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Sequential Manual Transmission Unit: Removal

WARNING: This page is about a different variant/trim than selected.
  1. CONFIRM THAT GEAR IS IN N POSITION (See  SEQUENTIAL MANUAL TRANSMISSION SYSTEM   ) 
  2. REDUCE ACCUMULATOR PRESSURE (See  PRE-CHECK  ) 
  3. REMOVE ENGINE HOOD 

    Remove the 4 bolts and engine hood.

  4. REMOVE SUSPENSION UPPER BRACE 

    Remove the 2 bolts, 2 nuts and suspension upper brace.

  5. REMOVE AIR CLEANER CAP AND AIR HOSE ASSEMBLY, AIR FILTER AND AIR CLEANER CASE (See  REMOVAL  ) 
  6. REMOVE FRONT AND REAR ENGINE UNDER COVERS 
    Fig 1: Disconnecting System Return Hose Using SST
    G02631478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT SMT SYSTEM HOSES 
    1. Disconnect the SMT system return hose.
      1. Hold the system return hose with the SST as shown in the illustration.

        SST 09340-00010

      2. Then disconnect the system return hose by pushing the SST downward until a click sound is heard.

      HINT:

      Put force equally and horizontally against the system hose with the SST.

    2. Disconnect the SMT system clutch hose and SMT system master hose.

      HINT:

      The way of removing the 2 SMT system hoses is the same.

      1. Hold the system clutch and master hoses with the SST as shown in the illustration.

        SST 09340-00010

      2. Then disconnect the system clutch and master hoses by pushing the SST upward until a click sound is heard.

      HINT:

      Put force equally and horizontally against the system hose with the SST.

  8. REMOVE BATTERY BRACKET 
    1. Loosen the clamp nut, and remove the clamp, battery and tray.
    2. Remove the 3 bolts and battery bracket.
    Fig 2: Disconnecting System Clutch And Master Hoses Using SST
    G02631479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT HPU CONNECTOR 
    Fig 3: Disconnecting HPU Connector
    G02631480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT ENGINE WIRE FROM TRANSMISSION 
    1. Disconnect the 2 clamps.
    2. Remove the bolt, and disconnect the engine wire.
    Fig 4: Identifying Clamps, Bolt And Engine Wire
    G02631481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT GROUND CABLE FROM TRANSMISSION 

    Remove the bolt and disconnect the ground cable.

  12. DISCONNECT PNP SWITCH CONNECTOR AND 2 BACK-UP LIGHT SWITCH CONNECTORS 
  13. REMOVE THROTTLE BODY (See  REMOVAL  ) 
    Fig 5: Identifying Bolt And Ground Cable
    G02631482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT GSA CONNECTORS 
    Fig 6: Disconnecting GSA Connectors
    G02631483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT GSA CONNECTOR BRACKET 

    Remove the bolt and disconnect the GSA connector bracket.

    Fig 7: Identifying GSA Connector Bracket Bolt
    G02631484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE 2 MOUNTING BOLTS OF TRANSMISSION UPPER SIDE 
    Fig 8: Removing 2 Mounting Bolts Of Transmission Upper Side
    G02631485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. ATTACH ENGINE SUPPORT FIXTURE 
    1. Install the No. 1 engine hanger with the bolt in the correct direction.

      Part the No.:

      ENGINE HANGER SPECIFICATION TABLE

      No. 1 engine hanger 12281-15040
      Bolt 91642-81025

      Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 

    2. Attach the engine support fixture to the engine hanger.
    Fig 9: Attaching Engine Support Fixture To Engine Hanger
    G02631486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE LEFT ENGINE MOUNTING BRACKET 
    1. Remove the through bolt and nut.
    2. Remove the 3 bolts and mounting bracket.
    NOTE: Make sure that the vehicle is securely supported.
    Fig 10: Identifying Bolts And Mounting Bracket
    G02631487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT INPUT SENSOR CONNECTOR 
  20. DRAIN TRANSMISSION OIL (See  SEQUENTIAL MANUAL TRANSMISSION UNIT   ) 
  21. JACK UP TRANSMISSION SLIGHTLY 

    Using a transmission jack, support the transmission.

  22. REMOVE REAR DRIVE SHAFTS (See  REMOVAL  ) 
    Fig 11: Disconnecting Input Sensor Connector
    G02631488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT ENGINE MOUNTING BRACKET 
    1. Remove the through bolt and nut.
    2. Remove the 2 bolts and front engine mounting bracket from the transmission.
    Fig 12: Identifying Front Engine Mounting Bracket Bolts And Nut
    G02631489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE STARTER 
    1. Disconnect the starter connector.
    2. Remove the nut and disconnect the starter cable.
    3. Remove the 2 bolts and starter.
    Fig 13: Removing Starter
    G02631490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR ENGINE MOUNTING INSULATOR 
    1. Remove the through bolt and nut.
    2. Remove the 4 bolts and mounting insulator.
    Fig 14: Identifying Bolts And Mounting Insulator
    G02631491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE REAR ENGINE MOUNTING BRACKET 

    Remove the 3 bolts and mounting bracket.

    Fig 15: Identifying Bolts And Mounting Bracket
    G02631492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE 4 MOUNTING BOLTS OF TRANSMISSION LOWER SIDE 
  28. REMOVE TRANSMISSION 

    Lower the engine left side, then slowly and carefully remove the transaxle from the engine.

    Fig 16: Removing Mounting Bolts Of Transmission Lower Side
    G02631493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE GSA ASSEMBLY FROM TRANSMISSION 
    1. Remove the GSA cover.
      Fig 17: Removing GSA Cover
      G02631494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the actuator link fixing plate to the GSA. Part the No.:

      Actuator link fixing plate: 33963-0W010

      Fig 18: Installing Actuator Link Fixing Plate To GSA
      G02631495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt.
      Fig 19: Identifying Bolt
      G02631496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 C bolts and stiffener plate.
    5. Remove the A and B bolt.
      NOTE: Because the B bolt is tensed up by the release cylinder cable of the GSA assembly, hold the GSA assembly not to damage the bolt's thread when removing the B bolt.
    6. Take out the GSA assembly from the transmission assembly.
      Fig 20: Removing A, B And C Bolts
      G02631497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Pulling the release cylinder cable while the GSA assembly is close to the clutch fork, separate the cable from the clutch fork.
    Fig 21: Pulling Release Cylinder Cable
    G02631498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    Place the GSA assembly as shown in the illustration after the GSA assembly is removed.

    Fig 22: Placing GSA Assembly
    G02631499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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