In Part 3 we are going to test fit the C60 internals into the C50 case and shoot for a final assembly. First we need to take some measurements to verify the C50 bell housing bearings are compatible with the C60 shafts and differential. Lets get started:
Now that we have some C60 measurements, I compared them to the C50 and almost everything was identical including the center case measurements! The C50 case I have is from an xD so these numbers will differ from the measurements of a Yaris/xA/xB C50 in ONLY one area - The pinion shaft bearing in the bell housing is the larger 40mm version instead of the Yaris 33mm bearing. This is a happy coincidence for me since my xD case has the correct bearing already, but for those wanting to attempt this swap without the xD case you'll need to change to this bearing pictured below:
Since all of my case measurement are in line with the C60, I'm going to install all of the internals onto the xD bell housing one by one verifying all of the 6 speed parts fit properly. Next I'll remove the reverse lock out from the xD center case and test fit that as well. Lets get started:
Well there we have it, the cases fit! You can use either the C50 or C60 center case upon final assembly but I went with the C50 so my case mates as intended and it allows for easier axle removal. At this point I removed all of the gears from the case so I could test fit the complete 6 speed case into the engine bay empty. HUGE thanks to Sam and Jamie for suggesting this trick, otherwise I would have struggled A LOT! I'll mention the fitting modifications in the next part of this series, but for now, lets get the transmission fully assembled using these images from the Celica GTS service manual:
I cleaned all the 5th and 6th components in the parts washer, inspected for defects, and soaked the parts in gear oil. I then installed everything using a torch to heat up the tight fitting parts, and don't forget the wood block under the input shaft. I cleaned up and installed the 5th/6th cover and sealed that as well, then I installed the C60 shift selector and verified I can shift into all gears and the shafts turn smoothly. If you use the C50 center case you will also need to install a short 12mm hex bolt into the old shifter guide pin hole on top of the selector tunnel. Next I installed the C60 speed sensor since it has 1 less tooth than the C50 part, and attached the shift linkage and clutch release components from my C50. The C60/C50 hybrid transmission is now ready to be installed onto any 2ZR-FE or 1NZ-FE class engine!. Stay tuned for Part 4 where we modify the chassis to fit the 6 speed, install the transmission, and figure out the axles we need!