Hi Ed, welcome to the board!

Here's a tech article we have in our Toyota section for ya:

http://www.4x4wire.com/toyota/tech/r151f/

You didn't say where you folks are located; www.marlincrawler.com is another option for a swap for the tranny and having a warranty.

When it comes to rebuilds on trannys, sometimes just the synchros and bearings need replaced, as long as the 'hard parts' are still good. The bigger components of a tranny have a coating of harder metal on them, if that breaks down, then a major overhaul is in order.

You might investigate just what all comes in the rebuild kits you're looking at. The R-series trannys for the most part are robust unit.

In addition to the article I listed, your boss can also go to www.techinfo.toyota.com to download the tranny section for $10. We also have a link for some factory service manuals over in the Taco section that he can look at as well; check out the sticky posted there.

Hopefully this will get you guys into a game plan; keep us posted!

PS- Reminder to the boss also to get a pilot bearing and plan on getting the flywheel turned; no half-steppin', or you guys will be back under there in 4 months for the clutch.