Medium and High gears One way to do th
17. y be possible to remove the gear cluster inside Transmission Case C chose not to do so in this document There is another bushing inside the gear cluster but just leave it as is PI ier Tic tam 11 a 227 13 T iu Y p rn y as Ki LL n U par s i h aola bui RC i n 1 Figure 26 This is completely disassembled transmission Figure 27 Version 1 03 Page 21 of 25 Copyright 1999 2007 Ko ping Hu Tamiya Bruiser Mountaineer Transmission Service Manual End of Disassembly The transmission can be re assembled in the reverse order find it easier to reinstall the parts in Transmission Case C D in the following order 1 Itis not necessary to attach Transmission Case D to Transmission Case C first You can do it either now or after you reinstall the internals up to you Low Speed Countershaft and Gear Unit Assembly Shift Rail with one Shift Fork B along with one Shifting Ring Shift Spring B Main Gear Cluster The other Shift Fork B and the other Shifting Ring Everything else 2 3 4 5 6 7 Modifying the Transmission for Full Time 4WD The stock transmission only operates in 4WD in Low gear It is possible to modify the transmission to have full time 4WD If you study the power flow diagram Figure 2 you will see that the Front Drive Shaft and Gear Unit Assembly meshes with the Fron
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