MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE

1. INSTALL SHIFT FORK SHAFT BEARING

   1. 

      Using SST and a press, install 4 new shift fork shaft bearings to the front transaxle case.

      09820-00031

      Standard Clearance

      0 to 0.5 mm (0 to 0.0197 in.)

2. INSTALL OUTPUT SHAFT COVER

   1. 

      *a	Protrusion
      *b	Groove

      Align the protrusion on the output shaft cover with the groove on the front transaxle case as shown in the illustration, and install the output shaft cover to the front transaxle case.

3. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING OUTER RACE

   1. 

      Using SST and a hammer, install the No. 2 output shaft front bearing outer race to the front transaxle case.

      09950-70010

      09951-07100

      09950-60020

      09951-00710

4. INSTALL OUTPUT SHAFT COVER

   1. 

      *a	Protrusion
      *b	Groove

      Align the protrusion on the output shaft cover with the groove on the front transaxle case as shown in the illustration, and install the output shaft cover to the front transaxle case.

5. INSTALL OUTPUT SHAFT FRONT BEARING

   1. 

      Coat a new output shaft front bearing with gear oil.

   2. Using SST and a press, install the output shaft front bearing to the front transaxle case.

      09223-15020

   3. 

      Install the bolt to the front transaxle case.

      11.3 N*m

      115 kgf*cm

      8 ft.*lbf

6. INSTALL FRONT TRANSAXLE CASE OIL SEAL

   1. 

      *a

      Depth

      Using SST and a hammer, install a new front transaxle case oil seal to the front transaxle case.

      09950-60010

      09951-00580

      09950-70010

      09951-07200

      Standard Depth

      4.4 to 5.0 mm (0.173 to 0.197 in.)

   2. Coat a front transaxle case oil seal lip with MP grease.

7. INSTALL INPUT SHAFT FRONT BEARING

   1. Coat a new input shaft front bearing with gear oil.

   2. 

      Using SST and a press, install the input shaft front bearing to the front transaxle case.

      09223-00010

   3. 

      Install the bolt to the front transaxle case.

      11.3 N*m

      115 kgf*cm

      8 ft.*lbf

8. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING

   1. 

      *1	Input Shaft Rear Bearing Shaft Snap Ring
      *2	Output Shaft Rear Bearing Shaft Snap Ring

      Using snap ring pliers, install the input shaft rear bearing shaft snap ring to the manual transmission case.

   2. Using snap ring pliers, install the output shaft rear bearing shaft snap ring to the manual transmission case.

9. INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING

   1. 

      *a

      Depth

      Using SST and a press, install a new shift and select lever shaft needle roller bearing to the manual transmission case.

      09285-76010

      Standard Clearance

      177.8 to 178.7 mm (7.00 to 7.04 in.)

10. INSTALL SHIFT FORK SHAFT BEARING

    1. 

       *a	Clearance (A)
       *b	Clearance (B)
       *c	Depth

       Using SST and a press, install 4 new shift fork shaft bearings to the manual transmission case.

       09307-12010

       09820-00031

       Standard Clearance (A)

       168.2 to 169.3 mm (6.62 to 6.67 in.)

       Standard Clearance (B)

       162.2 to 163.3 mm (6.39 to 6.43 in.)

11. INSTALL FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE

    1. 

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

       09950-60020

       09951-00910

       09950-70010

       09951-07150

12. INSTALL FRONT DIFFERENTIAL CASE REAR SHIM

    1. 

       Install the front differential case rear shim to the manual transmission case.

13. INSTALL FRONT DIFFERENTIAL CASE REAR BEARING OUTER RACE

    1. 

       Using SST and a hammer, install the front differential case rear bearing outer race to the manual transmission case.

       09950-60020

       09951-00910

       09950-70010

       09951-07100

14. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

    1. 

       Install the differential gear assembly to the front transaxle case.

    2. 

       Install the manual transmission case to the front transaxle case with the 12 bolts.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

    3. 

       Install the 6 bolts to the manual transmission case.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

    4. Turn the differential gear assembly in both directions to settle it.

    5. 

       *a

       Mark

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

       09564-33010

       Preload

       1.00 to 2.49 N*m (10 to 25 kgf*cm, 9 to 22 in.*lbf)

    6. Select a front differential case rear shim.

       Table 1. Front Differential Case Rear Shim Thickness:

       Mark	Thickness mm (in.)	Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
       0	1.99 to 2.01 (0.0783 to 0.0791)	6	2.29 to 2.31 (0.0902 to 0.0909)	C	2.59 to 2.61 (0.1020 to 0.1028)
       1	2.04 to 2.06 (0.0803 to 0.0811)	7	2.34 to 2.36 (0.0921 to 0.0929)	D	2.64 to 2.66 (0.1039 to 0.1047)
       2	2.09 to 2.11 (0.0823 to 0.0831)	8	2.39 to 2.41 (0.0941 to 0.0949)	E	2.69 to 2.71 (0.1059 to 0.1067)
       3	2.14 to 2.16 (0.0843 to 0.0850)	9	2.44 to 2.46 (0.0961 to 0.0969)	F	2.74 to 2.76 (0.1079 to 0.1087)
       4	2.19 to 2.21 (0.0862 to 0.0870)	A	2.49 to 2.51 (0.0980 to 0.0988)	G	2.79 to 2.81 (0.1098 to 0.1106)
       5	2.24 to 2.26 (0.0882 to 0.0890)	B	2.54 to 2.56 (0.1000 to 0.1008)	H	2.84 to 2.86 (0.1118 to 0.1126)

    7. Remove the 6 bolts from the manual transmission case.

    8. Remove the 12 bolts from the front transaxle case.

    9. Remove the manual transmission case from the front transaxle case.

    10. Remove the differential gear assembly from the front transaxle case.

15. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING OUTER RACE

    1. 

       *a

       Mark

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

       Tip:

       When reusing the No. 2 output shaft rear bearing outer race, first install an output shaft rear bearing shim of the same thickness as the original. When installing a new No. 2 output shaft rear bearing outer race, first select and install an output shaft rear bearing shim which is thinner than the original.

    2. 

       Using SST and a hammer, install the No. 2 output shaft rear bearing outer race to the manual transmission case.

       09950-60010

       09951-00650

       09950-70010

       09951-07200

16. ADJUST NO. 2 OUTPUT SHAFT REAR BEARING PRELOAD

    1. 

       Install the No. 2 output shaft assembly and differential gear assembly to the front transaxle case.

    2. 

       Install the manual transmission case to the front transaxle case with the 12 bolts.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

    3. 

       Install the 6 bolts to the manual transmission case.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

    4. 

       Using SST, measure the No. 2 output shaft rear bearing preload. Subtract the value of the differential side bearing preload from the measured No. 2 output shaft rear bearing preload. Select an output shaft rear bearing shim that will set the preload within the specified range below and install the output shaft rear bearing shim.

       09564-33010

       Preload

       3.66 to 5.18 N*m (37 to 53 kgf*cm, 32 to 46 in.*lbf)

       Table 2. Output Shaft Rear Bearing Shim Thickness:

       Mark	Thickness mm (in.)	Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
       A	1.79 to 1.81 (0.0705 to 0.0713)	G	2.09 to 2.11 (0.0823 to 0.0831)	N	2.39 to 2.41 (0.0941 to 0.0949)
       B	1.84 to 1.86 (0.0724 to 0.0732)	H	2.14 to 2.16 (0.0843 to 0.0850)	P	2.44 to 2.46 (0.0961 to 0.0969)
       C	1.89 to 1.91 (0.0744 to 0.0752)	J	2.19 to 2.21 (0.0862 to 0.0870)	Q	2.49 to 2.51 (0.0980 to 0.0988)
       D	1.94 to 1.96 (0.0764 to 0.0772)	K	2.24 to 2.26 (0.0882 to 0.0890)	R	2.54 to 2.56 (0.1000 to 0.1008)
       E	1.99 to 2.01 (0.0783 to 0.0791)	L	2.29 to 2.31 (0.0902 to 0.0909)	S	2.59 to 2.61 (0.1020 to 0.1028)
       F	2.04 to 2.06 (0.0803 to 0.0811)	M	2.34 to 2.36 (0.0921 to 0.0929)	T	2.64 to 2.66 (0.1039 to 0.1047)

    5. Remove the 6 bolts from the manual transmission case.

    6. Remove the 12 bolts from the front transaxle case.

    7. Remove the manual transmission case from the front transaxle case.

    8. Remove the No. 2 output shaft assembly from the front transaxle case.

    9. Remove the differential gear assembly from the front transaxle case.

17. INSTALL TRANSMISSION MAGNET

    1. 

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

18. INSTALL DIFFERENTIAL GEAR ASSEMBLY

    1. 

       Coat the front differential case tapered roller bearings with gear oil and install the differential gear assembly to the front transaxle case.

19. INSTALL TRANSMISSION OIL SEPARATOR

    1. 

       Install the transmission oil separator to the front transaxle case with the 2 bolts.

       8.5 N*m

       87 kgf*cm

       75 in.*lbf

20. INSTALL INPUT SHAFT, NO. 1 OUTPUT SHAFT AND NO. 2 OUTPUT SHAFT

    1. 

       Install the input shaft assembly, No. 1 output shaft assembly and No. 2 output shaft assembly at the same time.

21. INSTALL REVERSE IDLER GEAR

    1. Clean and degrease the installation holes in the reverse idler gear shaft.

    2. 

       *1	Reverse Idler Gear
       *2	Needle Roller Bearing
       *3	Reverse Idler Thrust Washer
       *4	Reverse Idler Gear Shaft

       Coat the reverse idler gear, needle roller bearing, and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.

       Tip:

       Make sure that the protruding part on the reverse idler thrust washer is fitted into the groove of the reverse idler shaft.

    3. 

       Install the reverse idler gear shaft by sliding and lifting it.

    4. 

       *a	Align the mark with the hole

       Align the mark of the reverse idler gear shaft with the hole of the bolt.

22. INSTALL REVERSE SHIFT FORK

    1. 

       Install the reverse shift fork to the No. 2 output shaft assembly.

23. INSTALL NO. 3 GEAR SHIFT FORK

    1. 

       Install the No. 3 gear shift fork to the No. 2 output shaft assembly.

24. INSTALL 5TH AND 6TH SHIFT FORK SHAFT

    1. Clean and degrease the bolt and installation holes in the 5th and 6th shift fork shaft.

    2. 

       Install the 5th and 6th shift fork shaft to the front transaxle case.

    3. 

       *a	Adhesive 1344

       Apply adhesive to 2 or 3 threads on the end of the bolt.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. 

       Install the bolt to the No. 3 gear shift fork.

       19.6 N*m

       200 kgf*cm

       14 ft.*lbf

25. INSTALL REVERSE SHIFT FORK SHAFT

    1. Clean and degrease the bolt and installation holes in the reverse shift fork shaft.

    2. 

       Install the reverse shift fork shaft to the front transaxle case.

    3. 

       *a	Adhesive 1344

       Apply adhesive to 2 or 3 threads on the end of the bolt.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. 

       Install the bolt to the reverse shift fork.

       19.6 N*m

       200 kgf*cm

       14 ft.*lbf

26. INSTALL SHIFT ARM

    1. 

       Install the shift arm to the front transaxle case.

27. INSTALL NO. 1 GEAR SHIFT FORK

    1. 

       Install the No. 1 gear shift fork to the No. 1 output shaft assembly.

28. INSTALL NO. 5 GEAR SHIFT FORK SHAFT

    1. 

       *1	Slotted Spring Pin
       *a	Depth

       Install the No. 3 gear shift head to the No. 5 gear shift fork shaft.

    2. Using a 5 mm pin punch and hammer, install a new slotted spring pin into the No. 3 gear shift head.

       Standard Depth

       -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

    3. 

       Install the No. 5 gear shift fork shaft to the front transaxle case.

    4. 

       Install the shift arm to the No. 5 gear shift fork shaft.

    5. 

       Install the pin to the shift arm.

    6. 

       Using a brass bar and hammer, install a new E-ring to the pin.

29. INSTALL NO. 2 GEAR SHIFT FORK

    1. 

       Install the No. 2 gear shift fork to the No. 1 output shaft assembly.

30. INSTALL 3RD AND 4TH SHIFT FORK SHAFT

    1. 

       Install the No. 2 gear shift head to the 3rd and 4th shift fork shaft.

    2. Install the 3rd and 4th shift fork shaft to the front transaxle case.

    3. 

       *1	Slotted Spring Pin
       *a	Depth

       Using a 5 mm pin punch and hammer, install a new slotted spring pin into the No. 2 gear shift fork.

       Standard Depth

       -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

    4. 

       *1	Slotted Spring Pin
       *a	Depth

       Using a 5 mm pin punch and hammer, install a new slotted spring pin into the No. 2 gear shift head.

       Standard Depth

       -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

31. INSTALL 1ST AND 2ND SHIFT FORK SHAFT

    1. Clean and degrease the bolt and installation holes in the 1st and 2nd shift fork shaft.

    2. 

       Install the 1st and 2nd shift fork shaft to the front transaxle case.

    3. 

       *a	Adhesive 1344

       Apply adhesive to 2 or 3 threads on the end of the bolt.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. 

       Install the bolt to the No. 1 gear shift fork.

       19.6 N*m

       200 kgf*cm

       14 ft.*lbf

32. INSTALL TRANSMISSION OIL SEPARATOR

    1. 

       Install the transmission oil separator to the manual transmission case with the 2 bolts.

       8.5 N*m

       87 kgf*cm

       75 in.*lbf

33. INSTALL NO. 1 OIL RECEIVER PIPE

    1. 

       Install the No. 1 oil receiver pipe to the manual transmission case.

       Note:

       Do not damage the No. 1 oil receiver pipe.

34. INSTALL MANUAL TRANSMISSION CASE

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

       Note:

       Make sure that there is no manual transaxle oil on the contact surfaces.

    2. 

       *a

       FIPG

       Apply FIPG to the manual transmission case as shown in the illustration.

       FIPG

       Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

       Note:

       Install the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

    3. 

       Use 2 snap ring pliers to keep the snap rings stretched and install the manual transmission case.

    4. 

       *a	Service Hole
       *b	8.5 mm (0.335 in. )
       *c	9.3 mm (0.366 in. )

       Install the bolt to the No. 1 output shaft assembly and lift the bolt from the service hole as shown in the illustration. Make sure that the snap rings are positioned correctly in the bearing grooves by checking that the distances between the centers of the snap ring holes are as shown in the illustration.

    5. 

       Install the manual transmission case to the front transaxle case with the 12 bolts.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

    6. 

       Install the 6 bolts to the manual transmission case.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

35. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    1. Clean and degrease the bolt.

    2. 

       *a	Adhesive 1344

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

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

       Install the reverse idler gear shaft bolt and a new gasket to the manual transmission case.

       80 N*m

       816 kgf*cm

       59 ft.*lbf

36. INSTALL SHIFT DETENT BALL

    1. Clean and degrease the 4 detent ball plugs and installation holes in the manual transmission case.

    2. 

       *a	Adhesive 1344

       Apply adhesive to 2 or 3 threads on the ends of 4 detent ball plugs.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

       *1	Shift Detent Ball
       *2	Spring
       *3	Spring Seat

       Install the 4 shift detent balls, 4 springs, 4 spring seats and 4 detent ball plugs to the front transaxle case using a 6 mm hexagon wrench.

       22.4 N*m

       228 kgf*cm

       17 ft.*lbf

37. INSTALL MANUAL TRANSMISSION CASE PLUG

    1. Remove any remaining seal packing from the contact surfaces of the manual transmission case.

       Note:

       Make sure that there is no manual transaxle oil on the contact surfaces.

    2. Clean and degrease the 2 manual transmission case plugs and installation holes in the manual transmission case.

    3. 

       *a	FIPG
       *b	Manual Transmission Case Plug (A)
       *c	Manual Transmission Case Plug (B)

       Apply FIPG to the manual transmission case as shown in the illustration.

       FIPG

       Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

       Note:

       Install the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

    4. 

       Apply adhesive to 2 or 3 threads on the ends of the 2 manual transmission case plugs.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Install the manual transmission case plugs to the manual transmission case.

       Manual Transmission Case Plug (A)

       55 N*m

       561 kgf*cm

       41 ft.*lbf

       Manual Transmission Case Plug (B)

       22.4 N*m

       228 kgf*cm

       17 ft.*lbf

38. INSTALL O-RING

    1. 

       *1	O-ring
       *2	Shift and Select Pin

       Coat a new O-ring with the MP grease, and install it to the shift and select pin.

39. INSTALL SHIFT AND SELECT PIN

    1. 

       *a	Press and hold
       *b	Push in the shift and select pin

       Install the spring.

    2. While pressing in the shift and select pin in as far as it will go, push in the shift and select pin to install it.

40. INSTALL MANUAL TRANSMISSION FILLER PLUG

    1. 

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

       39.2 N*m

       400 kgf*cm

       29 ft.*lbf

41. INSTALL DRAIN PLUG

    1. 

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

       39.2 N*m

       400 kgf*cm

       29 ft.*lbf

42. INSTALL TRANSMISSION CASE OIL SEAL

    1. Coat a new transmission case oil seal lip with MP grease.

    2. 

       *a

       Depth

       Using SST and a hammer, install the transmission case oil seal to the manual transmission case.

       09608-10010

       09950-70010

       09951-07200

       Standard Depth

       -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

       Note:

       Do not damage the transmission case oil seal lip.

43. INSTALL TRANSAXLE CASE OIL SEAL

    1. Coat a new transaxle case oil seal lip with MP grease.

    2. 

       *a

       Depth

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

       09608-32010

       09950-70010

       09951-07200

       Standard Depth

       -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

       Note:

       Do not damage the transaxle case oil seal lip.

44. INSTALL SHIFT AND SELECT LEVER ASSEMBLY

    Click here

45. INSTALL SHIFT GATE PIN

    1. Clean and degrease the shift gate pin and installation holes in the manual transmission case.

    2. 

       *a	Adhesive 1344

       Apply adhesive to 2 or 3 threads on the end of the shift gate pin.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

       Install the shift gate pin to the manual transmission case.

       30 N*m

       306 kgf*cm

       22 ft.*lbf

46. INSTALL NO. 2 LOCK BALL ASSEMBLY

    1. Clean and degrease the No. 2 lock ball assembly and installation holes in the manual transmission case.

    2. 

       *a	Adhesive 1344

       Apply adhesive to 2 or 3 threads on the end of the No. 2 lock ball assembly.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

       Install the No. 2 lock ball assembly to the manual transmission case.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

47. INSTALL NO. 1 LOCK BALL ASSEMBLY

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

    2. 

       *a	Adhesive 1344

       Apply adhesive to 2 or 3 threads on the end of the No. 1 lock ball assembly.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

       Install the No. 1 lock ball assembly to the manual transmission case.

       39.2 N*m

       400 kgf*cm

       29 ft.*lbf

48. INSTALL NEUTRAL POSITION SWITCH

    1. 

       Using SST, install the neutral position switch and a new gasket to the manual transmission case.

       09816-30010

       40.2 N*m

       410 kgf*cm

       30 ft.*lbf

49. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    1. 

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

       09816-30010

       40.2 N*m

       410 kgf*cm

       30 ft.*lbf

50. INSTALL SELECTING BELL CRANK ASSEMBLY

    1. 

       Install the selecting bell crank assembly to the manual transmission case with the 2 bolts.

       20 N*m

       204 kgf*cm

       15 ft.*lbf

51. INSTALL CONTROL CABLE BRACKET

    1. 

       Install the control cable bracket to the manual transmission case with the 3 bolts.

       17 N*m

       173 kgf*cm

       13 ft.*lbf

52. INSTALL CLUTCH RELEASE FORK BOOT

    Click here

53. INSTALL RELEASE FORK SUPPORT

    Click here

54. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here

55. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here