Manual Transmission Seal Replacement

I just replaced the seals on the Shifter Housing and didn't intend to do a thread about it, so didn't take many pics, but I found a mistake in the FSM, so here we are. I'm also assuming you'll reference the FSM for this job, so there are only the extra comments which I thought might be useful.

To get the cables off the shift levers, look for a well hidden nut under the boot. I wish Toyota had put a slightly thicker nut here so you can actually get some decent purchase on it. A 9mm wrench on this prevents rotation (in theory) of the ball joint as you unscrew the main nut.

Six bolts and the housing is off.
Have a good look inside the tranny so you know how the housing goes back in.
I took pics of the assembly outside and inside so I'd know how to reassemble it. As it happens, most parts can only go back one way if you're paying attention.

Attachment 13421

Attachment 13422

This shaft was an absolute b--ger to get off. Definitely use an aluminum or brass spacer between the nut and the hammer if your shafts don't come off easily. I was hitting this one much harder than I wanted to, but in the end it came off. I must have hit it 40 times before the vibration and oil did the job. Nice boot, eh?

Attachment 13423

The shaft seals were in there tight! The FSM says pry them out with a screwdriver. I was very concerned about damaging the aluminum surfaces so this is what I did and it worked...
First get a flat blade screwdriver about a foot long. The leverage really helps.
Second, grind an arc onto the tip to match the curvature of the seal surface and debur it well...

Attachment 13424

Third, put a few layers of folded tough card stock (or similar) on the edge of the area which will be the fulcrum of the screwdriver shaft.
Fourth, jam the tip under the bottom of the seal, then pull it back out about 2 mm so that Pythagoras does not become your enemy when the seal blows at the speed of sound and the screwdriver rotates, putting a giant gouge in your nice sealing surface.
Fifth, put some goggles on and pry that mfer out.

Here are the part numbers...
Top L, main gasket 33272-28010
Top R, boot 33555-28010
Bottom L, Select Lever Seal 90313-13001
Bottom R, Shift Lever Seal 90311-18002

Attachment 13425

Here is the mistake in the manual...

Attachment 13426

Looks like we are working on mirrored vans! Here is one more shot I took of mine to help the thread. My boot was also fully destroyed. I found removing the pins much easier with a small sledge (like a 6# masonry hammer). Much more control that a normal hammer. I used a socket extension to get at the pins. I agree though, it feels a bit sketchy, and I doubt we can get replacements for the those pins without picking them off at a salvage yard.

Attachment 13427

The initial post above was for my '91, whose transmission was out of the vehicle in my garage.

I just did the same job on my '93, whose transmission is on the vehicle.
A couple of additional points...
Make sure your transmission is in neutral before you take off the housing. When in neutral the two slots inside the tranny, which the inner lever mates with, are both lined up and makes reinstallation much, much easier. You can pry with a screwdriver after the fact to line them up if you have to.

The internals on my '93 are different. There is an additional spring and washer on the shift shaft. It's the smaller one with less coils on the right of this (rather fuzzy) photo, on the boot side of the inner lever.
B_K's pic in his post above does not have it, either, on his '92.

Attachment 13437

Those of you with eagle eyes will see that the thin stainless steel washer which sits between this smaller spring and the inner lever, making rotation of the lever smoother, is not installed. When I took it all apart the springs, seat and washer all went flying (take precautions), and I only found/discovered the existence of this washer, on the floor of the garage, after installing the assembly back on the vehicle, while cleaning up my mess. Created a bunch of duplicate work in the dark with a headlamp. Doh.

The FSM for the '93 does not reference this spring, so it's another rare mistake in that otherwise exceptionally useful tome.