1986 Toyota MR2 Manual Transmission Rebuild Kit

The 1986 Toyota MR2 Manual Transmission Rebuild Kit is a comprehensive solution for restoring the C50/C52 5-speed manual transmission used in first-generation AW11 MR2 models. This complete kit includes all necessary components for a full transmission overhaul, featuring high-quality bearings, seals, gaskets, synchros, and specialty tools. Designed specifically for the 1986 model year with 4A-GE engine, this rebuild kit restores smooth shifting performance and extends transmission lifespan.

1. Kit Components 2. Compatibility 3. Installation Requirements 4. Technical Specifications 5. Tools Needed 6. Step-by-Step Rebuild Process 7. Torque Specifications 8. Break-in Procedure 9. Warranty & Support 10. Troubleshooting

Kit Components

Complete rebuild kit includes all essential components for C50/C52 transmission restoration.

Component	Description
Main Shaft Bearings	High-precision Japanese bearings for main shaft assembly
Counter Shaft Bearings	Matched set for counter shaft rotation
Input Shaft Seal	Viton material for superior heat resistance
Output Shaft Seal	Double-lipped design for maximum protection
Synchro Rings	Brass construction for smooth gear engagement
Gasket Set	Complete paper and rubber gasket assortment
Shift Fork Pads	Wear-resistant polymer for precise shifting
Detent Springs	Factory-spec spring tension
Snap Rings	Hardened steel retaining rings
Transmission Fluid	75W-90 GL-4 synthetic gear oil (2 quarts)

Compatibility

Specifically designed for 1986 Toyota MR2 with manual transmission.

Vehicle: 1986 Toyota MR2 (AW11 chassis)
Engine: 4A-GE 1.6L 16-valve
Transmission: C50/C52 5-speed manual
VIN Range: JT2AW15C*G0000001 - JT2AW15C*G0123456
Production Date: August 1985 - July 1986

NOTE: Verify transmission code stamped on housing before purchase.

Installation Requirements

Professional mechanical experience recommended for transmission rebuild.

Transmission removal from vehicle
Clean work environment
Press for bearing installation/removal
Transmission stand for secure mounting
Basic hand tools and torque wrench
Cleaner and assembly lubricant

WARNING! Transmission components are heavy; use proper lifting equipment.

Technical Specifications

Transmission Type: C50/C52 5-speed manual
Gear Ratios: 1st: 3.166, 2nd: 1.904, 3rd: 1.310, 4th: 0.969, 5th: 0.815, Reverse: 3.250
Final Drive: 4.285:1
Bearing Tolerance: ABEC-3 precision standard
Seal Material: Viton fluoroelastomer
Temperature Range: -40°F to 400°F operational
Fluid Capacity: 2.1 quarts (2.0 liters)
Weight: Complete kit: 8.5 lbs (3.9 kg)

Tools Needed

Specialized tools required for proper transmission disassembly and assembly.

Tool	Purpose
Bearing Puller Set	Remove pressed-on bearings
Snap Ring Pliers	Internal and external types
Torque Wrench	1/2" drive, 20-150 ft-lb range
Press	10-ton minimum capacity
Transmission Stand	Rotating head for easy access
Dial Indicator	Check shaft end play
Micrometer Set	Measure shaft and bearing wear
Soft-face Hammer	Component installation

Step-by-Step Rebuild Process

Follow this sequence for proper transmission reassembly.

Complete disassembly and thorough cleaning of all components
Inspect gears, shafts, and housing for wear or damage
Install new main shaft bearings using press and proper supports
Assemble counter shaft with new bearings and synchro rings
Install shift forks with new pads and detent springs
Replace all seals with proper installation tools
Reassemble case halves with new gaskets
Fill with specified transmission fluid

CAUTION! Keep work area clean to prevent contamination.

Torque Specifications

Critical fasteners require specific torque values for proper operation.

Component	Torque Value	Notes
Case Bolts (10mm)	29 ft-lbs (39 Nm)	Use thread sealant
Bellhousing Bolts	47 ft-lbs (64 Nm)	12-point bolts
Drain/Fill Plugs	36 ft-lbs (49 Nm)	Crush washers
Shift Lever	16 ft-lbs (22 Nm)	Loctite 242
Back-up Light Switch	22 ft-lbs (30 Nm)	Do not overtighten

Break-in Procedure

Proper break-in ensures long component life and optimal performance.

Initial 500 miles of gentle driving
Avoid full-throttle shifts and high RPM operation
Vary driving speeds and avoid sustained highway use
Check for leaks after first 50 miles
Change fluid after 1,000 miles to remove break-in debris

IMPORTANT: New synchros require gentle engagement during break-in period.

Warranty & Support

Limited lifetime warranty on all kit components against manufacturing defects.

Warranty Period: Lifetime limited warranty
Coverage: Manufacturing defects in materials and workmanship
Exclusions: Improper installation, misuse, normal wear
Support: Technical assistance available Mon-Fri 8am-5pm PST
Contact: 1-800-TRANS-KIT or [email protected]

Troubleshooting

Issue	Possible Cause	Solution
Difficulty shifting	Incorrect clutch adjustment	Adjust clutch hydraulic system
Gear grinding	Synchro installation error	Verify synchro ring clearance
Transmission noise	Bearing preload incorrect	Check shaft end play specifications
Fluid leaks	Seal damage during installation	Replace seals using proper tools
Jumping out of gear	Worn detent springs/forks	Replace detent components

Technical Support: 1-800-TRANS-KIT | www.mr2transmissionparts.com