GR Yaris HOW TO: Adjust/reset gear linkage (fix for 1st/2nd gear issues)

[Onehp]

This DIY will help you align the gear shift cable linkage in its left gate together with the gearbox.

Dealer should do this under warranty if you have problems with crunchy 1st/2nd gear, do this on your own risk. But for me it was less hassle/wait DIY than going to the dealer.

Also if you have a bad case, probably better to go through dealer. Mine was almost on point with only the very odd clunky/crunchy change.

If you only have issues under quick changes, slow them down or get an torque mount insert.

Tools: set of screwdrivers 2x flat - and one +, and some masking tape. 10mm socket + extension

Step one: remove centre console according to this vid:

If you have a shift riser installed (like me), only need to remove top trim around shifter (as shown)

Step two: watch this vid first how to remove the intake but read on for a shortcut:

Shortcut: only remove snorkel and intake hose. Then, carefully take off the airbox lid and put to the side (use tape). Lift out vacuum hose running on the left/front on the airbox from its clips, then carefully lift off and put the airbox to the right and fix with tape for access to the gear linkage.

Step 3: open up the linkage joint to the left (green arrow first pic) of the shifter base according to this vid (shifter must be in NEUTRAL):



Step 4: lock the gear linkage at the gearbox (corresponding to left gate) as follows:

1) press down the linkage/black weight one notch (approx 8mm) and hold it there. (if you press down further it's reverse)
2) press and hold down button
3) push in handle rear-right direction (pushing in a pin and locking the linkage position)

Let go of button 2) and the linkage should stay put in its depressed position (some minor play there). Look like this

Step 5: Back in the car, move shift lever to the left (gate), the reverse lockout (black) resting against the white cam/ridge to the left (do NOT select 1st, 2nd or reverse). Holding the shift lever there, push back the orange clip in the shift linkage joint at the base of the shift assembly (the one we opened in step 3). Now we have reset the linkage to factory settings.

Step 6: free up the linkage at the gearbox by pulling left/forward the handle in step 4 nr 3. (DO NOT push button 2, you might inadvertently pull out the whole handle/pin). Now the linkage should jump back to neutral, just like the gearshift.

Step 7: test the gearshifts, if all feels good, reassemble the centre console and the airbox in reverse order. If not, redo from step 3 and find what you did wrong.

Done!

 

[Griippy]

Went for a drive other night with no issues, upon getting home and putting into reverse on my drive, was suddenly unable to put into reverse, first or second.

Left overnight still unable to put into those gears, gear stick physically won’t go in, but goes into third & up just fine.

Will be taking to Toyota but thinking it could be the linkage? Strange for it to suddenly happen and only when going to park up.

Thoughts?

 

[Onehp]

Could be the linkage if it slipped. In theory it then should be possible to select 1st or 2nd when lifting the reverse lockout and carefully trying to find the left gate position - trying to push lever forward or backward carefully somewhere to the left of the neutral position (try only when stationary).
If the left gate is nowhere to be found, could be the gearbox itself that has failed in it's shifting mechanism...

 

[Griippy]

Could be the linkage if it slipped. In theory it then should be possible to select 1st or 2nd when lifting the reverse lockout and carefully trying to find the left gate position - trying to push lever forward or backward carefully somewhere to the left of the neutral position (try only when stationary).
If the left gate is nowhere to be found, could be the gearbox itself that has failed in it's shifting

Thank you - it is strange, I just hopped in (stationary on drive) after not having tried it for a couple days and seems to now be selecting the gears, albeit clunky & often taking a couple of attempts. Trying to put it into first sometimes pushes the gearstick over into third. 4th too occasionally not wanting to go in.

Strange it has freed up without moving the car, I’ve booked it in with Toyota tomorrow & will update

 

[Griippy]

So I called out the AA, and he lubricated the gearbox droplink (I believe) whilst I moved it through the gears. Seemed to gradually help, and I drove to the Toyota garage with him following me. It seemed to be completely normal during the journey. After a day at Toyota, they reported they couldn't find any faults, and that these can be notchy (which makes me think the issue wasn't communicated very well as the mechanic wasn't aware that it would not go into gear at all).

What do you think could've caused it to completely refuse to to into those gears, but after two days of inactivity start to free up, and then totally free up. Not sure if the lubrication played a part at all or just moving it through the gears.

In summary it happened after a fairly long & spirited drive, no miss-shifts of apparent issues whilst driving, only for it to refuse to go into reverse, first and second when I arrived home and went to park up. Could something have heated up and then seized, but taken a couple of days to loosen up?

 

[GravelExx]

Just went to pick my wife up from the station in my GR, parked up locked up, came back 10 mins later and no gears?
Managed to start the car with clutch down and released clutch and it moved, i normally leave my car in second when i park.
clutch really smelling? Got back to my garage but could not select reverse.
How odd after reading the similar story above?
It`s a 21 plate with 6000 miles
Only cruised down to station, 5 min journey, first clutch problem i have had.

 

[Onehp]

Sounds like a shift cable hopped off or can shift for some reason?

 

[area_educator]

Do I understand correctly that this only adjusts in the lateral direction?

Does anyone know if there's a similar procedure for adjusting for fore and aft?

 

[Onehp]

Do I understand correctly that this only adjusts in the lateral direction?

Does anyone know if there's a similar procedure for adjusting for fore and aft?

Lateral direction is important to get exactly right as the position of the left gate, limited by the reverse lockout, and the 'gate' inside the gearbox MUST match up.

Fore and aft isn't needed in the same way as the movement of the gear stick is limited only by the gearbox. Unless the cable is way off and you hit a limit inside the gearstick mechanism first, this would cause problems too then, then you can lift off the shroud around the shifter, find where there is adjustment (haven't checked but probably similar) and just try a slightly different position that doesn't hit the mechanism fore-aft.

 

[area_educator]

Lateral direction is important to get exactly right as the position of the left gate, limited by the reverse lockout, and the 'gate' inside the gearbox MUST match up.

Fore and aft isn't needed in the same way as the movement of the gear stick is limited only by the gearbox. Unless the cable is way off and you hit a limit inside the gearstick mechanism first, this would cause problems too then, then you can lift off the shroud around the shifter, find where there is adjustment (haven't checked but probably similar) and just try a slightly different position that doesn't hit the mechanism fore-aft.

Great-- thanks for the information!
Mine is one that likes to pop out of 2nd. Sounds like this is unlikely to be the problem (but probably wouldn't hurt). Planning on having the dealership take a look at it.

 

[Onehp]

Great-- thanks for the information!
Mine is one that likes to pop out of 2nd. Sounds like this is unlikely to be the problem (but probably wouldn't hurt). Planning on having the dealership take a look at it.

Could actually be this, the gear lever itself hitting the end of throw before the gear locking pin inside the gearbox properly engages...

 

[nismohks]

@Onehp "Step 6: free up the linkage at the gearbox by pulling left/forward the handle in step 4 nr 3. (DO NOT push button 2, you might inadvertently pull out the whole handle/pin). Now the linkage should jump back to neutral, just like the gearshift."

Hello in step 6, I dont understand the instructions ? pull on what ? pull the black weight ?
thanks

 

[Onehp]

@Onehp "Step 6: free up the linkage at the gearbox by pulling left/forward the handle in step 4 nr 3. (DO NOT push button 2, you might inadvertently pull out the whole handle/pin). Now the linkage should jump back to neutral, just like the gearshift."

Hello in step 6, I dont understand the instructions ? pull on what ? pull the black weight ?
thanks

No, referenced step 4, nr 3 in the picture.

It is the white little tab, nr.3 in below picture, but now carefully pull outward in the other direction so the hear linkage pops upwards again (=neutral)

Hope that clears that up.