MULTI-MODE MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01VJA2E01

      Using SST and a press, install a new front differential case front tapered roller bearing to the differential case assembly.

      SST
      09309-37010
      09506-35010
    2. A01VH69E02

      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.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07200 )

  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01VJO2E01

      Using SST and a press, install a new front differential case rear tapered roller bearing to the differential case assembly.

      SST
      09636-20010
      09726-40010
    2. A01VJHUE07

      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.

      SST
      09309-36010
      09950-60020   ( 09951-00730 )
      09950-70010   ( 09951-07100 )

      Tech Tips

      Use a front differential case rear plate washer of the same thickness as the removed one.

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01VI6B

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

    2. A01VLIA

      Install the manual transmission case to the front transaxle case with the 16 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A01VDM1E02
      Text in Illustration
      *1 Front Differential Case Rear Plate Washer

      Using SST and a torque wrench, turn the differential case 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.

      SST
      09564-32011
      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, select a front differential case rear plate washer.

      Front Differential Case Rear Plate Washer Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90564-44039 10 2.100 (0.0827)
      90564-44040 11 2.125 (0.0837)
      90564-44041 12 2.150 (0.0846)
      90564-44042 13 2.175 (0.0856)
      90564-44043 14 2.200 (0.0866)
      90564-44044 15 2.225 (0.0876)
      90564-44045 16 2.250 (0.0886)
      90564-44046 17 2.275 (0.0896)
      90564-44047 18 2.300 (0.0906)
      90564-44048 19 2.325 (0.0915)
      90564-44049 20 2.350 (0.0925)
      90564-44050 21 2.375 (0.0935)
      90564-44051 22 2.400 (0.0945)
      90564-44052 23 2.425 (0.0955)
      90564-44053 24 2.450 (0.0965)
      90564-44054 25 2.475 (0.0974)
      90564-44055 26 2.500 (0.0984)
      90564-44056 27 2.525 (0.0994)
      90564-44057 28 2.550 (0.1004)
      90564-44058 29 2.575 (0.1014)
      90564-44059 30 2.600 (0.1024)
      90564-44060 31 2.625 (0.1033)
      90564-44061 32 2.650 (0.1043)
      90564-44062 33 2.675 (0.1053)
      90564-44063 34 2.700 (0.1063)
      90564-44064 35 2.725 (0.1073)
      90564-44065 36 2.750 (0.1083)
      90564-44066 37 2.775 (0.1093)
      90564-44067 38 2.800 (0.1102)
      90564-44068 39 2.825 (0.1112)
      90564-44069 40 2.850 (0.1122)

      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.

    5. Remove the 16 bolts and the manual transmission case from the front transaxle case.

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

  4. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A01VHS6

      Install the output shaft cover to the front transaxle case.

      Note

      Insert the output shaft cover key into the front transaxle case groove.

    2. A01VI5BE01

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

      SST
      09950-60010   ( 09951-00630 )
      09950-70010   ( 09951-07100 )

  5. INSTALL REAR OUTPUT SHAFT BEARING


    1. A01VER6E04

      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.

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07200 )

      Tech Tips

      Use a rear output shaft bearing shim of the same thickness as the removed one.

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A01VI6B

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

    2. A01VICU

      Coat the output shaft assembly with gear oil and install it to the front transaxle case.

    3. A01VLIA

      Install the manual transmission case to the front transaxle case with the 16 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A01VLVSE04
      Text in Illustration
      *1 Rear Output Shaft Bearing Shim

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

      SST
      09564-32011

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

      SST
      09564-32011
      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, select a rear output shaft bearing shim.

      Rear Output Shaft Bearing Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90564-45153 50 1.750 (0.0689)
      90564-45154 51 1.775 (0.0699)
      90564-45155 52 1.800 (0.0709)
      90564-45156 53 1.825 (0.0719)
      90564-45157 54 1.850 (0.0728)
      90564-45158 55 1.875 (0.0738)
      90564-45159 56 1.900 (0.0748)
      90564-45160 57 1.925 (0.0758)
      90564-45161 58 1.950 (0.0768)
      90564-45162 59 1.975 (0.0778)
      90564-45163 60 2.000 (0.0787)
      90564-45164 61 2.025 (0.0797)
      90564-45165 62 2.050 (0.0807)
      90564-45166 63 2.075 (0.0817)
      90564-45167 64 2.100 (0.0827)
      90564-45168 65 2.125 (0.0837)
      90564-45169 66 2.150 (0.0846)
      90564-45170 67 2.175 (0.0856)
      90564-45171 68 2.200 (0.0866)
      90564-45172 69 2.225 (0.0876)
      90564-45173 70 2.250 (0.0886)
      90564-45174 71 2.275 (0.0896)
      90564-45175 72 2.300 (0.0906)
      90564-45176 73 2.325 (0.0915)
      90564-45177 74 2.350 (0.0925)
      90564-45178 75 2.375 (0.0935)
      90564-45179 76 2.400 (0.0945)
      90564-45180 77 2.425 (0.0955)
      90564-45181 78 2.450 (0.0965)
      90564-45182 79 2.475 (0.0974)
      90564-45183 80 2.500 (0.0984)
      90564-45184 81 2.525 (0.0994)
      90564-45185 82 2.550 (0.1004)
      90564-45186 83 2.575 (0.1014)
      90564-45187 84 2.600 (0.1024)
      90564-45188 85 2.625 (0.1033)
      90564-45189 86 2.650 (0.1043)
      90564-45190 87 2.675 (0.1053)
      90564-45191 88 2.700 (0.1063)
      90564-45192 89 2.725 (0.1073)
      90564-45193 90 2.750 (0.1083)
      90564-45194 91 2.775 (0.1093)
      90564-45195 92 2.800 (0.1102)

      Tech Tips

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

    6. Remove the 16 bolts and the manual transmission case from the front transaxle case.

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

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

  7. INSTALL TRANSMISSION CASE GASKET


    1. A01VL2OE04
      Text in Illustration
      *a Depth

      Using SST and a hammer, install a new transmission case gasket to the manual transmission case.

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )
      Drive in depth
      0 to 1.0 mm (0 to 0.0393 in.)

  8. INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A01VJZH

      Install the manual transmission oil separator sub-assembly to the manual transmission case with the 4 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      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.

  9. INSTALL TRANSMISSION OIL SEPARATOR


    1. A01VM83

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

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Make sure that the tip of the transmission oil separator is inserted in the groove of the manual transmission case.

  10. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A01VIBM

      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.

  11. INSTALL STRAIGHT PIN


    1. A01VJZZE03
      Text in Illustration
      *a Protrusion Height

      Using a plastic-faced 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.)

  12. INSTALL BREATHER PLUG


    1. A01VJUYE01

      Using SST and a hammer, install the breather plug to the front transaxle case.

      SST
      09350-30020   ( 09350-07110 )

  13. INSTALL TRANSMISSION OIL SEPARATOR


    1. A01VK8U

      Install the transmission oil separator to the front transaxle case with the 4 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  14. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A01VGB1E08
      Text in Illustration
      *a Depth

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

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )
      Driven in depth
      0.9 to 1.9 mm (0.0355 to 0.0748 in.)

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

  15. INSTALL TRANSMISSION MAGNET


    1. A01VF8W

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

  16. INSTALL INPUT SHAFT COVER


    1. A01VF4G

      Install the input shaft cover to the manual transmission case.

      Note

      Insert the input shaft cover key into the manual transmission case groove.

  17. INSTALL REAR INPUT SHAFT BEARING SHIM


    1. A01VJD6

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

      Note

      Apply MP grease to the shim as necessary to prevent the shim from falling off the case during assembly.

    2. A01VFFRE01
      Text in Illustration
      *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).

    3. Measure the area between the end of the front transaxle case and the installation surface of the front input shaft bearing (Dimension B).

    4. Measure the area between both input shaft bearing outer races (Dimension C).

      Note

      Measure Dimension C with each bearing having no axial clearance.

    5. 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 = Between 0.02 mm (0.000788 in.) and 0.14 mm (0.00551 in.)

      If the thickness is out of specification, select a rear input shaft bearing shim.

      Rear Input Shaft Bearing Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90564-54103 08 1.30 (0.0512)
      90564-54104 09 1.35 (0.0531)
      90564-54105 10 1.40 (0.0551)
      90564-54106 11 1.45 (0.0571)
      90564-54107 12 1.50 (0.0591)
      90564-54108 13 1.55 (0.0610)
      90564-54109 14 1.60 (0.0630)
      90564-54110 15 1.65 (0.0650)
      90564-54111 16 1.70 (0.0669)
      90564-54112 17 1.75 (0.0689)
      90564-54113 18 1.80 (0.0709)
      90564-54114 19 1.85 (0.0728)

    6. 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.

  18. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A01VI6B

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

  19. INSTALL INPUT SHAFT ASSEMBLY


    1. Apply gear oil to all sliding and rotating parts.

    2. A01VFU5E02
      Text in Illustration
      *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.

    3. A01VGPFE02
      Text in Illustration
      *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 the No. 3 gear shift fork shaft assembly with gear oil and install them to the input shaft assembly.

    4. Temporarily install the input shaft assembly, output shaft assembly and the 3 gear shift fork shaft assemblies, and tie them with a rope or string.

    5. A01VJCF

      Install the input shaft assembly, output shaft assembly and the 3 gear shift fork shaft assemblies to the front transaxle case.

  20. INSTALL SHIFT INTER LOCK PLATE


    1. A01VKM1

      Install the shift inter lock plate to the front transaxle case.

  21. INSTALL SHIFT AND SELECT LEVER SHAFT HEAD


    1. A01VIK8

      Make sure that the shift and select lever shaft is installed as shown in the illustration.

    2. A01VFDTE01
      Text in Illustration
      *a Depth

      Using a 5 mm pin punch and a hammer, install the shift and select lever shaft head and the slotted spring pin to the shift and select lever shaft.

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

  22. INSTALL INNER SELECT LEVER


    1. A01VK35E02
      Text in Illustration
      *a Depth

      Using a 5 mm pin punch and a hammer, install the inner select lever and the slotted spring pin to the shift and select lever shaft.

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

  23. INSTALL INNER NO. 1 SHIFT LEVER


    1. Using a 5 mm pin punch and a hammer, install the inner No. 1 shift lever and the slotted spring pin to the shift and select lever shaft.

      A01VGR9E01
      Text in Illustration
      *a Depth
      *b Plane
      Driven in depth
      -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

      Tech Tips

      The inner No. 1 shift lever can be installed in either direction.

  24. INSTALL FRONT INNER SHIFT LEVER


    1. A01VLAGE02
      Text in Illustration
      *a Depth

      Using a 5 mm pin punch and a hammer, install the front inner shift lever and the slotted spring pin to the shift and select lever shaft.

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

      Note

      Check the installation direction.

  25. INSTALL INNER NO. 2 SHIFT LEVER


    1. A01VHSOE02
      Text in Illustration
      *a Depth

      Using a 5 mm pin punch and a hammer, install the inner No. 2 shift lever and the slotted spring pin to the shift and select lever shaft.

      Driven in depth
      0 to 0.6 mm (0 to 0.0236 in.)

      Note

      Check the installation direction.

  26. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A01VES4

      Turn the shift and select lever shaft assembly and the shift inter lock 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 inter lock plate.

  27. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A01VHVW

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

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  28. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A01VGM6

      Coat the reverse shift fork shaft assembly with gear oil and install it to the front transaxle case.

  29. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01VKGXE02
      Text in Illustration
      *a Parallel

      Coat the reverse idler gear sub-assembly, reverse idler thrust washer and the 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.

  30. INSTALL MANUAL TRANSMISSION CASE


    1. A01VFO2E04
      Text in Illustration
      *1 Seal Packing
      *a 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.

    2. A01VLIA

      Install the manual transmission case to the front transaxle case with the 16 bolts.

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

  31. INSTALL TRANSMISSION CASE OIL SEAL

    Click here

  32. INSTALL TRANSAXLE CASE OIL SEAL

    Click here

  33. INSTALL SHIFT DETENT BALL


    1. A01VDV9

      Install the 2 shift detent balls and the 2 shift detent ball compression springs to the manual transmission case.

    2. Coat the threads of the 2 shift detent ball plugs with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a 6 mm hexagon socket wrench, install the 2 shift detent ball plugs to the manual transmission case.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    4. A01VL1M

      Install the shift detent ball and the shift detent ball compression spring to the manual transmission case.

    5. Coat the threads of the shift detent ball plug with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Using a 6 mm hexagon socket wrench, install the shift detent ball plug to the manual transmission case.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    A01VI7U

    1. Coat the threads of the reverse idler gear shaft bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  35. INSTALL TRANSMISSION CASE PLUG


    1. A01VHV2

      Install the transmission case plug to the manual transmission case with a new gasket.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  36. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

    Click here

  37. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  38. INSPECT CLUTCH PIPE LINE

    Click here

  39. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  40. INSTALL NO. 1 CLUTCH HOUSING COVER

    Click here

  41. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY


    1. A01VE57E03
      Text in Illustration
      *1 Seal Packing
      *a Seal Diameter 1.2 mm (0.0472 in.)

      Apply seal packing to the shift and select actuator assembly 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.

    2. Install the shift and select actuator assembly and the wire harness clamp bracket to the manual transmission case with the 6 bolts.

      A01VJPGE02
      Text in Illustration
      *1 Shift Sensor Shaft *2 Reverse Shift Head
      *3 Select Lever Gear *4 Inner Select Lever
      *5 Wire Harness Clamp Bracket - -
      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note


      • Securely engage the shift sensor shaft in the reverse shift head.

      • Securely engage the select lever gear engagement in the inner select lever.

  42. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01VF4P

      Using a 27 mm deep socket wrench, install the park/neutral position switch assembly to the manual transmission case with a new gasket.

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

  43. INSTALL TRANSMISSION REVOLUTION SENSOR


    1. Apply gear oil to a new O-ring and install it to the transmission revolution sensor.

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A01VI1N

      Install the transmission revolution sensor to the manual transmission case with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  44. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01VFKP

      Using a 27 mm deep socket wrench, install the back-up light switch assembly to the manual transmission case with a new gasket.

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

  45. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01VJY6

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

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

  46. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    1. A01VHIV

      Using a 10 mm hexagon socket wrench, install the manual transmission drain plug to the front transaxle case with a new gasket.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }