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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.
      1. Sealant:Part No. 08887-01806, RELEASE HUB GREASE or equivalent 
    2. Pay attention to combine the clutch cable and clutch fork.
      Fig 1: Releasing Hub Grease To Release Fork And Clutch Cable
      G00928017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pulling the clutch fork, install the GSA assembly.
      Fig 2: Pulling Clutch Fork
      G00928018Courtesy 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 install the B bolt.
      • Install the B bolt before the A bolt.
    5. Install the stiffener plate bracket with the 3 C bolts.
      1. Torque: 42 N.m (428 kgf.cm, 31 ft.lbf) 
    6. Tighten the A and B bolts.
      1. Torque: 42 N.m (428 kgf.cm, 31 ft.lbf) 
      Fig 3: Tightening Bolts
      G00928019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the bolt.
      1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
    8. Remove the actuator link fixing plate from the GSA assembly.
      Fig 4: Installing Bolts
      G00928020Courtesy 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
    G00928021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL LEFT ENGINE MOUNTING BRACKET 
    1. Install the mounting bracket to the transmission with the 3 bolts.
      1. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 
    2. Install the through bolt and nut.
      1. Torque: 87 N.m (887 kgf.cm, 64 ft.lbf) 
  5. REMOVE ENGINE SUPPORT FIXTURE 
    Fig 6: Installing Bolt And Nut
    G00928022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL 2 MOUNTING BOLTS OF TRANSMISSION UPPER SIDE 
    1. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 
    Fig 7: Installing Mounting Bolts Of Transmission Upper Side
    G00928023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. TIGHTEN 4 MOUNTING BOLTS OF TRANSMISSION LOWER SIDE 
    1. Torque: 
      1. 47 N.m (480 kgf.cm, 35 ft.lbf) for bolt A 
      2. 23 N.m (230 kgf.cm, 17 ft.lbf) for bolt B 
    Fig 8: Tightening Mounting Bolts Of Transmission Lower Side
    G00928024Courtesy 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: Installing Mounting Bracket With Bolts
    G00928025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR ENGINE MOUNTING INSULATOR 
    1. Install the mounting insulator with the 4 bolts.
      1. Torque: 89 N.m (908 kgf.cm, 66 ft.lbf) 
    2. Install the through bolt and nut.
      1. 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: Installing Mounting Insulator With Bolts
    G00928026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL STARTER 
    1. Install the starter with the 2 bolts.
      1. Torque: 37 N.m (378 kgf.cm, 28 ft.lbf) 
    2. Connect the starter cable with the nut.
      1. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf). 
    3. Connect the starter connector.
    Fig 11: Installing Starter With Bolts
    G00928027Courtesy 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.
      1. Torque: 78 N.m (796 kgf.cm, 56 ft.lbf) 
    2. Instal the through bolt and nut.
      1. 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  SEQUENTIAL MANUAL TRANSMISSION UNIT  ) 
    Fig 12: Installing Front Engine Mounting Bracket To Transmission With Bolts
    G00928028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CONNECT INPUT SENSOR CONNECTOR 
    Fig 13: Connecting Input Sensor Connector
    G00928029Courtesy 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: Install connector bracket with bolt
    G00928030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. CONNECT PNP SWITCH CONNECTOR AND 2 BACKUP LIGHT SWITCH CONNECTORS 
  20. CONNECT GROUND CABLE TO TRANSMISSION 
    1. Torque: 19 N.m (195 kgf.cm, 14 ft.lbf) 
    Fig 15: Connecting Ground Cable To Transmission
    G00928031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. CONNECT ENGINE WIRE TO TRANSMISSION 
    1. Connect the 2 clamps.
    2. Install the engine wire with the bolt.
    1. Torque: 8 N.m (82 kgf.cm, 71 in..lbf) 
    Fig 16: Installing Engine Wire With Bolt
    G00928032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. CONNECT HPU CONNECTOR 
  23. INSTALL BATTERY BRACKET 
    1. Install the battery carrier with the 3 bolts.
      1. 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: Installing Battery Tray And Battery Clamp
    G00928033Courtesy 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 New O-Rings
      G00928034Courtesy 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 By Pushing Downward
    G00928035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL SUSPENSION UPPER BRACE 

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

    1. Torque: 
      1. 74 N.m (755 kgf.cm, 55 ft.lbf) for bolt 
      2. 80 N.m (816 kgf.cm, 59 ft.lbf) for nut 
  28. INSTALL ENGINE HOOD 
    1. Install the engine hood with the 4 bolts.
      1. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 
    2. Adjust the hood (See ADJUSTMENT ).
  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 WHEEL ALIGNMENT ).
    2. Do the road test.
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