TOYOTA Transmission G58, R150, R150F, W55, W56 Service Repai

DISASSEMBLY OF TRANSMISSION (G58 TRANSMISSION) Components – MANUAL TRANSMISSION Disassembly of Transmission (Components) MT1–26

Components (Cont’d) – MANUAL TRANSMISSION Disassembly of Transmission (Components) MT1–27

Components (Cont’d) – MANUAL TRANSMISSION Disassembly of Transmission (Components) MT1–28

4. REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL (a) Using a torx socket wrench, remove the screw plug from the transfer adaptor. (Torx socket wrench T40 09042–00020) (b) Using a magnetic finger, remove the spring and ball. 5. REMOVE SHIFT LEVER CONTROL RETAINER (a) Remove the four bolts and transmission shift lever control retainer. (b) Remove the four bolts, transfer shift lever control re– tainer and select return spring. Disassembly of Transmission (See pages MT1–26 to 28) 1. REMOVE RELEASE FORK AND BEARING 2. REMOVE BACK–UP LIGHT SWITCH 3. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE Remove the nine bolts and clutch housing. 6. REMOVE RESTRICT PINS – MANUAL TRANSMISSION Disassembly of Transmission MT1–29

7. REMOVE TRANSFER ADAPTOR (a) Using SST, remove the plug from the transfer adap– tor. SST 09923–00010 (b) Remove the shift lever housing set bolt. 8. REMOVE FRONT BEARING RETAINER Remove the eight bolts, and remove front bearing re– tainer and gasket. (d) Remove the eight bolts. (e) Using a plastic hammer, carefully tap off the trans– fer adaptor. 9. REMOVE TWO BEARING SNAP RINGS Using a snap ring expander, remove the two snap rings. (c) Remove the shift lever shaft and housing. – MANUAL TRANSMISSION Disassembly of Transmission MT1–30

11. MOUNT INTERMEDIATE PLATE IN VISE (a) Use two clutch housing bolts, plate washers and suitable nuts as shown. NOTICE: Install the plate washers in reverse of normal. Increase or decrease plate washers so that the bolt tip and front tip surface of the nut are aligned. (b) Mount the intermediate plate in a vise. 10. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE (a) Stand the transmission as shown. (b) Using a plastic hammer, carefully tap off the trans– mission case. 12. REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLS AND SPRINGS (a) Using a torx socket wrench, remove the four plugs. (Torx socket wrench T40 09042–00020) (c) Remove the transmission case from the intermedi– ate plate as shown. (b) Using a magnetic finger, remove the springs and balls. – MANUAL TRANSMISSION Disassembly of Transmission MT1–31

14. REMOVE SHIFT FORK SHAFT NO.5 (a) Using a pin punch and hammer, drive out the slotted spring pin. (b) Remove the shift fork shaft No.5. 15. REMOVE SHIFT FORK NO.3, SHIFT FORK SHAFT NO.4 AND REVERSE SHIFT HEAD (a) Using a pin punch and hammer, drive out the slotted spring pin. 13. REMOVE SHIFT FORK SHAFT SNAP RINGS Using two screwdrivers and a hammer drive out the three snap rings. (b) Remove the shift fork No.3, shift fork shaft No.4, re– verse shift head and two balls. – MANUAL TRANSMISSION Disassembly of Transmission MT1–32

17. REMOVE SHIFT FORK SHAFT NO.1, NO.2 AND SHIFT FORK NO. 1, NO.2 (a) Using a magnetic finger, remove the interlock pin No.2 from shift fork shaft No.2. 16. REMOVE REVERSE SHIFT ARM, REVERSE SHIFT FORK AND SHIFT FORK SHAFT NO–3 (a) Using a magnetic finger–, remove the interlock pin from shift fork shaft No.3. (e) Remove the reverse shift arm and fork. (f) Using a screwdriver, remove the two E–rings. (g) Separate the shift arm, fork and shoe. (b) Using a pin punch and hammer, drive out the slotted spring pin. (c) Remove the shift fork shaft No.3. (d) Remove the interlock pin No. 1. – MANUAL TRANSMISSION Disassembly of Transmission MT1–33

18. INSPECT COUNTER FIFTH GEAR THRUST CLEARANCE Using a feeler gauge, measure the counter 5th gear thrust clearance. Standard clearance: 0.10 – 0.30 mm (0.0039 – 0.0118 in.) Maximum clearance: 0.30 mm (0.0118 in.) 19. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS AND COUNTER FIFTH GEAR WITH HUB SLEEVE NO.3 (a) Using two screwdrivers and a hammer, tap out the snap ring. (e) Remove the shift fork No. 2 set bolt. (f) Remove the shift fork No.1, No.2 and shift fork shaft No.2. (c) Remove the shift fork shaft No. 1. (d) Remove the interlock pin No. 1. (b) Remove the shift fork No. 1 set bolt. – MANUAL TRANSMISSION Disassembly of Transmission MT1–34

(b) Using SST, remove the gear spline piece No. 5. SST 09213–60017 (09213–00020, 09213–00030, 09213–00060) (c) Remove the synchronizer ring, needle roller bearing and counter 5th gear. 22. REMOVE REVERSE IDLER GEAR AND SHAFT (a) Remove the reverse idler gear shaft stopper set bolt and stopper. 20. REMOVE SPACER AND BALL (a) Remove the spacer. (b) Using a magnetic finger, remove the ball. 21. REMOVE REVERSE SHIFT ARM BRACKET Remove the two bolts and reverse shift arm bracket. (b) Remove the reverse idler gear and shaft. – MANUAL TRANSMISSION Disassembly of Transmission MT1–35

TOYOTA Transmission G58, R150, R150F, W55, W56 Service Repai

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