The auto trans > manual trans conversion guide

[ArmstrongRacing]

Here we go again with another big project, haha. If your Yaris has a automatic transmission and you want to know what's needed to get a manual trans in there, take a look.

1)Transmission and 75W90 fluid
2)*Axles can be reused*
3)Shift cables
4)Floor shifter assy
5)Clutch/brake pedal assy
6)Brake master cylinder for manual trans car
7)Clutch master cylinder and line to brake reservoir
8)Clutch slave cylinder, bolts and lines
9)Clutch kit and bolts
10)flywheel and bolts
11)ECM/Wiring
12)MT mounts

[ArmstrongRacing]

I like to remove the engine and trans for this project, it gives you more room to work in the engine bay.

First step, remove the engine and auto trans, then split the two by removing the 6 12mm bolts behind the access cover, then remove the 14mm bell housing bolts and set your engine on a stand while you prep the chassis.

[ArmstrongRacing]

The pedals:

The AT brake pedal is one piece with one connector. You want to remove the pedal assy by disconnecting the brake light switch, then the return spring, then the pin to the booster. You then need to remove the upper dash pad via the service manual, then remove the top 12mm bolt. Now you can remove the (4) 12mm nuts on the main pedal bracket and pull the pedal out.

The MT pedal assy is 2 pieces, a clutch pedal and a brake pedal. (Before installation of the pedals you should install the clutch master). Start the install by sliding the clutch pedal assy over the clutch master studs and loosely attach the nuts, then install the top 12mm bolt and torque it all down. Attach the clutch master pin into the pedal and the return spring and plug in the clutch switch. Next, follow the same steps to install the brake pedal assy.

[ArmstrongRacing]

Clutch master install:

The automatic cars have no holes where the clutch master mounts, so you need to line up the clutch pedal withe the top bolt hole, trace the holes in the bracket, then drill out the holes. You can now slide the clutch master in and attach the hydraulic lines.

[ArmstrongRacing]

The brake master cylinder:

The MT part is different in only one way, it has a port on the bottom for the clutch hydraulics. You need to install the clutch master first because it's hard to get to. Start this by using a little 10mm line wrench to break loose the two brake lines on the master, then remove the (2) 12mm nuts holding the master to the brake booster. Unthread the brake lines the rest of the way then pull the master straight out of the booster.

You install the MT brake master then attach the hose from the clutch master on the side. Don't forget to fill with brake fluid and bleed the brakes/clutch once everything else is complete.

[ArmstrongRacing]

The shifter and cables:

You can see here the difference in the two cables, MT on the left and AT on the right. This is pretty easy, disconnect the cable ends and then get under the car. Remove the exhaust heat shield and then remove the (3) 10mm nuts securing the cable pass-through seal. Now you can just pull the AT cable out from the bottom, then feed in the 2 MT cables and secure the seal. The AT floor shifter is just (4) 12mm bolts and two electrical connectors, then install the MT shifter and connect the cables.

[ArmstrongRacing]

Flywheel and clutch:

The clutch and flywheel you need depends on your engine. If you keep your 1nz then a Yaris clutch is fine. But if you have a 2zr like me, you need these parts from a Scion Xd. You will also need flywheel bolts since they are different from the AT. Here is a picture of a Scion Xd disc on my Yaris C50 transmission...

[ArmstrongRacing]

The Yaris C50 transmission:

This is the easiest MT to swap in, you just need the mounts and this will go right in.

[ArmstrongRacing]

The trans install.

You will need the lift the engine off of its stand and get someone to hold the engine steady while you line up the transmission. First you put a small amount of grease on the input shaft and dowel pins, then you line up the input shaft with the clutch disc hole and wiggle/rotate the trans to align the two. When the shaft and disc align the trans will slide in and then you just align the dowel pins and install all of the bolts, but don't tighten until you get the starter in too.

[ArmstrongRacing]

Reserved for clutch slave

[ArmstrongRacing]

Reserved for wiring

[rabbito]

just shift through gears...only 4 speed with tiny little engine...😂😂😂😂😂

Sent from my SM-J700F using Tapatalk

[07dirtyaris]

I'm glad you are doing a write-up on this. I've been sourcing parts for a while to do this same project.
As soon as I get my subie to be a stable DD I'm going to do this same swap.

Look forward to watching your progress

[ArmstrongRacing]

For those of you like me that want to maximize you acceleration, there is a complete drop-in 4.31 final drive available from the 04-06 Scion Xb. I scored this from a wrecked car and it had case damage, but the gears are still in good condition. This upgrade will change your in-gear top speeds to the following:

1st- 29mph
2nd- 54
3rd- 80
4th- 101
5th- 121

[CrankyOldMan]

So sex. The mechanical engineer in me gets a chubby looking at this stuff. The electrical engineer, on the other hand, doesn't give a flying rat's ass. ;)

[ArmstrongRacing]

And a bit of engine enamel to spice things up

[ArmstrongRacing]

Update:

The ARtrackbox case is done and prepared for assembly. We're just waiting on the Cusco LSD

[ArmstrongRacing]

Update: it should be around 5 weeks for the LSD to get here, that gives me time to decide on a flywheel

[rabbito]

👍👍👍👍👍👍

Sent from my SM-J700F using Tapatalk

[ArmstrongRacing]

We disassembled, cleaned, inspected, and transferred the C50 gears over to the Scion driven shaft today.

[brushforhire]

Love watching this project.

[ArmstrongRacing]

Here is a side by side comparison of the Yaris & Xb C50 driven shafts. As you can see, the only difference is the number of pinion teeth.

[ArmstrongRacing]

The differential bearings and seals showed up today, only 7-9 more weeks until the Cusco LSD arrives lol

[ArmstrongRacing]

Something awesome showed up

http://youtu.be/Vjwhj7OS2ec

[ArmstrongRacing]

Disassembled, cleaned and measured all of the input shaft parts today. All is well, onto the Cusco LSD prep.

[Bluevitz-rs]

synchro rigs are all in good shape?

[rabbito]

looking great!! 👉👉👉👉👉👉👉👉

Sent from my SM-J700F using Tapatalk

[ArmstrongRacing]

All syncro gaps are well within spec, and they lock onto the gears.

[ArmstrongRacing]

Here is the stock open differential on the left, and the Cusco differential on the right... For comparison

[ArmstrongRacing]

Here is the Cusco LSD assembled and ready for install with the new Toyota bearings and the Scion 4.3 final drive

[ArmstrongRacing]

Here is the differential in the bell housing

[ArmstrongRacing]

This is what the differential preload adjusting shim looks like. The one with FF is the shim and the other one is just a case specific washer. They go under the bearing races

[ArmstrongRacing]

This is how you check preload, the spec is 6.9 - 13.8 inch pounds

[ArmstrongRacing]

We didn't quite reach the 6.9, so I ordered the one size larger GG shim

[ArmstrongRacing]

Here is the new GG shim we ordered

[ArmstrongRacing]

The new shim was the perfect size, we are now at 10.0 inch pounds witch is right in the middle of the specified range (6.9 - 13.8). Now let's assemble the transmission.

[ArmstrongRacing]

Here we have both shafts and all of the case components installed, time to seal it up.

[ArmstrongRacing]

The main case is sealed, and 5th gear assembly installed

[ArmstrongRacing]

Slide the shifter assy in just to verity you can shift to all 6 gears, if so you can seal the end case

[ArmstrongRacing]

Now you can install the shifter assy and all brackets/switches. Now you're ready to install the transmission

[Kasbien]

Thanks @ArmstrongRacing for taking the time to put this together! You rock man!

I know this is an old thread and all, but does anyone know if you'll lose your current odometer reading when swapping ECM? Can't seem to find a definitive answer in my searches.

[Bluevitz-rs]

I know this is an old thread and all, but does anyone know if you'll lose your current odometer reading when swapping ECM? Can't seem to find a definitive answer in my searches.

No, the odometer reading is built into the dash.

[Kasbien]

No, the odometer reading is built into the dash.

Music to my ears. Thanks!

[Abel teshome]

Can u tell as abt the throtel wiring ? Tnx