When I bought my Ace (Lite Ace 1991 2.0TD Auto4x4) the gearshifting was very late and quite harsh. I expected a kickdown cable adjustment but when I tried to adjust it I found that the upper end of the cable at the injection pump was very very slack and would not adjust in either direction. A look underneath revealed that the cable had been chafing on the transmission housing for some time and had worn right through the outer sheath allowing the inner cable to corrode away. The inner cable had seized in the full-welly position resulting in the delayed shifts. So, if any of you out there are contemplating changing your cable, here is the lowdown:
First, disconnect the upper end of the cable from the pump and loosen the two adjustment nuts in order to free the cable from the bracket.
Next, get underneath and free the cable from any clamps or clips securing it. Now you need to drain the transmission oil ( I suggest you throw it away and renew it ) and remove the 10mm bolts securing the transmission oil pan. Tip: you don't need to remove the dipstick tube as the oil pan will simply pull off it as you remove it.
I was worried that the valve body would need to be dropped, but thankfully it doesn't. The cable runs around a cam and the end is slotted into a hole in the end. Us a long thin screwdriver to turn the cam round and, while holding it in this position unhook the end of the cable with a pair of long nosed pliers. The outer cable pushes into the transmission and is held by four expanding fingers that lock it in. Use a screwdriver to lever the fingers in and basically poke the cable up out of the housing.
Refitting is a reverse of the above, but one word of advice: pass the cable up from underneath and make sure that it is correctly routed before fitting the bottom end into the trans. as if you make a mistake it would be difficult to remove it again without damaging the securing fingers. They are designed to be fitted, not removed! In order to prevent a recurrence I protected the cable by taking a length of fuel hose, splitting it along its length and slipping it over the cable. With the new cable costing 80 quid, I don't want to replace it too often. If you have an auto, check the routing of the cable next time you are underneath and make sure it is not rubbing anywhere. Mine must have taken some time to get to this stage.

- (#9630) John Shaw, 27 Mar 04 10:20

£80! Toyota are 'avin a larf!

- (#9630) Tom, 28 Mar 04 14:39