PROCEDURE
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
Using SST and a press, install a new front differential case front tapered roller bearing to the front differential case assembly.
Using SST and a press, install a new front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer to the front transaxle case.
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
Using SST and a press, install a new front differential case rear tapered roller bearing to the front differential case assembly.
Using SST and a press, install a new front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer to the manual transmission case.
Tech Tips
Use a front differential case rear plate washer of the same thickness as the removed one.
ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
Coat the front differential case assembly with gear oil and install it to the front transaxle case. (for Used Bearing)
Install the manual transmission case to the front transaxle case with the 16 bolts.
| *1 | Front Differential Case Rear Plate Washer |
Using SST and a torque wrench, turn the front differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
Using SST and a torque wrench, measure the preload.
| Preload (at starting) |
|---|
| New bearing |
| 1.0 to 1.6 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf) |
| Used bearing |
| 0.8 to 1.3 N*m (9 to 13 kgf*cm, 8 to 12 in.*lbf) |
If the preload is out of specification, replace the front differential case rear plate washer with one of a different thickness. Use the table below to select a front differential case rear plate washer which will ensure that the preload is within the specification.
| Front Differential Case Rear Plate Washer Thickness | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Tech Tips
Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.
Make a memo as the torque values will be needed to adjust output shaft bearing preload.
Remove the 16 bolts and manual transmission case from the front transaxle case.
Remove the front differential case assembly from the front transaxle case.
INSTALL FRONT OUTPUT SHAFT BEARING (OUTER RACE)
Install the output shaft cover to the front transaxle case.
Note
Insert the output shaft cover key into the front transaxle case groove.
Using SST and a press, install a new front output shaft bearing (outer race) to the front transaxle case.
INSTALL REAR OUTPUT SHAFT BEARING (OUTER RACE)
Using SST and a press, install a new rear output shaft bearing (outer race) with the rear output shaft bearing shim to the manual transmission case.
Tech Tips
Use a rear output shaft bearing shim of the same thickness as the removed one.
ADJUST OUTPUT SHAFT BEARING PRELOAD
Coat the front differential case assembly with gear oil and install it to the front transaxle case. (for Used Bearing)
Coat the output shaft assembly with gear oil and install it to the front transaxle case. (for Used Bearing)
Install the manual transmission case to the front transaxle case with the 16 bolts.
| *1 | Rear Output Shaft Bearing Shim |
Using SST and a torque wrench, turn the front differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
Using SST and a torque wrench, measure the preload. Calculate the rear output shaft bearing preload using the following formula.
| Formula |
|---|
| Measured preload - Differential side bearing preload = Output shaft bearing preload |
| Preload (at starting) |
|---|
| New bearing |
| 3.6 to 6.2 N*m (37 to 63 kgf*cm, 32 to 55 in.*lbf) |
| Used bearing |
| 2.3 to 4.0 N*m (24 to 41 kgf*cm, 21 to 35 in.*lbf) |
If the preload is out of specification, 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 | ||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Tech Tips
Select a thicker shim to increase the preload or a thinner shim to decrease the preload.
Remove the 16 bolts and manual transmission case from the front transaxle case.
Remove the output shaft assembly from the front transaxle case.
Remove the front differential case assembly from the front transaxle case.
INSTALL OUTER SHIFT LEVER OIL SEAL
| *a | Depth |
Using SST and a hammer, install a new outer shift lever oil seal to the manual transmission case.
| Standard depth |
|---|
| 0.5 to 1.0 mm (0.0197 to 0.0394 in.) |
Coat the lip of the outer shift lever oil seal with MP grease.
INSTALL OUTER NO. 1 SHIFT LEVER
| *a | Depth |
| *b | Mark |
Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.
| Standard depth |
|---|
| -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) |
Tech Tips
Install the inner No. 1 shift lever with its mark facing outside of the manual transmission case.
Using a 5 mm pin punch and a hammer, install the inner shift lever slotted spring pin to the inner No. 1 shift lever.
INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY
Install the manual transmission oil separator sub-assembly to the manual transmission case with the 4 bolts.
Tech Tips
Make sure that the end tabs of the manual transmission oil separator sub-assembly are inserted in the grooves of the manual transmission case.
INSTALL TRANSMISSION OIL SEPARATOR
Install the transmission oil separator to the manual transmission case with the 2 bolts.
Tech Tips
Make sure that the tip of the transmission oil separator is inserted in the groove of the manual transmission case.
INSTALL NO. 1 OIL RECEIVER PIPE
Install the No. 1 oil receiver pipe to the manual transmission case.
Tech Tips
Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.
INSTALL STRAIGHT PIN
| *a | Protrusion Height |
Using a plastic hammer, tap in 5 new straight pins to the specified protrusion height.
| Protrusion height |
|---|
| 8.5 to 9.5 mm (0.335 to 0.374 in.) |
INSTALL REVERSE RESTRICT PIN ASSEMBLY
Install the reverse restrict pin assembly to the front transaxle case.
INSTALL BREATHER PLUG
Using SST and a hammer, install the breather plug to the front transaxle case.
INSTALL TRANSMISSION OIL SEPARATOR
Install the transmission oil separator to the front transaxle case with the 4 bolts.
INSTALL FRONT TRANSAXLE CASE OIL SEAL
| *a | Depth |
Using SST and a hammer, install a new front transaxle case oil seal to the front transaxle case.
| Standard depth |
|---|
| 0.9 to 1.9 mm (0.0354 to 0.0748 in.) |
Coat the lip of the front transaxle case oil seal with MP grease.
INSTALL TRANSMISSION MAGNET
Clean the transmission magnet and install it to the front transaxle case.
INSTALL INPUT SHAFT COVER
Install the input shaft cover to the manual transmission case.
Note
Insert the input shaft cover key into the manual transmission case groove.
INSTALL REAR INPUT SHAFT BEARING SHIM
Install the rear input shaft bearing shim to the manual transmission case.
Note
Apply MP grease to the shim to prevent it from falling out of the case during reassembly.
| *1 | Manual Transmission Case |
| *2 | Input Shaft Assembly |
| *3 | Front Transaxle Case |
| *a | Dimension A |
| *b | Dimension B |
| *c | Dimension C |
Measure the area between the end of the manual transmission case and the rear input shaft bearing shim (Dimension A).
Measure the area between the end of the front transaxle case and the installation surface of the front input shaft bearing (Dimension B).
Measure the area between both input shaft bearing outer races (Dimension C).
Note
Measure Dimension C with each bearing having no axial clearance.
Calculate the rear input shaft bearing shim value using the following formula.
| Formula |
|---|
| (Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = 0.02 to 0.14 mm (0.000787 to 0.00551 in.) |
If the thickness is out of specification, 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 thickness is within the specification.
| Rear Input Shaft Bearing Shim Thickness | |||||||||||||||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Coat the rear input shaft bearing shim with MP grease and install it to the manual transmission case.
Note
Do not apply MP grease to the oil grooves.
INSTALL FRONT DIFFERENTIAL CASE ASSEMBLY
Coat the front differential case assembly with gear oil and install it to the front transaxle case.
INSTALL INPUT SHAFT ASSEMBLY
Apply gear oil to all sliding and rotating parts.
| *1 | No. 1 Gear Shift Fork Shaft Assembly |
| *2 | Output Shaft Assembly |
Coat the No. 1 gear shift fork shaft assembly with gear oil and install it to the output shaft assembly.
| *1 | No. 2 Gear Shift Fork Shaft Assembly |
| *2 | No. 3 Gear Shift Fork Shaft Assembly |
| *3 | Input Shaft Assembly |
Coat the No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly with gear oil and install them to the input shaft assembly.
Temporarily install the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly, and tie them with a rope or string.
Install the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly to the front transaxle case.
INSTALL OUTER SELECT LEVER OIL SEAL
| *a | Depth |
Using SST and a hammer, install a new outer select lever oil seal to the front transaxle case.
| Standard depth |
|---|
| 0.5 to 1.0 mm (0.0197 to 0.0394 in.) |
Coat the lip of the outer select lever oil seal with MP grease.
INSTALL OUTER SELECT LEVER
| *1 | Inner Select Lever |
| *2 | Outer Select Lever |
| *a | Mark |
Install the outer select lever and inner select lever to the front transaxle case.
Tech Tips
Install the inner select lever with its mark positioned outside of the front transaxle case.
INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
| *1 | Shift and Select Lever Shaft Assembly |
| *2 | Shift Interlock Plate |
| *3 | Inner Select Lever |
Turn the shift and select lever shaft assembly and shift interlock plate counterclockwise and install them to the front transaxle case.
Tech Tips
When installing the inner select lever, make sure to engage it with the shift interlock plate.
Coat the threads of the inner select lever set bolt with adhesive.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Note
To prevent contamination by foreign matter, install immediately after applying adhesive.
Using a 6 mm hexagon socket wrench, install the inner select lever set bolt.
INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
Install the reverse shift arm bracket assembly to the front transaxle case with the 2 bolts.
INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY
Coat the reverse shift fork shaft assembly with gear oil and install it to the front transaxle case.
INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
| *a | Parallel |
Coat the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.
Note
Make sure that the reverse idler gear shaft bolt hole of the reverse idler gear shaft is parallel to the bolt hole on the front transaxle case.
Tech Tips
Raise the edge of the reverse shift arm bracket assembly and install it to the reverse shift fork shaft assembly.
INSTALL MANUAL TRANSMISSION CASE
| *a | Seal Packing (Seal Diameter 1.2 mm (0.0472 in.)) |
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 |
Note
Remove any oil from the contact surfaces.
Assemble the parts within 10 minutes of application. Otherwise, the packing material must be removed and reapplied.
Push the outer No. 1 shift lever and install the manual transmission case to the front transaxle case.
Tech Tips
Pushing on the outer No. 1 shift lever allows the manual transmission case to be installed.
Pull the outer No. 1 shift lever out and turn it counterclockwise.
Install the 16 bolts.
INSTALL OUTER SHIFT LEVER E-RING
Install the outer shift lever E-ring to the outer No. 1 shift lever.
INSTALL FRONT DRIVE SHAFT OIL SEAL LH
| *a | Depth |
Using SST and a hammer, install a new front drive shaft oil seal LH to the manual transmission case.
| Standard depth |
|---|
| 10.6 to 11.6 mm (0.417 to 0.457 in.) |
Note
Do not damage the lip of the front drive shaft oil seal LH.
Coat the lip of the front drive shaft oil seal LH with MP grease.
INSTALL FRONT DRIVE SHAFT OIL SEAL RH
| *a | Depth |
Using SST and a hammer, install a new front drive shaft oil seal RH to the front transaxle case.
| Standard depth |
|---|
| 1.2 to 2.2 mm (0.0472 to 0.0866 in.) |
Note
Do not damage the lip of the front drive shaft oil seal RH.
Coat the lip of the front drive shaft oil seal RH with MP grease.
INSTALL SHIFT DETENT BALL
Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.
Coat the threads of the 2 shift detent ball plugs with adhesive.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Note
To prevent contamination by foreign matter, install immediately after applying adhesive.
Using a 6 mm hexagon socket wrench, install the 2 shift detent ball plugs to the manual transmission case.
Install the shift detent ball and shift detent ball compression spring to the manual transmission case.
Coat the threads of the shift detent ball plug with adhesive.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Note
To prevent contamination by foreign matter, install immediately after applying adhesive.
Using a 6 mm hexagon socket wrench, install the shift detent ball plug to the manual transmission case.
INSTALL LOCK BALL PIN
Install the lock ball pin and shift and select lever shaft compression spring to the manual transmission case.
Coat the threads of the shift and select lever shaft straight screw with head plug with adhesive.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Note
To prevent contamination by foreign matter, install immediately after applying adhesive.
Using a 10 mm hexagon socket wrench, install the shift and select lever shaft straight screw with head plug to the manual transmission case.
INSTALL REVERSE IDLER GEAR SHAFT BOLT
Coat the threads of the reverse idler gear shaft bolt with adhesive.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Note
To prevent contamination by foreign matter, install immediately after applying adhesive.
Install the reverse idler gear shaft bolt to the manual transmission case with a new gasket.
INSTALL NO. 1 LOCK BALL ASSEMBLY
Coat the threads of the No. 1 lock ball assembly with adhesive.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent |
Note
To prevent contamination by foreign matter, install immediately after applying adhesive.
Using a 24 mm deep socket wrench, install the No. 1 lock ball assembly to the manual transmission case.
INSTALL TRANSMISSION CASE PLUG
Install the transmission case plug to the manual transmission case with a new gasket.
INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSPECT CLUTCH PIPE LINE
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSTALL NO. 1 CLUTCH HOUSING COVER
INSTALL WIRE HARNESS CLAMP BRACKET (w/ Stop and Start System)
Install the wire harness clamp bracket to the manual transmission case with the bolt.
INSTALL CONTROL CABLE BRACKET ASSEMBLY
Hook the outer select lever to the reverse restrict pin assembly to secure it.
Install the control cable bracket assembly to the manual transmission case with the 3 bolts.
INSTALL NEUTRAL POSITION SWITCH (w/ Stop and Start System)
Using a 27 mm deep socket wrench, install the neutral position switch to the manual transmission case with a new gasket.
INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
Using a 27 mm deep socket wrench, install the back-up light switch assembly to the manual transmission case with a new gasket.
INSTALL MANUAL TRANSMISSION DRAIN PLUG
Using a 10 mm hexagon socket wrench, install the manual transmission drain plug to the front transaxle case with a new gasket.
INSTALL MANUAL TRANSMISSION FILLER PLUG
Install the manual transmission filler plug to the manual transmission case with a new gasket.