MANUAL TRANSAXLE UNIT REASSEMBLY

INSTALL OUTPUT SHAFT COVER

*a	Hole
*b	Protrusion

Install the output shaft cover to the front transaxle case as shown in the illustration.

INSTALL FRONT OUTPUT SHAFT BEARING (OUTER RACE)

Using SST and a hammer, install the front output shaft bearing (outer race) to the front transaxle case.

09950-60010

09951-00510

09950-70010

09951-07200

Note:
Do not damage or deform the front output shaft bearing (outer race).

INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)

Using SST and a hammer, install the front differential case front tapered roller bearing (outer race) to the front transaxle case.

09950-60010

09951-00620

09950-70010

09951-07200

Note:
Do not damage or deform the front differential case front tapered roller bearing (outer race).

INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)

Install the differential case shim to the manual transmission case.

Tip:
When reusing the front differential case rear tapered roller bearing (outer race), reuse the original differential case shim.

When installing a new front differential case rear tapered roller bearing (outer race), first select and install a differential case shim which is thinner than the original.
Using SST and a hammer, install the front differential case rear tapered roller bearing (outer race) to the manual transmission case.

09950-60020

09951-00710

09950-70010

09951-07200

Note:
Do not damage or deform the front differential case rear tapered roller bearing (outer race).

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Coat the front differential case front tapered roller bearing and front differential case rear tapered roller bearing with gear oil.
Install the front differential case to the front transaxle case.
Install the manual transmission case with the 13 bolts.

29.4 N*m

300 kgf*cm

22 ft.*lbf

Tip:
From manual transmission case side: 8 bolts

From front transaxle case side: 5 bolts
Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

09564-32011
Using SST and a torque wrench, measure the starting preload.

09564-32011

Standard Preload (at starting)

New Bearing

0.8 to 1.5 N*m (9 to 15 kgf*cm, 8 to 13 in.*lbf)

Used Bearing

0.5 to 0.9 N*m (6 to 9 kgf*cm, 5 to 7 in.*lbf)

If the result is not as specified, replace the differential case shim with one of a different thickness. Use the table below to select a differential case shim which will ensure that the preload is within the specification.

Differential Case Shim Thickness


Part No.	Mark	Thickness mm (in.)	Part No.	Mark	Thickness mm (in.)
90564-41065	01	1.10 (0.0433)	90564-41075	11	1.60 (0.0630)
90564-41066	02	1.15 (0.0453)	90564-41076	12	1.65 (0.0650)
90564-41067	03	1.20 (0.0472)	90564-41077	13	1.70 (0.0669)
90564-41068	04	1.25 (0.0492)	90564-41078	14	1.75 (0.0689)
90564-41069	05	1.30 (0.0512)	90564-41079	15	1.80 (0.0709)
90564-41070	06	1.35 (0.0531)	90564-41080	16	1.85 (0.0728)
90564-41071	07	1.40 (0.0551)	90564-41081	17	1.90 (0.0748)
90564-41072	08	1.45 (0.0571)	90564-41082	18	1.95 (0.0768)
90564-41073	09	1.50 (0.0591)	90564-41083	19	2.00 (0.0787)
90564-41074	10	1.55 (0.0610)	-	-	-

Remove the 13 bolts and manual transmission case from the front transaxle case.

Tip:
From manual transmission case side: 8 bolts

From front transaxle case side: 5 bolts
Remove the differential case assembly from the front transaxle case.

INSTALL REAR OUTPUT SHAFT BEARING SHIM

Install the rear output shaft bearing shim to the manual transmission case.

Tip:
When reusing the rear output shaft bearing (outer race), reuse the original rear output shaft bearing shim.

When installing a new rear output shaft bearing (outer race), first select and install a rear output shaft bearing shim which is thinner than the original.

INSTALL REAR OUTPUT SHAFT BEARING (OUTER RACE)

Using SST and a hammer, install the rear output shaft bearing (outer race) to the manual transmission case.

09950-60010

09951-00570

09950-70010

09951-07360

Note:
Do not damage or deform the rear output shaft bearing (outer race).

ADJUST OUTPUT SHAFT BEARING PRELOAD

Coat the front differential case front tapered roller bearing, front differential case rear tapered roller bearing, front output shaft bearing and rear output shaft bearing with gear oil.
Install the front differential case to the front transaxle case.
Install the output shaft assembly to the front transaxle case.
Install the manual transmission case to the front transaxle case with the 13 bolts.

29.4 N*m

300 kgf*cm

22 ft.*lbf

Tip:
From manual transmission case side: 8 bolts

From front transaxle case side: 5 bolts
Using SST and a torque wrench, turn the differential case assembly and output shaft assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

09564-32011
Using SST and a torque wrench, measure the starting preload. Calculate the rear output shaft bearing shim value using the following formula.

09564-32011

Formula

(Differential side bearing preload + Output shaft bearing preload) - Differential side bearing preload = Output shaft bearing preload

Preload (at starting)

New Bearing

2.8 to 5.5 N*m (29 to 56 kgf*cm, 25 to 48 in.*lbf)

Used Bearing

1.8 to 3.4 N*m (19 to 34 kgf*cm, 16 to 30 in.*lbf)

If the result is not as specified, replace the rear output shaft bearing shim with one of a different thickness. Use the table below to select a rear output shaft bearing shim which will ensure that the preload is within the specification.

Rear Output Shaft Bearing Shim Thickness


Part No.	Mark	Thickness mm (in.)	Part No.	Mark	Thickness mm (in.)
90564-38001	A	1.55 (0.0610)	90564-38009	J	1.95 (0.0768)
90564-38002	B	1.60 (0.0630)	90564-38010	K	2.00 (0.0787)
90564-38003	C	1.65 (0.0650)	90564-38011	L	2.05 (0.0807)
90564-38004	D	1.70 (0.0669)	90564-38012	M	2.10 (0.0827)
90564-38005	E	1.75 (0.0689)	90564-38013	N	2.15 (0.0846)
90564-38006	F	1.80 (0.0709)	90564-38014	P	2.20 (0.0866)
90564-38007	G	1.85 (0.0728)	90564-38015	Q	2.25 (0.0886)
90564-38008	H	1.90 (0.0748)	-	-	-

Remove the 13 bolts and manual transmission case from the front transaxle case.

Tip:
From manual transmission case side: 8 bolts

From front transaxle case side: 5 bolts
Remove the output shaft assembly and differential case assembly from the front transaxle case.

INSTALL REAR INPUT SHAFT BEARING SHIM

*1	Rear Input Shaft Bearing Shim

Using a vernier caliper, accurately measure the dimensions (A) and (B) shown in the illustration.

Select an rear input shaft bearing shim that brings the value to within the specifications.

Standard

Shim thickness (B - A) should be more than 0 mm (0 in.) and less than 0.1 mm (0.00393 in.)

Rear Input Shaft Bearing Shim Thickness


Part No.	Mark	Thickness mm (in.)	Part No.	Mark	Thickness mm (in.)
90564-38006	F	1.80 (0.0709)	90564-38013	N	2.15 (0.0846)
90564-38007	G	1.85 (0.0728)	90564-38014	P	2.20 (0.0866)
90564-38008	H	1.90 (0.0748)	90564-38015	Q	2.25 (0.0886)
90564-38009	J	1.95 (0.0768)	90564-38016	R	2.30 (0.0906)
90564-38010	K	2.00 (0.0787)	90564-38017	S	2.35 (0.0925)
90564-38011	L	2.05 (0.0807)	90564-38018	T	2.40 (0.0945)
90564-38012	M	2.10 (0.0827)	-	-	-

Install the rear input shaft bearing shim to the manual transmission case.

INSTALL NO. 2 OIL RECEIVER PIPE

Align the 2 protrusions with the 2 holes of the manual transmission case and install the No. 2 oil receiver pipe to the manual transmission case as shown in the illustration.

INSTALL FRONT DRIVE SHAFT OIL SEAL LH

Coat the lip of a new front drive shaft oil seal LH with MP grease.

*a	Depth

Using SST and a hammer, install the front drive shaft oil seal LH to the manual transmission case.

09316-60011

09316-00011

Standard Depth

2.1 to 3.1 mm (0.0827 to 0.122 in.)

Note:

Be careful not to damage the lip of the front drive shaft oil seal LH.

INSTALL FRONT DRIVE SHAFT OIL SEAL RH

Coat the lip of a new front drive shaft oil seal RH with MP grease.

*a	Depth

Using SST and a hammer, install the front drive shaft oil seal RH to the front transaxle case.

09636-20010

Standard Depth

1.7 to 2.7 mm (0.0670 to 0.106 in.)

Note:

Be careful not to damage the lip of the front drive shaft oil seal RH.

INSTALL FRONT TRANSAXLE CASE OIL SEAL

Coat the lip of a new front transaxle case oil seal with MP grease.
Using SST and a hammer, install the front transaxle case oil seal to the front transaxle case.

09950-60010

09951-00360

09950-70010

09951-07150

Standard Depth

14.4 to 15.4 mm (0.567 to 0.606 in.)

Note:
Be careful not to damage the lip of the front transaxle case oil seal.

INSTALL TRANSMISSION MAGNET

Clean and reinstall the transmission magnet to the front transaxle case.

INSTALL DIFFERENTIAL CASE ASSEMBLY

Coat the front differential case front tapered roller bearing and front differential case rear tapered roller bearing with gear oil.
Install the differential case assembly to the front transaxle case.

INSTALL OUTPUT SHAFT ASSEMBLY

Coat sliding and rotating surfaces of the output shaft assembly with gear oil, and install it to the front transaxle case.

INSTALL INPUT SHAFT ASSEMBLY

Coat sliding and rotating surfaces of the input shaft assembly with gear oil, and install it to the front transaxle case.

INSTALL NO. 2 GEAR SHIFT FORK SHAFT

Install the No. 2 gear shift fork to the No. 2 gear shift fork shaft.
Using a plastic hammer, install a new snap ring to the No. 2 gear shift fork shaft.

Tip:
Use a piece of cloth to keep the snap ring from flying off.
Install the reverse shift fork to the No. 2 gear shift fork shaft.

*1	No. 2 Transmission Hub Sleeve

Shift the No. 2 transmission hub sleeve to the 4th gear position.

*1	No. 2 Gear Shift Fork Shaft
*2	No. 2 Gear Shift Fork
*3	Reverse Shift Fork

Install the No. 2 gear shift fork shaft, No. 2 gear shift fork and reverse shift fork to the front transaxle case.

Install a new bolt to the No. 2 gear shift fork.

15.7 N*m

160 kgf*cm

12 ft.*lbf
Using a brass bar and a hammer, install a new snap ring to the No. 2 gear shift fork shaft.

Tip:
Use a piece of cloth to keep the snap ring from flying off.
Using a Magnet Hand, install the straight pin to the reverse shift fork.

INSTALL NO. 3 GEAR SHIFT FORK SHAFT

Using a plastic hammer, install a new snap ring to the No. 3 gear shift fork shaft.

Tip:
Use a piece of cloth to keep the snap ring from flying off.
Install the No. 3 gear shift fork to the No. 3 transmission hub sleeve.

*1	No. 3 Gear Shift Fork Shaft
*2	Compression Spring
*3	No. 3 Gear Shift Head
*4	No. 3 Gear Shift Fork

Pass the No. 3 gear shift fork shaft through the No. 3 gear shift fork, compression spring and No. 3 gear shift head, and then install them to the front transaxle case.

Using a 5 mm pin punch and a hammer, install the slotted spring pin to the No. 3 gear shift head to secure the No. 3 gear shift head to the No. 3 gear shift fork shaft.
Using a screwdriver and a hammer, install a new snap ring to the No. 3 gear shift fork shaft.

Tip:
Use a piece of cloth to keep the snap ring from flying off.
Install the straight pin to the No. 3 gear shift fork.

INSTALL NO. 1 GEAR SHIFT FORK SHAFT

Using a plastic hammer, install a new snap ring to the No. 1 gear shift fork shaft.

Tip:
Use a piece of cloth to keep the snap ring from flying off.
Install the No. 1 gear shift fork to the reverse gear.
Pass the No. 1 gear shift fork shaft through the No. 1 gear shift head and No. 1 gear shift fork, and then install them to the front transaxle case.
Using a 5 mm pin punch and a hammer, install the slotted spring pin to the No. 1 gear shift head to secure the No. 1 gear shift head to the No. 1 gear shift fork shaft.
Install a new bolt to the No. 1 gear shift fork.

15.7 N*m

160 kgf*cm

12 ft.*lbf

INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

Install the reverse idler gear sub-assembly to the front transaxle case.

INSTALL REVERSE IDLER GEAR SHAFT

Coat the reverse idler gear shaft with gear oil.
Pass the reverse idler gear shaft through the reverse idler gear sub-assembly, and then install it to the front transaxle case.

*a	Mark

Align the mark on the reverse idler gear shaft with the bolt hole, as shown in the illustration.

INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

*1	Reverse Shift Arm Bracket Assembly
*2	Reverse Idler Gear Sub-assembly

Install the reverse shift arm bracket assembly to the front transaxle case with the 2 bolts.

17.2 N*m

175 kgf*cm

13 ft.*lbf

Note:

Set the top of the reverse shift arm bracket assembly into the groove on the reverse idler gear sub-assembly.

INSTALL MANUAL TRANSMISSION CASE

Remove any remaining seal packing (FIPG) from the contact surfaces of the manual transmission case and front transaxle case.

Note:
Make sure that there is no gear oil on the contact surfaces.

*a	Seal Packing (FIPG) (Seal Width: 1.2 mm (0.0472 in.))

Apply seal packing (FIPG) to the manual transmission case.

Seal Packing (FIPG)

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Note:

Install the parts within 10 minutes of application. Otherwise, the seal packing (FIPG) must be removed and reapplied.
Apply seal packing (FIPG) in a continuous line (width 1.2 mm (0.0472 in.)) to the sealing surface of the manual transmission case.

Install the manual transmission case to the front transaxle case.
Install the 8 bolts to the manual transmission case side.

29.4 N*m

300 kgf*cm

22 ft.*lbf
Install the 5 bolts to the front transaxle case side.

29.4 N*m

300 kgf*cm

22 ft.*lbf

INSTALL REVERSE IDLER GEAR SHAFT BOLT

*a	Adhesive

Clean and degrease the reverse idler gear shaft bolt and installation hole in the manual transmission case.

Apply adhesive to 2 or 3 threads on the ends of the reverse idler gear shaft bolt.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Note:
In order to ensure proper installation of the reverse idler gear shaft bolt, apply adhesive to the reverse idler gear shaft bolt and install it within 10 minutes of adhesive application.
Install a new gasket and reverse idler gear shaft bolt to the manual transmission case.

29.4 N*m

300 kgf*cm

22 ft.*lbf

INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY

Move the gear position to N.
Remove any remaining seal packing (FIPG) from the contact surfaces of the shift and select lever shaft assembly and manual transmission case.

Note:
Make sure that there is no gear oil on the contact surfaces.
Install the select return compression spring to the manual transmission case.

*a	Seal Packing (FIPG) (Seal Width: 1.2 mm (0.0472 in.))

Apply seal packing (FIPG) to the shift and select lever shaft assembly.

Seal Packing (FIPG)

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Note:

Install the parts within 10 minutes of application. Otherwise, the seal packing (FIPG) must be removed and reapplied.
Apply seal packing (FIPG) in a continuous line (width 1.2 mm (0.0472 in.)) to the sealing surface of the shift and select lever shaft assembly.

*a	Adhesive

Clean and degrease the bolt (A) and installation hole in the manual transmission case.

Apply adhesive to 2 or 3 threads on the ends of the bolt (A).

Adhesive

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Note:
In order to ensure proper installation of the bolt (A), apply adhesive to the bolt (A) and install them within 10 minutes of adhesive application.

*a	Wire Harness Clamp

Install the shift and select lever shaft assembly and 2 wire harness clamps to the manual transmission case with the 4 bolts.

18 N*m

184 kgf*cm

13 ft.*lbf

INSTALL NO. 1 LOCK BALL ASSEMBLY

*a	Adhesive

Clean and degrease the No. 1 lock ball assembly and installation hole in the manual transmission case.

Coat the threads of the No. 1 lock ball assembly with adhesive.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Note:
In order to ensure proper installation of the No. 1 lock ball assembly, apply adhesive to the No. 1 lock ball assembly and install it within 10 minutes of adhesive application.
Using a 18 mm socket wrench, install the No. 1 lock ball assembly to the manual transmission case.

36.8 N*m

375 kgf*cm

27 ft.*lbf

INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

Using SST, install a new gasket and back-up light switch assembly to the manual transaxle assembly.

09817-16011

40.2 N*m

410 kgf*cm

30 ft.*lbf
Engage the 2 clamps to connect the back-up light switch wire harness to the manual transaxle assembly.

INSTALL NEUTRAL POSITION SWITCH

Using SST, install a new gasket and the neutral position switch to the manual transaxle assembly.

09817-16011

39.2 N*m

400 kgf*cm

29 ft.*lbf

INSTALL MANUAL TRANSAXLE FILLER PLUG

Install a new gasket and manual transaxle filler plug to the manual transmission case.

39.2 N*m

400 kgf*cm

29 ft.*lbf

INSTALL MANUAL TRANSAXLE DRAIN PLUG

Install a new gasket and manual transaxle drain plug to the manual transmission case.

39.2 N*m

400 kgf*cm

29 ft.*lbf

INSTALL MANUAL TRANSAXLE CASE PLUG

Install a new gasket and manual transaxle case plug to the front transaxle case.

39.2 N*m

400 kgf*cm

29 ft.*lbf

INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET

Install the floor shift control lever housing support bracket to the front transaxle case with the 2 bolts.

11.3 N*m

115 kgf*cm

8 ft.*lbf

INSTALL NO. 1 CLUTCH HOUSING COVER

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INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

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INSTALL CLUTCH RELEASE FORK LEVER

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INSTALL CLUTCH RELEASE BEARING ASSEMBLY

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