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Old 07-03-2016, 12:35 AM   #1
ArmstrongRacing
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The auto trans > manual trans conversion guide

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

Last edited by ArmstrongRacing; 09-17-2016 at 02:55 PM.
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Old 07-03-2016, 12:43 AM   #2
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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.
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Old 07-03-2016, 12:46 AM   #3
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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.
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Last edited by ArmstrongRacing; 07-18-2016 at 11:10 AM.
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Old 07-03-2016, 12:46 AM   #4
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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.
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Last edited by ArmstrongRacing; 07-12-2016 at 12:02 AM.
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Old 07-03-2016, 12:47 AM   #5
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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.
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Last edited by ArmstrongRacing; 09-17-2016 at 02:57 PM.
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Old 07-03-2016, 12:48 AM   #6
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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.
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Last edited by ArmstrongRacing; 07-16-2016 at 05:47 PM.
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Old 07-03-2016, 12:49 AM   #7
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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...
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Last edited by ArmstrongRacing; 07-24-2016 at 07:10 PM.
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Old 07-03-2016, 12:50 AM   #8
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The Yaris C50 transmission:

This is the easiest MT to swap in, you just need the mounts and this will go right in.
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Last edited by ArmstrongRacing; 07-24-2016 at 07:09 PM.
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Old 07-03-2016, 12:51 AM   #9
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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.
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Last edited by ArmstrongRacing; 09-17-2016 at 03:09 PM.
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Old 07-03-2016, 12:51 AM   #10
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Reserved for clutch slave
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Old 07-03-2016, 12:54 AM   #11
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Reserved for wiring
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Old 07-10-2016, 03:01 AM   #12
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just shift through gears...only 4 speed with tiny little engine...😂😂😂😂😂

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Old 07-11-2016, 01:10 AM   #13
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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
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Old 07-12-2016, 12:38 AM   #14
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Optional Scion Xb 4.31 final drive swap

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
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Old 07-12-2016, 10:49 PM   #15
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2ZR swap. DO IT! Ask how!
 
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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. ;)
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Old 07-13-2016, 01:16 PM   #16
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And a bit of engine enamel to spice things up
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Old 07-22-2016, 10:08 PM   #17
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Update:

The ARtrackbox case is done and prepared for assembly. We're just waiting on the Cusco LSD
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Old 08-10-2016, 04:43 PM   #18
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Update: it should be around 5 weeks for the LSD to get here, that gives me time to decide on a flywheel
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