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Sequential Manual Transmission Unit: Installation

  1. INSTALL GSA ASSEMBLY TO TRANSMISSION 
    1. Apply release hub grease to the release fork and clutch cable.

      Sealant: 

      Part No. 08887-01806, RELEASE HUB GREASE or equivalent 

    2. Pay attention to combine the clutch cable and clutch fork.
      Fig 1: Applying Release Hub Grease To Release Fork And Clutch Cable
      G02631500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pulling the clutch fork, install the GSA assembly.
      Fig 2: Pulling Clutch Fork And Installing GSA Assembly
      G02631501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily tighten the A and B bolts.
      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 installing the B bolt.
      • Install the B bolt before the A bolt.
    5. Install the stiffener plate bracket with the 3 C bolts.

      Torque: 42 N.m (428 kgf.cm, 31 ft.lbf) 

    6. Tighten the A and B bolts.

      Torque: 42 N.m (428 kgf.cm, 31 ft.lbf) 

      Fig 3: Identifying Bolts A, B And C
      G02631502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the bolt.

      Torque: 25 N.m (255 kfg.cm, 18 ft.lbf) 

    8. Remove the actuator link fixing plate from the GSA assembly.
      Fig 4: Installing Bolt
      G02631503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the GSA cover as shown in the illustration.
  2. INSTALL REAR ENGINE MOUNTING BRACKET TO TRANSMISSION 
  3. INSTALL TRANSMISSION TO ENGINE 
    1. Using a transmission jack, lift up the transmission.
    2. Lower the engine left side.
    3. Align the input shaft with the clutch disc, then slowly and carefully install the transmission to the engine.
    4. Temporarily tighten the 4 mounting bolts of the transmission lower side.
    Fig 5: Installing GSA Cover
    G02631504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL LEFT ENGINE MOUNTING BRACKET 
    1. Install the mounting bracket to the transmission with the 3 bolts.

      Torque: 52 N.m (530 kfg.cm, 38 ft.lbf) 

    2. Install the through bolt and nut.

      Torque: 87 N.m (887 kfg.cm, 64 ft.lbf) 

  5. REMOVE ENGINE SUPPORT FIXTURE 
    Fig 6: Identifying Mounting Bracket Bolts And Nut
    G02631505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL 2 MOUNTING BOLTS OF TRANSMISSION UPPER SIDE 

    Torque: 64 N.m (650 kfg.cm, 47 ft.lbf) 

    Fig 7: Installing Mounting Bolts Of Transmission Upper Side
    G02631506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. TIGHTEN 4 MOUNTING BOLTS OF TRANSMISSION LOWER SIDE 

    Torque: 

    47 N.m (480 kgf.cm, 35 ft.lbf) for bolt A 

    23 N.m (230 kgf.cm, 17 ft.lbf) for bolt B 

    Fig 8: Identifying Transmission Lower Side Mounting Bolts A And B
    G02631507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL REAR ENGINE MOUNTING BRACKET 

    Install the mounting bracket with the 3 bolts.

    1. Torque: 78 N.m (796 kgf.cm, 58 ft.lbf) 
    Fig 9: Identifying Mounting Bracket Bolts
    G02631508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR ENGINE MOUNTING INSULATOR 
    1. Install the mounting insulator with the 4 bolts.

      Torque: 89 N.m (908 kgf.cm, 66 ft.lbf) 

    2. Install the through bolt and nut.

      Torque: 93 N.m (949 kgf.cm, 69 ft.lbf) 

    NOTE: Be sure to tighten the bolt at the upper end of the slot.
    Fig 10: Identifying Mounting Insulator Bolts And Nut
    G02631509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL STARTER 
    1. Install the starter with the 2 bolts.

      Torque: 37 N.m (378 kgf.cm, 28 ft.lbf) 

    2. Connect the starter cable with the nut.

      Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) 

    3. Connect the starter connector.
    Fig 11: Installing Starter With Bolts
    G02631510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT ENGINE MOUNTING BRACKET 
    1. Install the front engine mounting bracket to the transmission with the 2 bolts.

      Torque: 78 N.m (796 kgf.cm, 56 ft.lbf) 

    2. Instal the through bolt and nut.

      Torque: 93 N.m (949 kgf.cm, 69 ft.lbf) 

  12. REMOVE TRANSMISSION JACK 
  13. INSTALL REAR DRIVE SHAFTS (See  INSTALLATION  ) 
  14. REFILL TRANSMISSION OIL (See  REPLACE TRANSMISSION OIL   ) 
    Fig 12: Installing Front Engine Mounting Bracket To Transmission With Bolts
    G02631511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CONNECT INPUT SENSOR CONNECTOR 
    Fig 13: Connecting Input Sensor Connector
    G02631512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL GSA CONNECTOR BRACKET 

    Install the connector bracket with the bolt.

    1. Torque: 8 N.m (82 kgf.cm, 71 in..lbf) 
  17. CONNECT GSA CONNECTORS 
  18. INSTALL THROTTLE BODY (See  INSTALLATION  ) 
    Fig 14: Identifying Connector Bracket Bolt
    G02631513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. CONNECT PNP SWITCH CONNECTOR AND 2 BACK-UP LIGHT SWITCH CONNECTORS 
  20. CONNECT GROUND CABLE TO TRANSMISSION 

    Torque: 19 N.m (195 kgf.cm, 14 ft.lbf) 

    Fig 15: Connecting Ground Cable To Transmission
    G02631514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. CONNECT ENGINE WIRE TO TRANSMISSION 
    1. Connect the 2 clamps.
    2. Install the engine wire with the bolt.

      Torque: 8 N.m (82 kgf.cm, 71 in..lbf) 

    Fig 16: Connecting Engine Wire To Transmission
    G02631515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. CONNECT HPU CONNECTOR 
  23. INSTALL BATTERY BRACKET 
    1. Install the battery carrier with the 3 bolts.

      Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) 

    2. Install the battery tray and also the battery with the battery clamp.
    Fig 17: Connecting HPU Connector
    G02631516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. CONNECT SMT SYSTEM HOSES 
    1. Apply a light coat of sequential M/T fluid to the 3 new O-rings.
    2. Install the 3 new O-rings.
      Fig 18: Installing O-Rings
      G02631517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 3 SMT system hoses by pushing downward until click sound is heard.
  25. CHECK SMT SYSTEM FLUID LEVEL (See  PRE-CHECK  ) 
  26. INSTALL AIR CLEANER CAP AND AIR HOSE ASSEMBLY, AIR FILTER AND AIR CLEANER CASE (See  REMOVAL  ) 
    Fig 19: Connecting SMT System Hoses
    G02631518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL SUSPENSION UPPER BRACE 

    Install the suspension upper brace with the 2 bolts and 2 nuts.

    1. Torque: 
    2. 74 N.m (755 kgf.cm, 55 ft.lbf) for bolt 
    3. 80 N.m (816 kgf.cm, 59 ft.lbf) for nut 
  28. INSTALL ENGINE HOOD 
    1. Install the engine hood with the 4 bolts.

      Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

    2. Adjust the hood (See HOOD ).
  29. PERFORM INITIAL LEARNING OF SMT SYSTEM (See  PRE-CHECK  ) 
  30. CHECK FOR LEAK 
  31. CHECK AND INSPECT ITEM AS FOLLOWS 
    1. Check the rear wheel alignment (See REAR WHEEL ALIGNMENT ).
    2. Do the road test.
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