Manual Transmission Seal Replacement

[Jonny]

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.

outside.jpg

inside.jpg

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?

bugger.jpg

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...

driver_tip.jpg

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

Part_#s.jpg

Here is the mistake in the manual...

Torque.jpg