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Toyota H41 H42 H50 H55F Gearbox transmission factory workshop and repair manual

- Quick orientation (one-line): Most Toyota H41 / H42 / H50 / H55F manual gearboxes do not have a serviceable internal “filter” — the routine service is to drain and refill the gear oil and replace the drain/fill plug seals; an internal filter would require gearbox removal. If you meant “change the gearbox fluid (and any serviceable screen/mesh)”, follow the steps below.

- Safety first
- Park on a flat level surface, set the parking brake, chock wheels.
- Work with the engine off and keys removed.
- Wait for hot drivetrain parts to cool.
- Wear nitrile or mechanic gloves, safety glasses, and keep rags ready.
- Collect oil in a closed container and dispose of used oil and contaminated rags per local regulations.

- Procedure — drain and refill gearbox oil (bullet steps)
- Raise and support the vehicle safely on jack stands if needed to access the gearbox; never rely on a jack alone.
- Locate the gearbox drain plug (lowest plug) and the fill/check plug (higher on the gearbox body). Clean area around plugs before opening to avoid contamination.
- Position a drain pan under the drain plug.
- Remove the fill/check plug first (so you can refill later) using the correct socket or wrench; this prevents vacuum locking during refill.
- Remove the drain plug using the correct socket; allow oil to drain fully until drops stop. Inspect the oil and the drain plug for metal flakes or heavy metallic sludge.
- While draining, inspect the drain plug’s magnetic tip (if fitted) and wipe metal particles into a rag; light copper/steel dust is normal, heavy chunks indicate internal damage.
- If drain plug uses a crush washer or gasket, remove and discard it.
- Clean the drain plug and magnetic surface; if plug threads or head are rounded/damaged replace the plug.
- Reinstall the cleaned drain plug with a new crush washer/gasket; tighten to manufacturer torque (see parts section for recommended action if you don’t have the spec).
- Refill gearbox fluid through the fill/check hole using a pump or funnel until fluid begins to run out of the fill hole or reaches the manufacturer’s specified level.
- Reinstall the fill/check plug with a new washer/O-ring if applicable and tighten to spec.
- Wipe all drips, lower the vehicle, run the engine and cycle gears (with vehicle stationary) or do a short low-speed drive, then recheck for leaks and recheck fluid level after a short run.

- How to judge if a deeper repair or part replacement is required
- Normal: clear brown gear oil, faint metallic dust on magnetic plug.
- Replace drain plug/crush washer/fill plug O-ring every service; inexpensive and prevents leaks.
- Excessive metal flakes, large metal shards, grinding noises, difficulty selecting gears, or severe leaks = gearbox damage. That requires inspection by a transmission specialist and possibly:
- Internal rebuild or replacement of worn gears/synchronizers/bearings
- Replacement of output shaft/input shaft seals
- Possibly a complete gearbox replacement
- If you find threads in the gearbox body damaged, you may need a helicoil/insert or replacement housing — specialist job.

- Fluids and replacement parts commonly required
- Fluid: manufacturer-specified manual gearbox oil. Commonly used: 75W-90 GL-4 manual transmission oil (but confirm with Toyota service spec for exact grade and capacity).
- Typical capacity varies by model — check factory manual; expect roughly 1.5–3.0 liters depending on gearbox.
- Parts to replace each service:
- Drain plug crush washer (copper or aluminum washer) or gasket
- Fill plug O-ring / crush washer if specified
- Drain plug if damaged (magnetic plug recommended)
- Parts to replace if faults found:
- Input/output shaft seals if leaking
- Internal bearings/gears/syncros if heavy metal contamination is present (requires rebuild or replacement)

- Tools — detailed description and how to use each
- Jack (hydraulic trolley jack)
- Use: Lift the vehicle at correct jacking points. Always follow vehicle manual jacking points.
- How to use: Pump handle to raise, position jack stands before getting under car, lower onto stands slowly.
- Why required: Provides access to gearbox underside safely when combined with stands.
- Jack stands (pair)
- Use: Support vehicle securely while working underneath.
- How to use: Place on solid level ground under recommended lift points, set height, lower vehicle onto stands; never use a jack alone.
- Why required: Safety — prevents crushing injuries.
- Wheel chocks
- Use: Prevent vehicle roll.
- How to use: Place behind wheels that remain on ground.
- Why required: Additional safety.
- Drain pan / oil catch container (large, with decent capacity)
- Use: Collect used gearbox oil.
- How to use: Place under drain plug, tilt as needed to catch drain flow.
- Why required: Contain hot oil and allow proper disposal.
- Socket set (metric), ratchet and extensions
- Use: Remove and install drain and fill plugs.
- How to use: Choose correct socket size that snugly fits plug head; use extension if space is tight; apply steady force to loosen/tighten.
- Why required: Most plugs use hex heads; using wrong size will round the plug head.
- Torque wrench (metric)
- Use: Tighten plugs to the correct torque.
- How to use: Set required torque on wrench, tighten until it clicks/releases at set torque.
- Why required: Prevent over-tightening (stripped threads) or under-tightening (leaks).
- Breaker bar
- Use: Apply extra leverage to free seized plugs.
- How to use: Fit socket and apply firm controlled force; avoid jerking.
- Why required: Some plugs are very tight or corroded.
- Funnel and long flexible spout or manual fluid pump / gear oil syringe
- Use: Refill gearbox through the fill/check hole without spilling.
- How to use: Insert funnel or pump tube into fill hole; use pump to push fluid in until level is correct.
- Why required: Fill hole is often high and cramped; pumps make refill clean and possible without tilting gearbox.
- Wire brush / clean rags / brake cleaner
- Use: Clean plug threads and gearbox exterior before opening; clean magnetic plug.
- How to use: Scrub loose corrosion and wipe surfaces; use solvent sparingly to remove oil.
- Why required: Keep contaminants out of gearbox.
- Flashlight or inspection mirror
- Use: See fill hole, threads, and interior condition.
- How to use: Shine into fill/drain openings to check level and debris.
- Why required: Visibility under the vehicle is limited.
- Gloves and safety glasses
- Use: Personal protection from hot oil and debris.
- How to use: Wear during entire job.
- Optional but useful: impact driver or impact wrench
- Use: Remove very tight plugs quickly.
- Why required: Saves effort; use carefully to avoid over-torquing on re-install.
- Optional but for problem jobs: penetrating oil, bolt extractor set, thread chaser/heli-coil kit
- Use: Penetrating oil to free seized plugs; extractor kit to remove rounded heads; thread chaser or helicoil to repair damaged threads.
- Why required: If plug is corroded or head stripped, these tools allow repair; helicoil/thread insert restores threads but requires skill.

- How to use the common tools safely and effectively (quick tips)
- Always match socket size exactly; slipping rounds off heads.
- Apply penetrating fluid and allow dwell time if plug won’t budge.
- Use steady pressure with breaker bar; avoid sudden jerks.
- Tighten drain/fill plugs using torque wrench to specified torque — if you don’t have the spec, tighten gently to snug + a small fraction (don’t exceed what socket/wrench feels safe) and replace any rounded or damaged plug.
- Use a pump to fill gear oil to avoid spills; overfilling can cause pressure/foaming, underfilling causes poor lubrication.

- Quick checklist of consumables to buy before starting
- Correct manual gearbox oil (manufacturer grade and quantity)
- Drain plug crush washer(s) and fill plug washer/O-ring
- Replacement drain plug if damaged (magnetic type preferred)
- Rags, disposable gloves, suitable waste container or sealable oil drain container

- Final checks after service
- Inspect for leaks at drain and fill plugs after tightening.
- Test-drive gently, check for noise, shifting feel, leaks again.
- Recheck fluid level when gearbox warm/cool per factory instructions.

- If you discover heavy metal contamination or serious symptoms
- Stop driving the vehicle.
- Do not attempt internal repairs without specialist tools and knowledge.
- Tow to a transmission specialist for inspection/rebuild or gearbox replacement.

- Important note (essential)
- Exact fluid grade, quantity, plug torques, and fill level are model/year-specific. Consult the Toyota service manual or official spec sheet for your exact vehicle/gearbox before final torque and fluid amounts.

- No extra yapping as requested.
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