Manual Transmission

Page

TROUBLESHOOTING MT-2

W58 TRANSMISSION MT-3

Removal of Transmission MT-3

Components MT-5

Disassembly of Transmission MT-7

Inspection of Transmission Components MT-14

Assembly of Transmission MT-21

Installation of Transmission MT-34

TROUBLESHOOTING

Problem

Possible cause

Remedy

Page

Hard to shift or will not shift

Splines on input shaft dirty or burred Transmission faulty

Repair as necessary

Disassemble and inspect transmission

MT-3 MT-3

Transmission jumps out of gear

Transmission faulty

Disassemble and inspect transmission

REMOVAL OF TRANSMISSION

1. REMOVE NEGATIVE BATTERY TERMINAL WIRE

2. DRAIN COOLANT FROM RADIATOR UPPER TANK

3. REMOVE UPPER HOSE FROM RADIATOR

4. REMOVE CONSOLE BOX

5. REMOVE SHIFT LEVER FROM INSIDE OF VEHICLE

6. RAISE VEHICLE AND DRAIN TRANSMISSION OIL CAUTION: Be sure the vehicle is securely supported.

7. REMOVE STEERING GEAR HOUSING

Remove the steering gear housing without disconnecting return and pressure tube, then suspend it.

Sst 09213 36020

8. REMOVE PROPELLER SHAFT

Remove the propeller shaft and insert SST into the extension housing.

SST 09325-20010

9. REMOVE EXHAUST PIPE CLAMP BOLT FROM STIFFENER PLATE

Toyota Celica Clutch Cylinder

10. REMOVE SPEEDOMETER CABLE

11. DISCONNECT BACK-UP LIGHT SWITCH

12. REMOVE CLUTCH RELEASE CYLINDER

CONNECTOR

13. REMOVE STARTER

A340f Transmission Manual

14. JACK UP TRANSMISSION SLIGHTLY

Raise the transmission enough to remove the weight from the rear support.

15. REMOVE ENGINE REAR MOUNTING

16. REMOVE TRANSMISSION ASSEMBLY

Pull out the transmission down and toward the rear.

COMPONENTS

Gear Shifting Clutch

Speedometer Driven Gear

Shift Lever Retainer

Restrict Pin

Clutch Housing

Front Bearing Retainer

Extension Housing

Restrict Pin ! 410 <30, 40) I "l 375 (27, 37)1

Intermediate Plate

Transmission Case

Output Shaft

-Locking Ball

-Spring

©—it Straight Screw Plug

Counter Gear

Reverse Idler Gear

Interlock Pin

Reverse Shift Arm

Shift Fork Shaft

No. 2 Interlock Pin

Lock Washer and Bolt

Slotted Spring Pin

No. 3 Interlock Pin

Reverse Idler Gear Shaft Stopper fkg-cm (ft-lb, N m)l : Specified torque t Non-reusable part * Precoated part

COMPONENTS (Cont'd)

Synchronizer Transmission Hilux

Reverse Gear

Center Bearing Retainer

Speedometer Rear Bearing Drive Gear

Output Shaft

Synchronizer Ring

5 I Snap Ring

Counter Center Bearing Outer Race

Needle Roller Bearing

Counter Gear

I Snap Ring Counter Rear ßearing

No. 3 Clutch Hub

Counter 5th Gear

Center Bearing

Synchronizer Ring

Synchronizer Ring

No. 2 Clutch Hub

Output Shaft

No. 1 Clutch Hub

Center Bearing

Needle Roller Bearing

Synchronizer Ring

Needle Roller Bearing

Synchronizer Ring

Snap

Disconnect Clutch Bearing Trooper

DISASSEMBLY OF TRANSMISSION

1. REMOVE BACK-UP LIGHT SWITCH. SPEEDOMETER DRIVEN GEAR, SHIFT LEVER RETAINER AND RESTRICT PINS

How Dismantle Manual Transmission

2. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE

Remove Transmission Clutch Housing

3. REMOVE EXTENSION HOUSING

(a) Remove the shift lever housing set bolt.

(b) Remove the nine bolts.

(c) Using a plastic hammer, tap the extension housing.

(d) Disengage the shift and select lever from the shift head.

(e) Pull out the extension housing.

NOTE: Leave the gasket attached to the intermediate plate.

4. REMOVE FRONT BEARING RETAINER AND BEARING SNAP RINGS

5. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE

(a) Using a plastic hammer, carefully tap the transmission case.

(b) Pull the transmission case from the intermediate plate.

NOTE: Leave the gasket attached to the intermediate plate.

6. MOUNT INTERMEDIATE PLATE IN VISE

(a) Use two long clutch housing bolts, plate washers and suitable nuts as shown.

CAUTION: Install the plate washers In reverse of normal. Increase or decrease plate washers so that the bolt tip and the front tip surface of the nut are aligned.

<b) Mount the intermediate plate in a vise.

7. REMOVE LOCKING BALL AND SPRING

(a) Using SST, remove the four plugs. SST 09313-30021

(b) Using a magnetic finger, remove the three springs and balls.

8. REMOVE SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR

(a) Pry out the lock washers of No. 1 and No. 2 shift fork, and remove the two set bolts.

(b) Using two screwdrivers and a hammer, tap out the two snap rings of No. 1 and No. 2 fork shafts.

Mk2 Supra Drive Shaft Fixing Shifter Plate 2003 Celica

(c) Remove the reverse idler gear stopper.

(d) Remove the reverse idler gear and shaft.

(e) Remove No. 1 shift fork and shaft.

Toyota R151 5th Gear Thrust Washer

(f) Using a magnetic finger, remove No. 1 and No. 2 interlock pins.

(g) Remove No. 2 shift fork and shaft.

M5r2 Fork Shaft Interlock Pin

(h) Using a magnetic finger, remove No. 3 interlock pin.

(i) Using a pin punch and hammer, drive out No. 3 fork shaft pin.

(k) Remove No. 3 shift fork. No. 3 fork shaft and reverse shift arm with the pin.

9. REMOVE SPEEDOMETER DRIVE GEAR

Pry out both ends of the clip and remove the drive gear. !

10. MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the counter 5th gear thrust clearance.

(0.0039 - 0.0161 in.) Maximum clearance: 0.46 mm (0.0181 in.)

11. REMOVE COUNTER REAR BEARING. SPACER. COUNTER FIFTH GEAR AND NEEDLE ROLLER BEARING

(a) Using snap ring pliers, remove the snap ring.

(b) Using SST, remove the rear bearing, spacer. 5th gear and bearing.

SST 09213-36020

CAUTION: Be careful not to catch the output shaft rear bearing roller on the counter 5th gear.

(c) Remove the spacer.

12. REMOVE NO. 3 HUB SLEEVE ASSEMBLY

(a) Using two screwdrivers and a hammer, tap out the snap ring.

(b) Using SST, remove No. 3 clutch hub. SST 09950-20016

CAUTION: Latch the claw of the SST onto the clutch hub. not the shifting key retainer.

Mr »#0043 (VM004?
Disconnect Clutch Bearing TrooperToyota Celica Supra Mk2Disconnect Clutch Bearing Trooper

13. REMOVE OUTPUT SHAFT REAR BEARING AND FIFTH GEAR

(a) Using two screwdrivers and a hammer, tap out the snap ring.

(b) Using SST, remove the rear bearing and 5th gear. SST 09312-20011

14. REMOVE REVERSE GEAR

(a) Using snap ring pliers, remove the snap ring.

(b) Using SST, remove the reverse gear. SST 09950-20016

15. REMOVE CENTER BEARING RETAINER

(a) Using a torx socket wrench, unscrew the torx screws and remove the retainer.

(b) Using snap ring pliers, remove the snap ring.

16. REMOVE OUTPUT SHAFT AND COUNTER GEAR ASA

UNIT FROM INTERMEDIATE PLATE

(a) Remove the output shaft, input shaft and counter gear as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.

(b) Remove the input shaft from output shaft.

17. MEASURE EACH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the thrust clearance of each gear.

Standard clearance: Maximum clearance:

0.10 - 0.25 mm (0.0039 - 0.0098 in.) 0.30 mm (0.0118 in.)

Torx Socket Wrench

Torx Socket Wrench

*WOOM

18. REMOVE OUTPUT SHAFT CENTER BEARING AND FIRST GEAR ASSEMBLY

(a) Shift No. 1 hub sleeve onto the 2nd gear.

(b) Using a press, remove the center bearing, 1st gear, needle roller bearing, inner race and synchronizer ring.

19. REMOVE LOCKING BALL

Manual Transmission Locking Ball

20. REMOVE NO. 1 HUB SLEEVE ASSEMBLY, SECOND GEAR AND NEEDLE ROLLER BEARING

Using a press, remove the parts from the shaft as an assembly.

21. REMOVE NO. 2 HUB SLEEVE ASSEMBLY AND THIRD GEAR

(a) Using snap ring pliers, remove the snap ring.

(b) Using a press, remove No. 2 hub sleeve, synchronizer ring and 3rd gear.

Celica Clutch Pack
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