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Toyota Yaris 6 Speed Swap Part 1 | The C60 Tear Down

11/17/2017

8 Comments

 
Picture
C60 transmission
Here in Part 1 we will be disassembling the 2003 Toyota Celica GTS C60 transmission and comparing parts to the common C50 5 speed. The bell housing on the C60 has a different starter orientation and the rear mount attachment is different. We are hoping the 6 speed parts can be installed in the 5 speed case, making it a direct fit. The tools required to disassemble and service these transmissions varies, and gears can break when stressed in the wrong areas. Armed with that information, please proceed with this project at your own risk and consult a transmission specialist if you are not comfortable. Now, Lets get started:
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C60 5th and 6th gears
We start by removing the end cap, exposing the 5th and 6th gear components. This is the hardest part of the disassembly, you need to knock out the keepers and use pullers to remove all of these parts. You need the proper tools, penetrating oil, and a torch to complete this part of the job. First you need to remove the shifter rod from the case:
Picture
C60 shift rod
Remove the shift bracket attachment point and the end cap, then just pull the rod out paying attention to it's orientation and springs. Then you want to reach into the case and pry up both the 1-2 and 3-4 shift rods, locking the gears together. Now you can start pulling off the 5th and 6th components:
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C60 6th gear bearings
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C60 6th gear
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C60 5th and 6th removal
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C60 bare shift hub
Picture
C60 5th gear removal
Picture
C60 rear case bearing snap rings
Once you pull off all of the gears you can then knock the keepers off the shift rods and remove the rear bearing plate. There are snap rings holding the bearings to the case that need to be expanded to remove.
Next you can remove the shift rod detent springs and balls under these covers. Use a small pick and a magnet to remove the parts from the case, then remove the reverse holder screw and case bolts (don't forget the 3 bolts inside the bell housing).
Picture
C60 shift rod detents
Picture
Reverse holder set screw
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C60 case bolts
Picture
C60 internals
Now we can start comparing things, of course the gears are different but the forks and rods look the same as the C50. The shafts are longer to accommodate the 6th gear, but otherwise the look identical to the Scion xD shafts. Reverse looks identical, no surprise there. Lets keep going, remove the reverse gear and shaft, then the linkage. Remove 1st and 2nd shift rod  detent spring and ball then grab both shafts and the rods together and wiggle them up and out of the bell housing. You can then just lift the differential out of the bell housing.
Picture
C60 reverse removed
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C60 1-2 shift rod detent
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C60 shafts, rods, forks
Picture
C60 bell housing
Picture
C60 and C50 bell housing/case comparison.
Now is the moment of truth, will all of these fancy 6 speed parts fit in a C50 bell housing and case? I believe they will, I've compared the two cases and the only differences are: 1-C50 has a reverse lockout(removable, no big deal). 2-pinion shaft bearing size in the bell housing(can be changed, no big deal). This is great news, we can keep moving forward with this project! Stay tuned for Part 2 where we will address some issues we found with the 6 speed synchronizers, and thoroughly inspect all the gears and bearings. We are still unsure on what axles we need, but that can be dealt with later.
8 Comments
Brian Gaines
3/13/2018 11:57:02 am

Please let me know how this works out! I'm hoping someday to swap the C50 in my '06 Scion xB to a 6-speed...

Reply
Tom
3/29/2018 06:05:03 pm

So far after 3 races its been great, just needs an LSD for maximum traction. The xB has good gearing, I used those parts in my 5 speed. Why do you want the 6 speed?

Reply
Alex
12/3/2018 01:20:51 pm

tuviste algún problema al hacer el cambio?

Reply
Tom
12/3/2018 06:15:09 pm

No, todos muy bien!

Reply
Max
2/16/2019 11:09:58 pm

Oh...

Never ever try to pull out bearings with removal tool like shown on 4th photo, you WILL damage them!

Toyota service manual shows that removal tool should be connected to the gear wheel underneath, so the solid gear's body is pushing against bearing's centre race, and pulled together.

Reply
Tom
2/17/2019 01:21:18 pm

You are correct. But once you pull one of these apart you’ll quickly realize the 6th driven gear is extremely difficult to remove. It’s best to just replace the end bearings anyway

Reply
Cary Cameron
2/17/2019 12:24:56 pm

Is the part 2 out there somewhere? I haven't been able to find it

Reply
Tom
2/17/2019 01:19:39 pm

Yes all of the parts on on this website. Just search for C60

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