MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL OUTPUT SHAFT COVER


    1. A01VHFNE01
      Text in Illustration
      *a Protrusion
      *b Oil Groove

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

  2. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A01VENBE05

      Using SST and a press, press in the output shaft front bearing outer race to the front transaxle case.

      SST
      09950-60010   ( 09951-00510 )
      09950-70010   ( 09951-07150 )

  3. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01VKLVE01

      Using SST and a press, press in the front differential case front tapered roller bearing outer race to the front transaxle case.

      SST
      09350-32014   ( 09351-32111, 09351-32130 )

  4. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01VHRAE06

      Install the differential case shim to the manual transmission case.

      Tech Tips

      When reusing the front differential case rear tapered roller bearing, reuse the original shim. When installing a new front differential case rear tapered roller bearing, first select and install a shim which is thinner than the original.

    2. Using SST and a press, press in the front differential case rear tapered roller bearing outer race.

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07100 )

  5. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01VF1Q

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

    2. A01VGMH

      Install the manual transmission case with the 13 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

      Tech Tips

      From manual transmission case side: 8 bolts From front transaxle case side: 5 bolts

    3. A01VKTLE05

      Using SST and a torque wrench, turn the differential case right and left 2 or 3 times to allow the bearings to settle.

      SST
      09564-32011

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

      SST
      09564-32011
      New bearing preload
      0.78 to 1.57 N*m (7.96 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf)
      Used bearing preload
      0.49 to 0.98 N*m (5.00 to 1.00 kgf*cm, 4.33 to 8.67 in.*lbf)

      If the preload 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.

      Plate Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90564-41065 01 1.100 (0.0433)
      90564-41066 02 1.150 (0.0453)
      90564-41067 03 1.200 (0.0472)
      90564-41068 04 1.250 (0.0492)
      90564-41069 05 1.300 (0.0512)
      90564-41070 06 1.350 (0.0532)
      90564-41071 07 1.400 (0.0551)
      90564-41072 08 1.450 (0.0571)
      90564-41073 09 1.500 (0.0590)
      90564-41074 10 1.550 (0.0610)
      90564-41075 11 1.600 (0.0630)
      90564-41076 12 1.650 (0.0650)
      90564-41077 13 1.700 (0.0669)
      90564-41078 14 1.750 (0.0689)
      90564-41079 15 1.800 (0.0709)
      90564-41080 16 1.850 (0.0728)
      90564-41081 17 1.900 (0.0748)
      90564-41082 18 1.950 (0.0768)
      90564-41083 19 2.000 (0.0787)
      90564-41014 AA 2.100 (0.0827)
      90564-41015 BB 2.150 (0.0847)
      90564-41016 CC 2.200 (0.0866)
      90564-41017 DD 2.250 (0.0886)
      90564-41018 EE 2.200 (0.0866)
      90564-41019 FF 2.300 (0.0906)
      90564-41020 GG 2.400 (0.0945)
      90564-41021 HH 2.450 (0.0965)
      90564-41022 JJ 2.500 (0.0984)
      90564-41023 KK 2.550 (0.0915)
      90564-41024 LL 2.600 (0.1004)
      90564-41025 MM 2650 (0.1043)
      90564-41026 NN 2.700 (0.1063)
      90564-41027 PP 2.750 (0.1083)
      90564-41028 QQ 2.800 (0.1102)
      90564-41029 RR 2.850 (0.1122)
      90564-41030 SS 2.900 (0.1142)
      90564-41031 TT 2.950 (0.1161)
      90564-41032 UU 3.000 (0.1181)

      Tech Tips


      • Select a thicker plate shim to increase the preload, or a thinner plate shim to decrease the preload.

      • Make a memo, as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.

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

    6. Remove the differential case assembly from the front transaxle case.

  6. INSTALL REAR OUTPUT SHAFT BEARING


    1. A01VJOL

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

      Tech Tips

      When reusing the rear output shaft tapered roller bearing, reuse the original shim. When installing a new rear output shaft tapered roller bearing, first select and install a shim which is thinner than the original.

    2. A01VHZFE05

      Using SST and a press, press in the rear output shaft bearing outer race to the manual transmission case.

      SST
      09950-60010   ( 09951-00570 )
      09950-70010   ( 09951-07200 )

  7. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A01VGAS

      Install the output shaft assembly and the differential case to the front transaxle case.

    2. A01VGMH

      Install the manual transmission case to the front transaxle case with the 13 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

      Tech Tips

      Manual transmission case side: 8 bolts

      Front transaxle case side: 5 bolts

    3. A01VM6GE01

      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.

      SST
      09564-32011

    4. Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing preload using the following formula.

      Formula
      Value A - Differential side bearing preload = Output shaft bearing preload
      Preload (at starting)
      New bearing
      3.37 to 6.73 N*m (34.36 to 68.63 kgf*cm, 29.82 to 59.56 in.*lbf)
      Used bearing
      2.10 to 4.20 N*m (21.41 to 42.83 kgf*cm, 18.59 to 37.17 in.*lbf)

      If the preload 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 reload is within the specification.

      Bearing Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90564-38001 A 1.550 (0.0610)
      90564-38002 B 1.600 (0.0630)
      90564-38003 C 1.650 (0.0650)
      90564-38004 D 1.700 (0.0669)
      90564-38005 E 1.750 (0.0689)
      90564-38006 F 1.800 (0.0709)
      90564-38007 G 1.850 (0.0728)
      90564-38008 H 1.900 (0.0748)
      90564-38009 J 1.950 (0.0768)
      90564-38010 K 2.000 (0.0787)
      90564-38011 L 2.050 (0.0807)
      90564-38012 M 2.100 (0.0827)
      90564-38013 N 2.150 (0.0846)
      90564-38014 P 2.200 (0.0866)
      90564-38015 Q 2.250 (0.0886)

      Note

      Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

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

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

  8. ADJUST REAR INPUT SHAFT BEARING SHIM


    1. A01VFI7E01
      Text in Illustration
      *1 Rear Input Shaft Bearing Shim
      *a Dimension A
      *b Dimension B

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

    2. Calculate the rear input shaft bearing shim clearance using the following formula.

      Formula
      Dimension B - Dimension A - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

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

      Plate Washer Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90564-38006 F 1.800 (0.0709)
      90564-38007 G 1.850 (0.0728)
      90564-38008 H 1.900 (0.0748)
      90564-38009 J 1.950 (0.0768)
      90564-38010 K 2.000 (0.0787)
      90564-38011 L 2.050 (0.0807)
      90564-38012 M 2.100 (0.0827)
      90564-38013 N 2.150 (0.0846)
      90564-38014 P 2.200 (0.0866)
      90564-38015 Q 2.250 (0.0886)
      90564-38016 R 2.300 (0.0906)
      90564-38017 S 2.350 (0.0925)
      90564-38018 T 2.400 (0.0945)

    3. Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the selected one.

  9. INSTALL TRANSMISSION CASE OIL SEAL

    Click here

  10. INSTALL TRANSAXLE CASE OIL SEAL

    Click here

  11. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A01VG1N

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

      SST
      09710-20011   ( 09710-06071 )
      09950-70010   ( 09951-07150 )
      Standard depth
      14.4 to 14.9 mm (0.567 to 0.586 in.)

      Note

      Do not damage the lip of the oil seal.

    2. Coat the tip of the front transaxle case oil seal with MP grease.

  12. INSTALL TRANSMISSION MAGNET


    1. A01VGW0

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

  13. INSTALL NO. 2 OIL RECEIVER PIPE


    1. A01VF00

      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.

      Note

      Do not damage the No. 2 oil receiver pipe.

  14. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A01VF1Q

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

  15. INSTALL OUTPUT SHAFT ASSEMBLY


    1. Install the output shaft assembly to the front transaxle case.

  16. INSTALL INPUT SHAFT ASSEMBLY


    1. A01VLUF

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

      Note

      Do not damage the lip of the front transaxle case oil seal.

  17. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A01VITG

      Install the No. 2 gear shift fork to the No. 2 gear shift fork shaft.

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

    3. Install the reverse shift fork to No. 2 gear shift fork shaft.

    4. A01VGKQ

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

    5. While aligning the No. 2 gear shift fork with the No. 2 transmission hub sleeve, install the No. 2 gear shift fork shaft together with the No. 2 gear shift fork and reverse shift fork to the front transaxle case.

    6. Coat the gear shift fork No. 2 bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    7. A01VGFP

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

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }
    8. A01VHJ3

      While lifting the reverse shift fork, using a brass bar and hammer, install a new snap ring to the No. 2 gear shift fork shaft.

    9. A01VKEO

      Install the straight pin to the reverse shift fork.

  18. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A01VGSW

      Install the No. 3 gear shift fork to the No. 3 transmission hub sleeve.

    2. A01VDXX

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

    3. A01VH7E

      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.

    4. Using a pin punch and hammer, tap in 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.

    5. A01VLN5

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

    6. Install the straight pin to the No. 3 gear shift fork.

  19. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A01VK9E

      Install the No. 1 gear shift fork to the No. 1 transmission hub sleeve.

    2. A01VDXX

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

    3. A01VI61

      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.

    4. Using a pin punch and hammer, tap in 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.

    5. Coat the gear shift fork No. 1 bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }

  20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. Coat the reverse idler gear shaft with gear oil.

    2. A01VH2W

      Install the reverse idler gear sub-assembly to the front transaxle case, and then pass the reverse idler gear shaft through the reverse idler gear sub-assembly to install it.

    3. A01VJVEE02
      Text in Illustration
      *1 Alignment Mark

      Align the alignment mark on the reverse idler gear shaft with the bolt hole of the front transaxle case as shown in the illustration.

  21. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01VM95E05

      Coat the bolt A with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  22. INSTALL MANUAL TRANSMISSION CASE


    1. A01VFLN

      the manual transmission case as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Note


      • Remove any oil from the contact surfaces.

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

    2. A01VGMH

      Install the manual transmission case to the front transaxle case with the 13 bolts.

      Tech Tips

      From manual transmission case side: 8 bolts

      From front transaxle case side: 5 bolts

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  23. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A01VEBO

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  24. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. Install the select return compression spring to the manual transmission case.

    2. A01VLIL

      Apply seal packing to the control shaft cover of the shift and select lever shaft assembly as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    3. A01VIESE02

      Coat the bolt A with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  25. INSTALL SHIFT GATE PIN


    1. Coat the shift gate pin with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      37 N*m  { 375 kgf*cm, 27 ft.*lbf }

  26. INSTALL CONTROL CABLE BRACKET


    1. Coat the 2 bolts with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the control cable bracket with the 2 bolts.

      Torque:
      11 N*m  { 115 kgf*cm, 8.3 ft.*lbf }

  27. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. Using SST, install the back-up light switch with a new gasket onto the manual transmission case.

      SST
      09817-16011
      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }

    2. Engage the 2 clamps and connect the wire harness connector.

  28. INSTALL MANUAL TRANSMISSION CASE PLUG


    1. Install the manual transaxle case plug with a new gasket.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  29. INSTALL CLUTCH RELEASE FORK LEVER

    Click here

  30. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here