MANUAL TRANSMISSION ASSEMBLY INSTALLATION


  1. INSTALL RELEASE FORK SUPPORT


    1. A01CHMM

      Install the release fork support to the transmission assembly.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

  2. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


    1. A01CHX9E01

      Apply release hub grease to the release fork as shown in the illustration.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
    2. A01CIT1

      Install the release bearing to the release fork.

    3. A01CHWJE01

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

    4. Install the boot.

    5. Install the clutch release fork assembly to the transmission assembly.

    6. A01CJ29

      Install the release fork to the release fork support.

      Note

      After installation, move the fork back and forth to check that the release bearing slides smoothly.

  3. INSTALL MANUAL TRANSMISSION ASSEMBLY


    1. A01CHNG

      Support the manual transmission with a transmission jack.

    2. Install the transmission.

      Note

      Do not apply excessive force to the transmission assembly as this will cause the input shaft to break.

    3. Install the 12 bolts.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

    4. Install the connector and clamp.

  4. INSTALL NO. 1 ENGINE MOUNTING BRACKET


    1. A01CI3C

      Install the No. 1 engine mounting bracket with the 3 bolts and 3 washers.

      Torque:
      103 N*m  { 1050 kgf*cm, 76 ft.*lbf }
    2. A01CH1X

      Install the nut.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  5. INSTALL NO. 3 ENGINE MOUNTING BRACKET


    1. A01CI1C

      Install the No. 3 engine mounting bracket with the 3 bolts and 3 washers.

      Torque:
      103 N*m  { 1050 kgf*cm, 76 ft.*lbf }
    2. A01CH6D

      Install the nut.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  6. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01CHMO

      Install the clutch release cylinder assembly with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  7. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. A01CIE5E01

      Install the control shift cable to the shift lever with the nut.

      Torque:
      28 N*m  { 280 kgf*cm, 20 ft.*lbf }

  8. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. A01CHK5E01

      Install the control select cable to the select lever with the nut.

      Torque:
      28 N*m  { 280 kgf*cm, 20 ft.*lbf }

  9. INSTALL PARKING BRAKE PLATE SUB-ASSEMBLY


    1. A01CI7A

      Install the parking brake plate sub-assembly with the 4 nuts.

      Torque:
      127 N*m  { 1290 kgf*cm, 93 ft.*lbf }

  10. INSTALL PARKING BRAKE DRUM SUB-ASSEMBLY


    1. Install the companion flange.

    2. A01CID4

      Install the parking brake dust cover to the parking drum sub-assembly with the bolt.

      Torque:
      8.2 N*m  { 84 kgf*cm, 73 in.*lbf }

    3. Install the parking drum sub-assembly.

  11. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. Apply engine oil to a new O-ring, and install it to the companion flange.

    2. Pull the parking brake lever fully, and shift into the 1st position.

    3. A01CHRW

      Using a 36 mm socket wrench, install a new transmission output shaft rear set nut.

      Torque:
      289 N*m  { 2947 kgf*cm, 213 ft.*lbf }
    4. A01CH0V

      Using a chisel and hammer, stake the transmission output shaft rear set nut.

  12. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here.

  13. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. A01CJ79

      Install the No. 1 exhaust pipe support bracket with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  14. INSTALL EXHAUST FRONT PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe assembly, and temporarily tighten 3 new nuts.

    2. Temporarily tighten a new bolt.

    3. Tighten the 3 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    4. Tighten the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  15. INSTALL EXHAUST RETARDER ASSEMBLY


    1. Install 2 new gaskets and exhaust retarder assembly with 4 new bolts.

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

    2. Connect the vacuum hose.

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  17. INSPECT AND ADJUST MANUAL TRANSMISSION OIL


    1. A01CH1VE01

      Park the vehicle in a level place.

    2. Remove the transmission filler plug and gasket.

    3. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

      Oil grade
      API CD, CE, CF, CH-4 or CL-4
      Viscosity
      SAE 10W-30 or 10W-40

      Note


      • Problems may occur when the oil level is too high or too low.

      • After replacing the oil, drive the vehicle and check the oil level again.

    4. Check for oil leaks if the oil level is low.

    5. Install the transmission filler plug and a new gasket.

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

  18. INSPECT FOR EXHAUST GAS LEAK