1971 Toyota Corolla OHV 1600 with a four speed trans and rear drive. I bought it used at around 55k miles from a neighbor who bought it new. I ran it for an additional 40k miles. Things broke on that car, giving me some repair lessons that I didn’t need previously and have not needed since. I have posted comments about this car before but it’s hard to resist doing it again.
The cylinder head sealing surface was unbelievably roughly machined and so the head leaked antifreeze into the oil and oil to the outside. It was repaired with a large file and a new head gasket; easy to do as the head was aluminum.
One of the valve springs broke and needed replacing as did the valve that was found to be burned.
The lower “A” frame ball joints were worn out so the “A” frames that included the ball joints were replaced. The neighbor said that he had it serviced regularly. Fortunately parts were cheap, even at the Toyota dealer.
The front struts leaked their oil out so a quick and dirty repair took care of it. Drilled a small hole with a magnet in close contact to catch the chips near the top of each front strut to squirt in some power steering or auto trans lube, I have forgotten which, and then closed each hole with a trilobular thread-forming screw and a small “O” ring under the head. I can recall adding oil to the struts two or three times. This could be a useful repair now for someone with little money to spare.
The side gears in the differential stripped due to poor heat treating as per the metallurgist where I worked. As can be recalled, he could determine that by looking at the surfaces where the teeth broke off. That gave me a little exposure to differential assembly including shim adjustment of ring and pinion gear engagement with Prussian Blue.
The clutch slave cylinder leaked and was inside the bell housing so the trans had to be pulled to replace the cylinder; threw in a new friction disk and TO bearing while convenient. A new clutch friction disk did not eliminate the clutch chatter.
No matter how carefully done, it was not possible to get the front wheels in balance; have balanced wheels for years before and since with no problem. I finally stumbled on removing one front wheel, turning it 90 degrees and then remounting it. That got the front wheels into balance and to this day I don’t know why it worked.
The final gear ratio was grossly undergeared, probably due to Japanese homeland needs but for the US it was a problem. The engine sounded like it would self-destruct at 60 mph so I drove it during my 40k miles ownership at around 52-53 mph on freeways, in the right lane, of course.
About once a week the starter would make an awful gear clashing sound instead of starting the engine. The start attempt would be abandoned and repeated and the clash would not happen again for a while. Inspection of the starter revealed nothing obvious. The starter behaved like that during my entire ownership time and seemed to cause no apparent damage to the gears.
This car was so badly done that I still feel that Toyota cheated me. I find it hard to imagine how they managed to stay in business after producing a car such as this.