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Transmission Assembly (Manual, 5spd)
Here is the follow up to my tC Manual Transmission Dis-assembly(https://www.scionlife.com/forums/sho...d.php?t=183344)...hopefully mod will move this to the tech section as well.
**First the transmission is a very complicated mechanical device, so working on it yourself is done at your own risk, there are precise tolerances that have to be kept or met when working on such a job** I would say this is definitely a project for the very mechanically inclined, this also requires a few special tools to do this job right. Tools Needed: Inch Pound Dial Torque Wrench 10-120Ft lbs Torque Wrench Gear Oil Red Loctite RTV Silcone Sealant/Gasket Maker Bearing Grease Rubber Hammer/Mallet Punch or Flat Blade Screw Driver 12mm Socket 14mm Socket 24mm Socket 27mm Socket 30mm Socket T45 Torx Bit New output shaft rear nut Optional Tools: Snap Ring Pliers Needle Nose Pliers Vise Grips Bench Grinder W/Wire Wheel Die Grinder W/Wire Wheel Harmonic Balancer Puller(Can be rented from Auto parts store) 34mm Socket 1) Clean the bell housing, and transmission case mating surfaces, I used my trusty die grinder w/wire wheel http://i77.photobucket.com/albums/j5...ssembly002.jpg http://i77.photobucket.com/albums/j5...ssembly001.jpg http://i77.photobucket.com/albums/j5...ssembly004.jpg Also would recommend cleaning up all the bolts, especially the thread surfaces...for this I used my bench grinder w/wire wheel Before and after http://i77.photobucket.com/albums/j5...ssembly009.jpg http://i77.photobucket.com/albums/j5...ssembly010.jpg 2) Make sure everything inside is clean http://i77.photobucket.com/albums/j5...ssembly043.jpg 3) First thing we need to do is to measure/adjust the preload on the output shaft bearing. To do this we install the output shaft in the transmission case http://i77.photobucket.com/albums/j5...ssembly007.jpg http://i77.photobucket.com/albums/j5...ssembly006.jpg 4) Then we install the bell housing, and the 14 12mm bolts on the outside and the 3 12mm bolts on the inside. Torque the 12mm bolts to 21 ft.lbs. http://i77.photobucket.com/albums/j5...ssembly008.jpg http://i77.photobucket.com/albums/j5...ssembly016.jpg http://i77.photobucket.com/albums/j5...ssembly018.jpg http://i77.photobucket.com/albums/j5...ssembly019.jpg 5)Time for parts bag No.1(Just like Legos)....lol http://i77.photobucket.com/albums/j5...ssembly020.jpg 6) Install the output shaft rear bearing shim http://i77.photobucket.com/albums/j5...ssembly021.jpg http://i77.photobucket.com/albums/j5...ssembly022.jpg 7) Install the rear bearing retainer using the 7 T45 Torx screws, and torque them to 32 ft.lbs http://i77.photobucket.com/albums/j5...ssembly023.jpg http://i77.photobucket.com/albums/j5...ssembly034.jpg http://i77.photobucket.com/albums/j5...ssembly029.jpg 8) Turn the output shaft and make sure it turns smoothly, then install the 30mm output shaft nut. Using your Inch Pound Dial Torque Wrench, and 30mm socket slowly turn the output shaft, when doing this also watch the dial on the torque wrench. What you are looking for is the force(torque) it takes for the output shaft to begin turning. The numbers should correspond with the followings specification: New Bearing: 14.2 in.lbs Used Bearing: 8.9 in.lbs If the reading you get does not match very close to those numbers then you will need to change the output shaft rear bearing shim using the following guidelines: If the value you got was less than the specification, then you need to add a thicker shim If the value you got was more than the specification, then you need to add a thinner shim http://i77.photobucket.com/albums/j5...ssembly030.jpg The following are the part numbers for shims: The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 NVm (0.408 to 0.612 kgfVcm, 0.354 to 0.531 in.lbs). Shim: mm (in.) [table]Part No.|Thickness: mm (in.)| Mark 90564–59001|1.30 (0.0512)|0 90564–59002|1.35 (0.0531)|1 90564–59003|1.40 (0.0551)|2 90564–59004|1.45 (0.0571)|3 90564–59005|1.50 (0.0591)|4 90564–59006|1.55 (0.0610)|5 90564–59007|1.60 (0.0630)|6 90564–59008|1.65 (0.0650)|7 90564–59009|1.70 (0.0669)|8 90564–59010|1.75 (0.0689)|9 90564–59011|1.80 (0.0709)|A 90564–59012|1.85 (0.0728)|B 90564–59013|1.90 (0.0748)|C 90564–59014|1.95 (0.0768)|D 90564–59015|2.00 (0.0787)|E 90564–59016|2.05 (0.0807)|F 90564–59017|2.10 (0.0827)|G 90564–59018|2.15 (0.0846)|H 90564–59019|2.20 (0.0866)|J 90564–59020|2.25 (0.0886)|K 90564–59021|2.30 (0.0906)|L 90564–59022|2.35 (0.0925)|M 90564–59023|2.40 (0.0945)|N 90564–59024|2.45 (0.0965)|P 90564–59025|2.50 (0.0984)|Q [/table]9) Remove the 30mm output shaft nut, 7 T45 Torx screws, rear bearing retainer, output shaft rear bearing shim, the 17 12mm bell housing bolts(14 on outside, 3 on inside), bell housing itself, and then the output shaft. This should leave you with an empty transmission case again 10) Its now time to adjust the differential preload. http://i77.photobucket.com/albums/j5...ssembly035.jpg 11) Install the differential into the transmission case http://i77.photobucket.com/albums/j5...ssembly036.jpg http://i77.photobucket.com/albums/j5...ssembly037.jpg 12) Then we install the bell housing, and the 14 12mm bolts on the outside and the 3 12mm bolts on the inside. Torque the 12mm bolts to 21 ft.lbs http://i77.photobucket.com/albums/j5...ssembly038.jpg http://i77.photobucket.com/albums/j5...ssembly040.jpg http://i77.photobucket.com/albums/j5...ssembly018.jpg http://i77.photobucket.com/albums/j5...ssembly019.jpg 13) Using your Inch Pound Dial Torque Wrench, and the attachment used to turn the differential(either you can buy from Toyota, or make your own using an extension) slowly turn the differential, when doing this also watch the dial on the torque wrench. What you are looking for is the force(torque) it takes for the differential to begin turning. The numbers should correspond with the followings specification: New Bearing: 14.2 in.lbs Used Bearing: 8.9 in.lbs If the reading you get does not match very close to those numbers then you will need to change the differential case rear shim using the following guidelines: If the value you got was less than the specification, then you need to add a thicker shim If the value you got was more than the specification, then you need to add a thinner shim, or you need to replace the differential bearing and race if no shim is already in place http://i77.photobucket.com/albums/j5...ssembly041.jpg The following are the part numbers for shims: The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 NVm (0.408 to 0.612 kgfVcm, 0.354 to 0.531 in.lbs). Shim: mm (in.)[/b] [table]Part No.|Thickness: mm (in.)| Mark 90564–56055|2.00 (0.0787)|0 90564–56056|2.05 (0.0807)|1 90564–56057|2.10 (0.0827)|2 90564–56058|2.15 (0.0846)|3 90564–56059|2.20 (0.0866)|4 90564–56060|2.25 (0.0886)|5 90564–56061|2.30 (0.0906)|6 90564–56062|2.35 (0.0925)|7 90564–56063|2.40 (0.0945)|8 90564–56064|2.45 (0.0965)|9 90564–56065|2.50 (0.0984)|A 90564–56066|2.55 (0.1004)|B 90564–56067|2.60 (0.1024)|C 90564–56068|2.65 (0.1043)|D 90564–56069|2.70 (0.1063)|E 90564–56070|2.75 (0.1083)|F 90564–56071|2.80 (0.1102)|G 90564–56072|2.85 (0.1122)|H [/table]14) Remove the 17 12mm bell housing bolts(14 on outside, 3 on inside), bell housing itself, and then the differential. This should leave you with an empty transmission case again 15) Again make sure everything is clean, as its time to assemble http://i77.photobucket.com/albums/j5...ssembly043.jpg 16) Make sure the transmission magnet is in place http://i77.photobucket.com/albums/j5...ssembly044.jpg http://i77.photobucket.com/albums/j5...ssembly045.jpg 17) Coat the differential bearing race with gear oil http://i77.photobucket.com/albums/j5...ssembly046.jpg http://i77.photobucket.com/albums/j5...ssembly047.jpg 18) Coat differential bearings, and mating surfaces with gear oil, and install differential http://i77.photobucket.com/albums/j5...ssembly048.jpg http://i77.photobucket.com/albums/j5...ssembly049.jpg 19) Apply gear oil to output shaft bearing race http://i77.photobucket.com/albums/j5...ssembly051.jpg 20) Coat output shaft bearings and mating surfaces with gear oil http://i77.photobucket.com/albums/j5...ssembly052.jpg http://i77.photobucket.com/albums/j5...ssembly053.jpg 21) Install output shaft(you might have to lift up on the differential slightly to get the output shaft to fall into place) http://i77.photobucket.com/albums/j5...ssembly055.jpg http://i77.photobucket.com/albums/j5...ssembly054.jpg http://i77.photobucket.com/albums/j5...ssembly056.jpg http://i77.photobucket.com/albums/j5...ssembly058.jpg 22) Apply gear oil to input shaft bearing and mating surfaces http://i77.photobucket.com/albums/j5...ssembly062.jpg http://i77.photobucket.com/albums/j5...ssembly063.jpg 23) Install input shaft(you might have to tilt the output shaft slightly to get the input shaft to fall into place) http://i77.photobucket.com/albums/j5...ssembly065.jpg http://i77.photobucket.com/albums/j5...ssembly068.jpg 24) Make sure and coat slider surfaces with gear oil http://i77.photobucket.com/albums/j5...ssembly070.jpg 25) Time for parts bag number 2! http://i77.photobucket.com/albums/j5...ssembly077.jpg 26) Coat shift fork 2 sliding surfaces with gear oil http://i77.photobucket.com/albums/j5...ssembly079.jpg http://i77.photobucket.com/albums/j5...ssembly080.jpg 27) Install shift fork http://i77.photobucket.com/albums/j5...ssembly081.jpg 28) Make sure the 2 snap rings, and reverse shift fork are now on shift fork shaft 3 http://i77.photobucket.com/albums/j5...ssembly087.jpg 29) Install shift fork shaft 3 into transmission(make sure all sliding surfaces are coated with gear oil) http://i77.photobucket.com/albums/j5...ssembly088.jpg http://i77.photobucket.com/albums/j5...ssembly090.jpg 30)Coat shift fork 1 sliding surfaces with gear oil http://i77.photobucket.com/albums/j5...ssembly093.jpg http://i77.photobucket.com/albums/j5...ssembly094.jpg 31) Install shift fork 1 http://i77.photobucket.com/albums/j5...ssembly095.jpg http://i77.photobucket.com/albums/j5...ssembly096.jpg 32) Install shift fork shaft 2 into transmission(make sure all sliding surfaces are coated with gear oil) http://i77.photobucket.com/albums/j5...ssembly098.jpg http://i77.photobucket.com/albums/j5...ssembly099.jpg **Make sure to install gear shift head after you pass shift fork shaft 2 through shift fork 2** http://i77.photobucket.com/albums/j5...ssembly100.jpg 33) Install the 12mm bolts into shift fork 2, and gear shift head and torque to 18 ft.lbs http://i77.photobucket.com/albums/j5...ssembly105.jpg http://i77.photobucket.com/albums/j5...ssembly108.jpg http://i77.photobucket.com/albums/j5...ssembly109.jpg http://i77.photobucket.com/albums/j5...ssembly110.jpg Here is where you should be at http://i77.photobucket.com/albums/j5...ssembly116.jpg 34) Hopefully on dis-assembly you did not lose this next item(reverse shift fork roller), using a small magnet feed the reverse shift fork roller into the reverse shift fork http://i77.photobucket.com/albums/j5...ssembly117.jpg http://i77.photobucket.com/albums/j5...ssembly118.jpg http://i77.photobucket.com/albums/j5...ssembly119.jpg 35) Make sure snap ring is on shift fork shaft 1, and coat all sliding surfaces with gear oil http://i77.photobucket.com/albums/j5...ssembly120.jpg 36) Install shift fork shaft 1(you might have to pull up on shift fork shaft 3 to get this to fall into place) http://i77.photobucket.com/albums/j5...ssembly121.jpg 37) Install 12mm bolt in shift fork 1 and torque to 18 ft.lbs http://i77.photobucket.com/albums/j5...ssembly122.jpg http://i77.photobucket.com/albums/j5...ssembly125.jpg 38) Time for parts bag 3, and reverse shift arm bracket http://i77.photobucket.com/albums/j5...ssembly127.jpg http://i77.photobucket.com/albums/j5...ssembly128.jpg 39) Install reverse shift arm bracket and the 2 12mm bolts, and torque to 13 ft.lbs http://i77.photobucket.com/albums/j5...ssembly131.jpg http://i77.photobucket.com/albums/j5...ssembly133.jpg http://i77.photobucket.com/albums/j5...ssembly134.jpg http://i77.photobucket.com/albums/j5...ssembly135.jpg 40) Coat reverse idler gear, and sliding surfaces with gear oil http://i77.photobucket.com/albums/j5...ssembly137.jpg 41) Install reverse idler gear in transmission http://i77.photobucket.com/albums/j5...ssembly138.jpg http://i77.photobucket.com/albums/j5...ssembly139.jpg http://i77.photobucket.com/albums/j5...ssembly140.jpg http://i77.photobucket.com/albums/j5...ssembly143.jpg 42) Orient reverse idle gear as shown, that way when you put the idler gear shaft bolt in through the bell housing the holes will line up http://i77.photobucket.com/albums/j5...ssembly145.jpg Status Check here is what the transmission assembly should look like http://i77.photobucket.com/albums/j5...ssembly147.jpg http://i77.photobucket.com/albums/j5...ssembly149.jpg http://i77.photobucket.com/albums/j5...ssembly151.jpg http://i77.photobucket.com/albums/j5...ssembly157.jpg 43) Make sure transmission to bell housing mating surface is clean and free of gear oil as you will be apply a bead of RTV Silicon to it in the next step 44) Using RTV Silcone Sealant/Gasket Maker, apply a continuous bead around outside of transmission case the mates to bell housing http://i77.photobucket.com/albums/j5...ssembly158.jpg http://i77.photobucket.com/albums/j5...ssembly163.jpg 45) Carefully install bell housing, tapping it into place with rubber hammer/mallet http://i77.photobucket.com/albums/j5...ssembly165.jpg http://i77.photobucket.com/albums/j5...ssembly166.jpg 46) Install the 14 12mm bolts on the outside of bell housing and torque the 12mm bolts to 21 ft.lbs(you want to do this fairly quickly before the RTV has a chance to dry/cure) http://i77.photobucket.com/albums/j5...ssembly167.jpg 47) Coat the 3 inside bell housing bolts with red loctite, install and torque to 21 ft.lbs http://i77.photobucket.com/albums/j5...ssy_Sun002.jpg http://i77.photobucket.com/albums/j5...ssembly018.jpg http://i77.photobucket.com/albums/j5...ssembly019.jpg http://i77.photobucket.com/albums/j5...ssembly172.jpg 48) Install the 2 snap rings on the ends of shift fork shafts 1 & 2(the way I do this is I clamp the snap ring in my vise grips and then tap the end of the vise grips with hammer, that way the snap ring does not have a chance to fly away) http://i77.photobucket.com/albums/j5...ssembly173.jpg http://i77.photobucket.com/albums/j5...ssembly175.jpg http://i77.photobucket.com/albums/j5...ssembly176.jpg http://i77.photobucket.com/albums/j5...ssembly177.jpg 49) Apply red loctite to the 12mm reverse idler gear shaft bolt http://i77.photobucket.com/albums/j5...ssy_Sun041.jpg 50) Install 12mm reverse idler gear shaft bolt through bell housing hole and into reverse idler gear(this should screw in fairly easy, do not force it, take your time you do not want to strip this) Torque this bolt to 13 ft.lbs http://i77.photobucket.com/albums/j5...ssy_Sun042.jpg 51) Time to install rear bearing shaft snap ring. While you can use snap ring pliers for this...I found it just as easy to push the snap ring over the outside of the bearing, then lift up on the input shaft, and then using a small punch gentle tap the ring down, and it snaps right into place http://i77.photobucket.com/albums/j5...ssembly178.jpg http://i77.photobucket.com/albums/j5...ssembly179.jpg http://i77.photobucket.com/albums/j5...ssembly180.jpg http://i77.photobucket.com/albums/j5...ssembly181.jpg http://i77.photobucket.com/albums/j5...ssembly183.jpg 52) Install the output shaft rear bearing shim http://i77.photobucket.com/albums/j5...ssembly184.jpg http://i77.photobucket.com/albums/j5...ssembly185.jpg 53) Put rear bearing retainer in place http://i77.photobucket.com/albums/j5...ssembly187.jpg 54) Apply red loctite to the 7 T45 Torx screws, install these and torque them to 32 ft.lbs http://i77.photobucket.com/albums/j5...ssy_Sun003.jpg http://i77.photobucket.com/albums/j5...ssy_Sun004.jpg 55) Install driven 5th gear to the output shaft, I simply used a 34mm socket and using a rubber hammer/mallet tapped the gear into position http://i77.photobucket.com/albums/j5...ssy_Sun006.jpg http://i77.photobucket.com/albums/j5...ssy_Sun007.jpg http://i77.photobucket.com/albums/j5...ssy_Sun008.jpg http://i77.photobucket.com/albums/j5...ssy_Sun009.jpg 56) Coat the 5th gear caged needle bearings with gear oil and install on input shaft http://i77.photobucket.com/albums/j5...ssy_Sun012.jpg http://i77.photobucket.com/albums/j5...ssy_Sun013.jpg http://i77.photobucket.com/albums/j5...ssy_Sun014.jpg http://i77.photobucket.com/albums/j5...ssy_Sun015.jpg 57) Coat 5th gear with gear oil and install(this should slide into place and not require any tools) http://i77.photobucket.com/albums/j5...ssy_Sun016.jpg http://i77.photobucket.com/albums/j5...ssy_Sun017.jpg http://i77.photobucket.com/albums/j5...ssy_Sun018.jpg http://i77.photobucket.com/albums/j5...ssy_Sun019.jpg http://i77.photobucket.com/albums/j5...ssy_Sun021.jpg 58) Install transmission clutch hub(again you can use a harmonic balancer puller to do this but I used the 34mm socket and using a rubber hammer/mallet tapped the gear into position, when you do this make sure hold the assembly together or it will fall apart until it contacts 5th gear) Also make sure the fingers on the bottom of the synchronizer ring align to the holes in 5th gear http://i77.photobucket.com/albums/j5...ssy_Sun022.jpg http://i77.photobucket.com/albums/j5...ssy_Sun023.jpg http://i77.photobucket.com/albums/j5...ssy_Sun024.jpg http://i77.photobucket.com/albums/j5...ssy_Sun026.jpg http://i77.photobucket.com/albums/j5...ssy_Sun027.jpg 59) Install 5th gear shift fork and slider(make sure to coat shift fork slider surfaces, and slider itself with gear oil) http://i77.photobucket.com/albums/j5...ssy_Sun028.jpg http://i77.photobucket.com/albums/j5...ssy_Sun029.jpg http://i77.photobucket.com/albums/j5...ssy_Sun030.jpg 60) Apply red loctite to 5th gear shift fork 12mm bolt, install and torque to 18 ft.lbs http://i77.photobucket.com/albums/j5...ssy_Sun031.jpg http://i77.photobucket.com/albums/j5...ssy_Sun032.jpg http://i77.photobucket.com/albums/j5...ssy_Sun033.jpg 61) Install the clutch hub assembly snap ring http://i77.photobucket.com/albums/j5...ssy_Sun034.jpg http://i77.photobucket.com/albums/j5...ssy_Sun036.jpg http://i77.photobucket.com/albums/j5...ssy_Sun037.jpg http://i77.photobucket.com/albums/j5...ssy_Sun038.jpg http://i77.photobucket.com/albums/j5...ssy_Sun040.jpg 62) Now you need to lock the transmission so you can install/torque the output shaft nut, to do so use long pry bar and stick it into shifter opening and engage two gears(push up on the prong looking things) You will know if you have done this correct as you should not be able to turn the gears http://i77.photobucket.com/albums/j5..._finish007.jpg 63) Install new output shaft nut and torque to 90 ft.lbs http://i77.photobucket.com/albums/j5..._finish008.jpg http://i77.photobucket.com/albums/j5..._finish009.jpg 64) Using a punch stake(dent in) the output shaft rear nut at the cut out on the output shaft, this ensures the nut will not loosen http://i77.photobucket.com/albums/j5..._finish010.jpg http://i77.photobucket.com/albums/j5..._finish012.jpg 65) Clean the black transmission case cover, mating surface, and the mating surface on the transmission http://i77.photobucket.com/albums/j5..._finish016.jpg http://i77.photobucket.com/albums/j5..._finish015.jpg 66) Apply a continuous bead of RTV(I use the actual Toyota stuff FIPG 1281) to the transmission case cover mating surface http://i77.photobucket.com/albums/j5..._finish018.jpg http://i77.photobucket.com/albums/j5..._finish019.jpg http://i77.photobucket.com/albums/j5..._finish021.jpg 67) Install the case cover, and 10 12mm bolts case cover bolts. Torque the 10 12mm case cover bolts to 21ft.lbs(Install the case cover and torque the bolts within 10 minutes of applying the RTV) http://i77.photobucket.com/albums/j5..._finish022.jpg http://i77.photobucket.com/albums/j5..._finish023.jpg http://i77.photobucket.com/albums/j5..._finish024.jpg http://i77.photobucket.com/albums/j5..._finish026.jpg 68) Coat shift lever assembly with gear oil http://i77.photobucket.com/albums/j5..._finish027.jpg http://i77.photobucket.com/albums/j5..._finish028.jpg 69) Install shift lever assembly in transmission http://i77.photobucket.com/albums/j5..._finish029.jpg http://i77.photobucket.com/albums/j5..._finish032.jpg 70) Install the shift lever assembly cover http://i77.photobucket.com/albums/j5..._finish034.jpg http://i77.photobucket.com/albums/j5..._finish035.jpg 71) Apply red loctite to the 4 14mm shift lever assembly cover bolts, install them and torque to 15ft.lbs http://i77.photobucket.com/albums/j5..._finish036.jpg http://i77.photobucket.com/albums/j5..._finish040.jpg 72) Using 24mm socket install the transmission breather plug and torque to 36ft.lbs http://i77.photobucket.com/albums/j5..._finish041.jpg http://i77.photobucket.com/albums/j5..._finish042.jpg http://i77.photobucket.com/albums/j5..._finish044.jpg 73) Using 24mm socket install the lock ball assembly and torque to 21ft.lbs http://i77.photobucket.com/albums/j5..._finish045.jpg http://i77.photobucket.com/albums/j5..._finish046.jpg http://i77.photobucket.com/albums/j5..._finish047.jpg http://i77.photobucket.com/albums/j5..._finish048.jpg 74) Using 27mm socket install the backup light switch assembly and torque to 30ft.lbs http://i77.photobucket.com/albums/j5..._finish049.jpg http://i77.photobucket.com/albums/j5..._finish050.jpg http://i77.photobucket.com/albums/j5..._finish052.jpg http://i77.photobucket.com/albums/j5..._finish053.jpg 75) If you have had the transmission setting on its bell housing, it is best to now turn the transmission upright(like it would be setting in the car) 76) Time to install shift control lever http://i77.photobucket.com/albums/j5..._finish054.jpg 77) Install shift control lever, feed lock pin though the hole, install washer, and 12mm nut and torque to 57in.lbs(4.75ft.lbs) http://i77.photobucket.com/albums/j5..._finish055.jpg 78) Time to install selecting bell crank assembly http://i77.photobucket.com/albums/j5..._finish057.jpg 79) Apply red loctite to the 2 14mm bell crank assembly bolts, and loosely install one of them into bell crank assembly and transmission http://i77.photobucket.com/albums/j5..._finish063.jpg 80) Install the black bushing on bell crank assembly http://i77.photobucket.com/albums/j5..._finish062.jpg 81) Install the remaining 14mm bolt and torque both bolts to 15ft.lbs **make sure black bushing on bell crank assembly lines up with the shift control lever opening http://i77.photobucket.com/albums/j5..._finish064.jpg http://i77.photobucket.com/albums/j5..._finish065.jpg http://i77.photobucket.com/albums/j5..._finish066.jpg 82) Make sure the release fork support ball is clean, and lightly coat it with bearing grease http://i77.photobucket.com/albums/j5..._finish067.jpg http://i77.photobucket.com/albums/j5..._finish069.jpg http://i77.photobucket.com/albums/j5..._finish076.jpg 83) Time to install release fork assembly, throwout bearing, and fork boot http://i77.photobucket.com/albums/j5..._finish068.jpg 84) Install fork boot into transmission http://i77.photobucket.com/albums/j5..._finish077.jpg 85) Apply grease to input shaft throw out bearing retainer & inside of throw out bearing http://i77.photobucket.com/albums/j5..._finish079.jpg http://i77.photobucket.com/albums/j5..._finish078.jpg 86) Make sure shift fork is clean, and then assemble(if you took apart to clean). Apply small amount of grease to the area in the release lever where the release lever support ball will ride, then install release lever support ball retaining spring http://i77.photobucket.com/albums/j5..._finish072.jpg http://i77.photobucket.com/albums/j5..._finish073.jpg http://i77.photobucket.com/albums/j5..._finish074.jpg http://i77.photobucket.com/albums/j5..._finish075.jpg 87) Install throw out bearing on release lever http://i77.photobucket.com/albums/j5..._finish081.jpg http://i77.photobucket.com/albums/j5..._finish084.jpg http://i77.photobucket.com/albums/j5..._finish086.jpg http://i77.photobucket.com/albums/j5..._finish087.jpg http://i77.photobucket.com/albums/j5..._finish088.jpg 88) Feed release lever through release fork boot, and align throwout bearing with input shaft http://i77.photobucket.com/albums/j5..._finish089.jpg 89) Slide throw out bearing over throwing bearing retainer and input shaft http://i77.photobucket.com/albums/j5..._finish090.jpg http://i77.photobucket.com/albums/j5..._finish091.jpg 90) Push hard on the bump on the release fork until you feel the release fork support ball retaining spring snap/push over the release fork support ball http://i77.photobucket.com/albums/j5..._finish094.jpg 91) The release shift fork should now slide smoothly over the throw out bearing retainer http://i77.photobucket.com/albums/j5..._finish095.jpg http://i77.photobucket.com/albums/j5..._finish096.jpg Make sure the input shaft turns smoothly, and that you can shift through all the gears And there you have it all done!!! http://i77.photobucket.com/albums/j5..._finish001.jpg |
Best write up ive seen on SL :bow:
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Most detailed writeup online, better than the Toyota manual
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Wow, thanks for taking the time to do this.
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finished the install/DIY today!
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Very nice! I'll be keeping this in my favorites list for in the future, knowing how much transmission luck I have.
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Originally Posted by juzlookzfazt
(Post 3520912)
Very nice! I'll be keeping this in my favorites list for in the future, knowing how much transmission luck I have.
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awesome writeup man i will probably use this one day in the future, so thanks a ton. quick question, how much does the tranny weigh?
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Originally Posted by Laminate
(Post 3523979)
awesome writeup man i will probably use this one day in the future, so thanks a ton. quick question, how much does the tranny weigh?
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wow thats hella work
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J3st3r, first of all great write up, second, you have some big ones, i would never attempt to fully disassemble a transmission. and finally third, i have a clunking noise on my 5th gear and it only makes the noise when the gear spins, should the output shaft be this loose?
https://www.scionlife.com/forums/sho...d.php?t=203515 Thanks. |
Originally Posted by injector
(Post 3847369)
J3st3r, first of all great write up, second, you have some big ones, i would never attempt to fully disassemble a transmission. and finally third, i have a clunking noise on my 5th gear and it only makes the noise when the gear spins, should the output shaft be this loose?
https://www.scionlife.com/forums/sho...d.php?t=203515 Thanks. I responded on the thread...That nut should absolutely not be loose, the gear is ok to spin but that nut should not be loose at all |
This is an excellent writeup, and is a huge help for me.
One important note on the assembly, the factory service manual says to use Loctite 242 or equivalent. That is Blue loctite, not Red. I strongly recommend against using red, as is is intended for permanent installation and is very difficult to break loose later without using lots of heat. Unlike RTV, For Loctite red means high strength, not high temperature. |
I replaced my clutch and now I have gear oil coming from the passenger side of the trans. I'm sure it's the seal buti can't find anything definitive part number wise. I'm going to call Toyota tomorrow. Any advice is appreciated.
Also, I have a small gap between the trans and the thin metal plate on the drive shafts on the passenger side. Should that be flush? |
Fantastic wrote up! Keep up the good work
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Just finished my LSD install into an E351, and this was immensely helpful. One point to note is on Step 58, it says to tap the Clutch hub assembly using a socket and a mallet. I would not recommend this. It is difficult to get on and the assembly falls apart so easily. Instead, go to an auto parts store and borrow a harmonic dampener installer tool. The M12 size adapter will thread right into the shaft, then you use a wrench in conjunction with the tools to press it onto the shaft. It's a little tough, but this is the proper method, and you don't risk trashing bearings with repeated impacts.
Can't wait to have this installed in a few weeks! |
Is it just me or did all the photos disappear? They were here a few weeks ago ...I can also see pictures on other threads. /:
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[Edit: So much for not botching my first post and looking like an idiot. bbsciontc saved the day and this great guide with a downloadable link to the guide WITH the images.(in the trans disassembly guide) Thank you!!]
Not just you, the photos show up as cute little kittens now. Which is really a bummer because this looks like a fantastic DIY guide and is just what I was looking for. Don't get me wrong, still has a lot of value even without the images. Just lost use of 5th gear(pop out at any RPMs) and have been searching high and low for all information I could gather on this issue. Hoping to be able to do the repair myself and save $$$$. |
is there a differential between spec and regular tc's? I recently blew a stock clutch and was having issues with synchros so i purchased a used, really low mileage trans. Now i am one wheel wonder..... any help would be awesome.
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I'm not sure I understand your question. All tC's have open differentials. You have to take it apart to install an aftermarket limited slip differential like Quaife/TRD. Your stock one was the same, unless the previous owner installed one.
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