MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE

1. INSTALL SHIFT FORK SHAFT BEARING

   1. 

      Using SST and a press, press in 4 new shift fork shaft bearings.

      09820-00031

      Standard depth

      0 to 0.5 mm (0 to 0.0197 in.)

2. INSTALL OUTPUT SHAFT COVER

   1. 

      Install the output shaft cover as shown in the illustration.

      Table 1. Text in Illustration

      *a	Protrusion
      *b	Groove

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

   1. 

      Using SST and a hammer, tap in the No. 2 output shaft front bearing outer race.

      09950-70010

      09951-07100

      09951-00710

4. INSTALL OUTPUT SHAFT COVER

   1. 

      Install the output shaft cover as shown in the illustration.

      Table 2. Text in Illustration

      *a	Protrusion
      *b	Groove

5. INSTALL OUTPUT SHAFT FRONT BEARING

   1. 

      Coat a new front bearing with gear oil. Then, using SST and a press, install the bearing to the front transaxle case.

      09223-15020

   2. 

      Install the bearing lock plate bolt.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

6. INSTALL FRONT TRANSAXLE CASE OIL SEAL

   1. 

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

      09950-60010

      09951-00580

      Standard depth

      4.4 to 5.0 mm (0.174 to 0.196 in.)

   2. Coat the lip of the oil seal with MP grease.

7. INSTALL INPUT SHAFT FRONT BEARING

   1. 

      Coat a new input shaft front bearing with gear oil. Then, using SST and a press, install the bearing to the front transaxle case.

      09223-00010

   2. 

      Install the bearing lock plate bolt.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

8. INSTALL INPUT AND OUTPUT SHAFT REAR BEARING SHAFT SNAP RING

   1. 

      Using snap ring expander, install the 2 snap rings.

9. INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING

   1. 

      Using SST and a press, press in a new shift and select lever shaft needle roller bearing.

      09285-76010

      Standard distance

      177.8 to 178.7 mm (7.00 to 7.03 in.)

10. INSTALL SHIFT FORK SHAFT BEARING

    1. 

       Using SST and a press, press in 4 new shift fork shaft bearings.

       09307-12010

       09820-00031

       Standard distance A

       168.2 to 169.3 mm (6.63 to 6.66 in.)

       Standard distance B

       162.2 to 163.3 mm (6.39 to 6.42 in.)

11. INSTALL FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE

    1. 

       Using SST and a hammer, tap in the front differential case front bearing outer race.

       09950-70010

       09951-00910

       09951-07150

12. INSTALL FRONT DIFFERENTIAL CASE REAR BEARING OUTER RACE

    1. 

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

    2. 

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

       09950-60010

       09951-00910

       09950-70010

       09951-07100

13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

    1. 

       Install the differential case assembly to the front transaxle case.

    2. 

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

       29 N*m

       300 kgf*cm

       22 ft.*lbf

    3. 

       Install the 6 bolts to the front transaxle case side.

       29 N*m

       300 kgf*cm

       22 ft.*lbf

    4. Turn the differential case in both directions and make sure it turns smoothly.

    5. 

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

       09564-33010

       New bearing preload

       1.00 to 2.49 N*m (10.2 to 25.4 kgf*cm, 8.85 to 22.04 in.*lbf)

       Table 3. Text in Illustration

       *a

       Mark

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

       Standard Shim Thickness

       Mark	Specified Condition	Mark	Specified Condition	Mark	Specified Condition
       0	1.99 to 2.01 mm (0.0783 to 0.0791 in.)	6	2.29 to 2.31 mm (0.0902 to 0.0909 in.)	C	2.59 to 2.61 mm (0.1020 to 0.1027 in.)
       1	2.04 to 2.06 mm (0.0803 to 0.0811 in.)	7	2.34 to 2.36 mm (0.0921 to 0.0929 in.)	D	2.64 to 2.66 mm (0.1040 to 0.1047 in.)
       2	2.09 to 2.11 mm (0.0823 to 0.0831 in.)	8	2.39 to 2.41 mm (0.0941 to 0.0949 in.)	E	2.69 to 2.71 mm (0.1060 to 0.1066 in.)
       3	2.14 to 2.16 mm (0.0843 to 0.0850 in.)	9	2.44 to 2.46 mm (0.0961 to 0.0969 in.)	F	2.74 to 2.76 mm (0.1079 to 0.1086 in.)
       4	2.19 to 2.21 mm (0.0862 to 0.0870 in.)	A	2.49 to 2.51 mm (0.0981 to 0.0988 in.)	G	2.79 to 2.81 mm (0.1099 to 0.1106 in.)
       5	2.24 to 2.26 mm (0.0882 to 0.0890 in.)	B	2.54 to 2.56 mm (0.1000 to 0.1007 in.)	H	2.84 to 2.86 mm (0.1119 to 0.1125 in.)

    6. Remove the 18 bolts and manual transmission case.

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

    1. 

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

       Table 4. Text in Illustration

       *a

       Mark

       Tip:

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

    2. 

       Using SST and a press, press in the No. 2 output shaft rear bearing outer race.

       09950-60010

       09951-00650

       09950-70010

       09951-07200

15. ADJUST NO. 2 OUTPUT SHAFT REAR BEARING PRELOAD

    1. 

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

    2. 

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

       29 N*m

       300 kgf*cm

       22 ft.*lbf

    3. 

       Install the 6 bolts to the front transaxle case side.

       29 N*m

       300 kgf*cm

       22 ft.*lbf

    4. 

       Using SST and a torque wrench, 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.

       09564-33010

       New bearing preload

       3.9 to 5.5 N*m (40 to 56 kgf*cm, 35 to 49 in.*lbf)

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

       Standard Bearing Shim Thickness

       Mark	Specified Condition	Mark	Specified Condition	Mark	Specified Condition
       A	1.79 to 1.81 mm (0.0705 to 0.0713 in.)	G	2.09 to 2.11 mm (0.0823 to 0.0831 in.)	N	2.39 to 2.41 mm (0.0941 to 0.0949 in.)
       B	1.84 to 1.86 mm (0.0724 to 0.0732 in.)	H	2.14 to 2.16 mm (0.0843 to 0.0850 in.)	P	2.44 to 2.46 mm (0.0961 to 0.0969 in.)
       C	1.89 to 1.91 mm (0.0744 to 0.0752 in.)	J	2.19 to 2.21 mm (0.0862 to 0.0870 in.)	Q	2.49 to 2.51 mm (0.0980 to 0.0988 in.)
       D	1.94 to 1.96 mm (0.0764 to 0.0772 in.)	K	2.24 to 2.26 mm (0.0882 to 0.0890 in.)	R	2.54 to 2.56 mm (0.1000 to 0.1007 in.)
       E	1.99 to 2.01 mm (0.0783 to 0.0791 in.)	L	2.29 to 2.31 mm (0.0902 to 0.0909 in.)	S	2.59 to 2.61 mm (0.1020 to 0.1027 in.)
       F	2.04 to 2.06 mm (0.0803 to 0.0811 in.)	M	2.34 to 2.36 mm (0.0921 to 0.0929 in.)	T	2.64 to 2.66 mm (0.1040 to 0.1047 in.)

    5. Remove the 18 bolts and manual transmission case.

    6. Remove the output shaft assembly from the front transaxle case.

    7. Remove the differential case from the front transaxle case.

16. INSTALL TRANSMISSION MAGNET

    1. 

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

17. INSTALL FRONT DIFFERENTIAL CASE ASSEMBLY

    1. 

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

18. INSTALL TRANSMISSION OIL SEPARATOR

    1. 

       for Front Transaxle Case Side:

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

       8.5 N*m

       87 kgf*cm

       75 in.*lbf

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

    1. 

       Install the 3 shafts at the same time.

20. INSTALL REVERSE IDLER GEAR

    1. 

       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 of the reverse idler thrust washer fits into the groove of the reverse idler shaft.

    2. 

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

    3. 

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

       Table 5. Text in Illustration

       *a	Alignment Mark

21. INSTALL REVERSE SHIFT FORK

    1. 

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

22. INSTALL NO. 3 GEAR SHIFT FORK

    1. 

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

23. INSTALL 5TH AND 6TH SHIFT FORK SHAFT

    1. 

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

    2. Coat the bolt with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

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

       20 N*m

       200 kgf*cm

       14 ft.*lbf

24. INSTALL REVERSE SHIFT FORK SHAFT

    1. 

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

    2. Coat the bolt with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

       Install the bolt to the reverse shift fork shaft.

       20 N*m

       200 kgf*cm

       14 ft.*lbf

25. INSTALL SHIFT ARM

    1. 

       Install the shaft arm to the front transaxle case.

26. INSTALL NO. 1 GEAR SHIFT FORK

    1. 

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

27. INSTALL NO. 5 GEAR SHIFT FORK SHAFT

    1. 

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

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

       Standard depth

       -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

    3. 

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

    4. 

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

    5. 

       Install the shift arm pin to the shift arm.

    6. 

       Using a brass bar and hammer, tap a new E-ring to the shift arm pin.

28. INSTALL NO. 2 GEAR SHIFT FORK

    1. 

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

29. 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 transaxle case.

    3. 

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

       Standard depth

       -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

    4. 

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

       Standard depth

       -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

30. INSTALL 1ST AND 2ND SHIFT FORK SHAFT

    1. 

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

    2. Coat the bolt with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. 

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

       20 N*m

       200 kgf*cm

       14 ft.*lbf

31. INSTALL TRANSMISSION OIL SEPARATOR

    1. 

       for Manual Transmission Case Side:

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

       8.5 N*m

       87 kgf*cm

       75 in.*lbf

32. 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.

33. INSTALL MANUAL TRANSMISSION CASE

    1. 

       Apply seal packing to the manual transmission case as shown in the illustration.

       Seal packing

       Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

       Seal diameter

       1.2 mm (0.0472 in.)

       Table 6. Text in Illustration

       *a	Seal Packing

       Note:

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

    2. 

       Using 2 pairs of snap ring pliers to keep the snap ring stretched, install the manual transmission case.

    3. 

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

       Table 7. Text in Illustration

       *a	less than 8.5 mm (0.335 in.)
       *b	less than 9.3 mm (0.366 in.)

    4. 

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

       29 N*m

       300 kgf*cm

       22 ft.*lbf

    5. 

       Install the 6 bolts to the front transaxle case.

       29 N*m

       300 kgf*cm

       22 ft.*lbf

34. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    1. 

       Coat the reverse idler gear shaft bolt with adhesive, and install a new gasket and the shaft bolt.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

       80 N*m

       816 kgf*cm

       59 ft.*lbf

35. INSTALL BALL

    1. 

       Coat the 4 detent ball plugs with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Using a 6 mm hexagon wrench, install the 4 balls, 4 springs, 4 spring seats and 4 detent ball plugs.

       22 N*m

       228 kgf*cm

       17 ft.*lbf

36. INSTALL MANUAL TRANSMISSION CASE PLUG

    1. 

       Apply seal packing to the manual transmission case as shown in the illustration.

       Seal packing

       Toyota Genuine Seal Packing, Three Bond 1207B or equivalent

       Table 8. Text in Illustration

       *a	Seal Packing

    2. Coat the transmission case plug with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the manual transmission case plug to the manual transmission case.

       for case plug A

       55 N*m

       561 kgf*cm

       41 ft.*lbf

       for case plug B

       22 N*m

       228 kgf*cm

       17 ft.*lbf

37. INSTALL O-RING

    1. 

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

38. INSTALL SHIFT AND SELECT PIN

    1. 

       Install the spring.

    2. While pressing in the shift and select pin *1 in as far as it will go, push in the shift and select pin *2 to install it.

39. INSTALL MANUAL TRANSMISSION FILLER PLUG

    1. 

       Install a new gasket and the manual transmission filler plug.

       39 N*m

       400 kgf*cm

       29 ft.*lbf

40. INSTALL DRAIN PLUG

    1. 

       Install a new gasket and the drain plug.

       39 N*m

       400 kgf*cm

       29 ft.*lbf

41. INSTALL TRANSAXLE CASE OIL SEAL LH

    Click here

42. INSTALL TRANSAXLE CASE OIL SEAL RH

    Click here

43. INSTALL SHIFT AND SELECT LEVER ASSEMBLY

    1. 

       Align the 4 shift fork shafts as shown in the illustration.

    2. 

       Apply seal packing to the transmission case as shown in the illustration

       Seal packing

       Toyota Genuine Seal Packing, Three Bond 1207B or equivalent

       Table 9. Text in Illustration

       *a	Seal Packing

       Note:

       Assemble parts within 10 minutes of application otherwise, packing (FIPG) material must be removed and reapplied.

    3. Coat the 4 bolts with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. 

       Install the shift and select lever assembly to the manual transmission case with the 4 bolts.

       19 N*m

       190 kgf*cm

       14 ft.*lbf

44. INSTALL SHIFT GATE PIN

    1. 

       Coat the shift gate pin with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the shift gate pin to the manual transmission case.

       30 N*m

       306 kgf*cm

       22 ft.*lbf

45. INSTALL NO. 2 LOCK BALL ASSEMBLY

    1. 

       Coat the No. 2 lock ball with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

       29 N*m

       300 kgf*cm

       22 ft.*lbf

46. INSTALL NEUTRAL POSITION SWITCH (w/ Stop And Start System)

    Click here

47. INSTALL NO. 1 LOCK BALL ASSEMBLY

    1. 

       Coat the No. 1 lock ball with adhesive.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the No. 1 lock ball onto the manual transmission case.

       39 N*m

       400 kgf*cm

       29 ft.*lbf

48. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

49. INSTALL SELECTING BELLCRANK ASSEMBLY

    1. 

       Install the selecting bellcrank to the manual transmission case with the 2 bolts.

       20 N*m

       204 kgf*cm

       15 ft.*lbf

50. INSTALL CONTROL CABLE BRACKET

    1. 

       Install the control cable bracket to the manual transaxle with the 3 bolts.

       17 N*m

       173 kgf*cm

       13 ft.*lbf

51. INSTALL RELEASE FORK SUPPORT

    Click here

52. INSTALL CLUTCH RELEASE FORK BOOT

    Click here

53. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

54. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here