If you do decide to make your own cable, I would go to a home improvement center like Lowes. They have much heavier and wider selection of cables then what you would find at bike shop. They will also have ferrules for the end of the cable. You can run the new cable thru your current outer casing, th...

Chances are that you can not feel it in the steering wheel, but in the vehicle as it travels down the road. It will be most noticealbe when the car runs over an undulation on one side, the car will want to wander to the left or right. The higher the speed the more the wandering effect will be notice...

I just check on Rock auto. It looks like your slave cylinder is from an FX16.
A new [with correctly located mounting tabs] AE86 slave is dirt cheap, and it appears to have an adjustable push rod. Dave W

Just eye balling the pictures, the slave looks like a stock toyota one. If the rest of the system checks out. Pull the slave push rod out of the cylinder and shorten the push rod. Dave W

I would check the master cylinder push rod. You need 1mm of free play at the M/C cylinder push rod before it contacts the piston . You need to allow enough travel for the M/C piston to uncover a port to release the pressure in the system. A quick check , break open the slave cylinder bleed valve to ...

I think the only other bolt on option worth considering is the Planatary gear reduction type 0.8kw starter, 2.85kg: P/N 28100-15190 for a AE92. This is the type with the long through bolts. It does not look like a reduction starter at first, but it has planatary gears inside. It came on some AE92s w...

To verify the timing mark on the crank pulley, stick a screw driver down number one plug hole and slowly turn the crank. when the piston reaches TDC, your notch on the crank pulley should be very close to your zero timing mark on the cam cover. My crank pulley's outer ring had moved about 25 degrees...

If you are going down the the T-VIS elimination road, remove the plate completely. Just make sure you pull the locator dowels stuck in the head before attaching. You will have to source shorter attaching bolts that are 8mm x 35mm lg. If you have the time, $, and tools, get a new themo gasket for the...

I got rear axle bears from professionalautoparts.com The SKF Part number K8000-23939. It's a stock replacement axle bearing for the AE86 and it only cost about 40% of what the dealer was asking. Dave W

When you build your heat shield, I would extend the shield up and around the back side of the distributor. [even with a ceramic coated exhaust] You could attach the top of the shield to the rear distributor mounting bolt, and use one or both the engine block bosses near the oil pressure sensor. You ...

I had the same problem about 4 years ago. The synchro has a spring clip that hold three dog keys on the inside of the hud. The spring actually got mis-located that hold the dogs on the under side of the hub. One end of the spring clip was protruding above the hub, preventing the hub from sliding int...

Since you have gone this far, even if you do not see any coolant, I would clean around the freeze plug and then use 2 part epoxy to add a safety factor for a good seal. It might only weep coolant when hot. Dave W

Before you jump into replacing a freeze plug [a real pain] Also check the steel coolant tubes with a mirror and a lite. I though I had a leaking freeze plug, when in fact it was a small pin hole rusted thru the coolant tube. Much easier to fit then a plug. Dave W

Search for radco, Radcoent/Uniiversal, for a replacement stake-in type U-joint for the AE86 drive shaft. This info is about 10 years old, So hopefully they still carry them. I was able to grind out the staking, replace the joint and just restake [after carefully centering the joint in the yoke]. Dav...

I've always had good luck when installing the cam seals, if I remove the front cam bearing cap , then side the seal on the shaft. That way you can verify that the seal is straight to both the shaft and head plus you can tell that the spring and lip are OK, before you re-install and troque down the c...

I've had real good luck using a vacuum pump to bleed the brakes. You might also try jacking up the rear if there is a high loop in the rear brake line. After the conversion is the bleed valve the highest point of the caliper? Dave W

Doug Disclaimer, I have not used these alternators, these alternators are just from my notes and would need further investigation. In all probability you are going have to make new mounting brackets to align correctly. I think the only direct fit alternator is from the early 4A motors [which I'm usi...

A quick check if you have an air compressor, is to apply air pressure to the cylinder(s) and listen to the intake, exhaust and crankcase for leaking air. Should help narrow down the problem. Dave W

I paid $250 for my drive shaft. All new parts. No shipping charges, local shop, but it seems that shipping over size parts also get $ plus, plus mark ups. Dave W

You are asking a lot from the tail shaft seal with that rough of a surface to seal against. Even if it would seal it, the seal probably would not last very long running on that surface. If you are getting a custom length drive shaft made, the drive shaft company should be able to get a new yoke in l...

Depending on how rough the surface is on the exhaust manifold, you met get better results using either an aluminum or brass washer from the local hardware store [will probably have to open up the I.D.] Plus adding a little permatex should solve the problem. Dave W

The cylinder head / rock arm bolts are 62-68 ft/lbs. Typical start in the center of the head and work outboard in two or three steps. Dave W7

If you remove the booster you really need to change the brake pedal lever ratio. The stock pedal ratio is about 3.8 to 1 [boosted]. You need to relocate the master cylinder up slightly and drill a new hole for the push rod that will give you a lever ratio of 5 to 1. You will be much happier with the...

If you are "sure" that the inner tie rod pivots for LH/RH are equal distance, [not clamped in AW-11 factory location] then you will have to adjust the elevation at each pivot point to get ends of the tie rods traveling thru the same arc. Get a suspension handling book that shows how to mak...

All you need to do is connect the multi-meter across the to pins on the switch [with the meter on ohm setting and zero'd] and then put the trans in reverse to verify a completed circuit. You could also used a battery powered test lamp. Dave W

You can try heating the copper sealing rings with a torch and quenching it in water to soften the sealing surface and add a small amount of gasket sealer around the rings. You can fill a tap with grease [to catch the chips] and run it into the hose attachment boss to clear out the threads. But the o...

It's been a few years, but I think you can still get replacement stake in u-joints for the AE86 drive shaft @ RADCO, try searching radcoent/universal. It requires grinding out the staking to remove the joint and re-staking after assembly. Dave W

Just double nut the studs and remove them. Then install longer bolts.
You may have the wrong pulley????
Dave W7

Jondee
Thanx for the replay. I thought it may have required re-sizing the photo. DaveW

I've tried adding two photos, but I get "attachment quota reached" and it's only 220KB?
Any suggestions.
Dave W7