MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT ASSEMBLY


    1. A01KGGD

      Apply gear oil to the sliding part of the output shaft assembly.

    2. Using a plastic hammer, install the output shaft assembly by tapping the intermediate plate.

  2. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01KFFV

      Using a snap ring expander, install the output shaft bearing shaft snap ring to the output shaft.

  3. INSTALL INPUT SHAFT ASSEMBLY


    1. A01KFP1

      Apply gear oil to the input shaft assembly and No. 2 synchronizer ring, and install them to the output shaft.

      Note


      • Make sure that the synchromesh shifting key fits into the grooves of the No. 2 synchronizer ring.

      • Check that the input shaft assembly rotates smoothly.

  4. INSTALL COUNTER GEAR


    1. A01KFJT

      Temporarily install the counter gear assembly to the intermediate plate.

  5. INSTALL COUNTER SHAFT CENTER BEARING


    1. A01KEXCE01

      Using SST and a hammer, install a new counter shaft center bearing to the intermediate plate.

      SST
      09316-60011   ( 09316-00011 )

      Tech Tips

      Remove the bearing while tapping the tip of the counter gear so that the counter gear assembly is not pushed forward into the side wall of the output shaft gear.

  6. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01KGMOE04

      Apply gear oil to each sliding part of the reverse idler gear and the reverse idler gear shaft, and install them to the intermediate plate.

      Note

      Orient the groove side of the reverse idler shaft to the rear side and install it from the rear side.

  7. INSTALL OUTPUT SHAFT REAR BEARING RETAINER


    1. A01KGXN

      Install the output shaft rear bearing retainer into the groove of the reverse idler gear shaft with the 4 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  8. INSTALL 5TH GEAR THRUST WASHER PIN


    1. A01KELK

      Apply MP grease to the 5th gear thrust washer pin, and install it to the counter gear.

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A01KF7F

      Apply gear oil to the 5th gear thrust washer, and install it to the counter gear.

      Note

      Install the thrust washer so that its chamfer side faces the front side.

  10. INSTALL NO. 3 TRANSMISSION HUB SLEEVE


    1. A01KENQ

      Apply gear oil to the sliding part of the No. 3 transmission hub sleeve, and install it to the counter shaft 5th gear.

      Note

      Make sure that the No. 3 transmission hub sleeve and counter 5th gear are oriented in the correct direction.

    2. Install the 3 synchromesh shifting keys and the 2 synchromesh shifting key springs to the counter shaft 5th gear.

  11. INSTALL COUNTER 5TH GEAR BEARING


    1. A01KF21E02

      Apply gear oil to the counter 5th gear bearing and install it to the counter 5th gear.

  12. INSTALL COUNTER SHAFT 5TH GEAR


    1. A01KFP4

      Apply gear oil to the counter 5th gear and No. 3 transmission hub sleeve assembly, and install them to the counter gear.

  13. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01KH8B

      Apply gear oil to the No. 3 synchronizer ring, and install it to the counter gear.

      Note

      Make sure that the synchromesh shifting key fits into the grooves of the No. 3 synchronizer ring outer.

  14. INSTALL NO. 5 GEAR SPLINE PIECE


    1. A01KINCE01

      Using SST and a press, install the No. 5 gear spline piece to the counter gear.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Check that the gear rotates smoothly.

  15. INSTALL COUNTER GEAR REAR SHAFT SNAP RING


    1. Select a counter gear rear shaft snap ring so that the thrust gap between the gear spline piece No.5 and counter gear rear shaft snap ring is within the specified values. Using a brass bar and a hammer, install it to the counter gear.

      Standard clearance
      0.1 mm (0.0039 in.) or less
      Mark Thickness: mm (in.)
      A 2.80 to 2.85 (0.1102 to 0.1122)
      B 2.85 to 2.90 (0.1122 to 0.1141)
      C 2.90 to 2.95 (0.1141 to 0.1160)
      D 2.95 to 3.00 (0.1160 to 0.1181)
      E 3.00 to 3.05 (0.1181 to 0.1200)
      F 3.05 to 3.10 (0.1200 to 0.1220)
      G 3.10 to 3.15 (0.1220 to 0.1240)

  16. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01KEBX

      Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)

  17. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A01KFUJ

      Using a dial indicator, measure the radial clearance of the counter shaft 5th gear.

      Standard clearance
      0.015 to 0.068 mm (0.0059 to 0.0027 in.)

      If the clearance is not within the specified values, replace the counter 5th gear bearing with a new one.

  18. INSTALL OUTPUT SHAFT REAR BEARING


    1. A01KI9GE02

      Using SST and a press, install the spacer and a new output shaft rear bearing to the output shaft.

      SST
      09309-35010

  19. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. Select an output shaft bearing shaft snap ring so that the thrust gap between the snap ring and the bearing is within the specified values. Use a brass bar and a hammer to install it to the output shaft.

      Standard clearance
      0.1 mm (0.0039 in.) or less
      Mark Thickness: mm (in.)
      A 2.65 to 2.70 (0.1043 to 0.1063)
      B 2.70 to 2.75 (0.1063 to 0.1083)
      C 2.75 to 2.80 (0.1083 to 0.1102)
      D 2.80 to 2.85 (0.1102 to 0.1122)
      E 2.85 to 2.90 (0.1122 to 0.1141)
      F 2.90 to 2.95 (0.1141 to 0.1160)
      G 2.95 to 3.00 (0.1160 to 0.1181)
      H 3.00 to 3.05 (0.1181 to 0.1200)
      J 3.05 to 3.10 (0.1200 to 0.1220)
      K 3.10 to 3.15 (0.1220 to 0.1240)
      L 3.15 to 3.20 (0.1240 to 0.1260)
      M 3.20 to 3.25 (0.1260 to 0.1280)
      N 3.25 to 3.30 (0.1280 to 0.1299)
      P 3.30 to 3.35 (0.1299 to 0.1319)
      Q 3.35 to 3.40 (0.1319 to 0.1339)
      R 3.40 to 3.45 (0.1339 to 0.1358)
      S 3.45 to 3.50 (0.1358 to 0.1378)

  20. INSTALL SPEEDOMETER DRIVE GEAR


    1. A01KEFC

      Using snap ring expander, install the snap ring.

    2. Install the ball and drive gear.

    3. Using snap ring expander, install the snap ring.

  21. INSTALL REVERSE SHIFT ARM BRACKET


    1. A01KGQ5

      Install the reverse shift arm bracket to the intermediate plate with the 2 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  22. INSTALL REVERSE SHIFT FORK


    1. A01KGMN

      Install the reverse shift arm to the reverse shift fork. Using a screwdriver and a hammer, install a new reverse shift arm end shaft ring.

    2. A01KG54

      Install the tip of the reverse shift arm to the reverse idler gear. Align the cut end of the reverse shift arm with the reverse shift arm bracket pin, and install them.

  23. INSTALL NO. 4 GEAR SHIFT FORK SHAFT


    1. A01KGSU

      Install the compression spring and the reverse shift fork ball into the reverse shift fork.

    2. A01KEK4

      Apply gear oil to the sliding part of the No. 4 gear shift fork shaft.

    3. Using a screwdriver, install the No. 4 gear shift fork shaft by gently pushing the reverse shift fork ball.

    4. A01KGAL

      Using a brass bar and a hammer, install the shift fork shaft snap ring to the No. 4 gear shift fork shaft.

  24. INSTALL NO. 1 GEAR SHIFT HEAD


    1. A01KHSD

      Apply gear oil to the No. 1 gear shift head, and install it to the reverse shift fork shaft.

    2. Using a pin punch (5 mm) and a hammer, install the slotted spring pin into the No. 3 gear shift fork shaft.

  25. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A01KEUB

      Install the reverse shift fork ball into the reverse shift fork.

    2. A01KFWQ

      Install the No. 1 shift interlock roller to the intermediate plate.

    3. A01KH9G

      Install the No. 3 gear shift fork to the No. 3 transmission hub sleeve and the No. 3 gear shift fork shaft to the intermediate plate from the front side.

    4. A01KFJ7

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

    5. A01KIN5

      Using a pin punch (5 mm) and a hammer, install the slotted spring pin into the No. 3 gear shift fork.

  26. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A01KFWQ

      Install the No. 1 shift interlock roller to the intermediate plate.

    2. A01KIB6

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

    3. Install the No. 2 gear shift fork to the No. 2 transmission hub sleeve.

    4. A01KFTZ

      Install the No. 2 gear shift head and No. 2 gear shift fork shaft to the intermediate plate from the front side.

    5. A01KEGN

      Using a pin punch (5 mm) and a hammer, install the slotted spring pin into the No. 2 gear shift fork.

    6. A01KGAT

      Install a new shift fork set bolt to the No. 2 gear shift fork.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    7. A01KEI0

      Using a brass bar and a hammer, install the snap ring to the No. 2 gear shift fork shaft.

  27. INSTALL SHIFT FORK SHAFT STOPPER


    1. A01KI5C

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

    2. Using a pin punch (5 mm) and a hammer, install the slotted spring pin into the No. 2 gear shift fork shaft.

  28. INSTALL NO. 1 GEAR SHIFT HEAD


    1. A01KHSD

      Apply gear oil to the No. 1 gear shift head, and install it to the No. 1 shift fork shaft.

    2. Using a pin punch (5 mm) and a hammer, install the slotted spring pin into the No. 1 gear shift fork shaft.

  29. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A01KII0

      Install the shift interlock pin (ball) and No. 1 shift interlock roller into the intermediate plate.

    2. A01KESA

      Apply gear oil to the No. 1 gear shift fork shaft, and install it to the intermediate plate from the front side.

    3. A01KHPT

      Install a new shift fork set bolt to the No. 1 gear shift fork.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    4. A01KFQ3

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

  30. INSTALL SHIFT FORK SHAFT STOPPER


    1. A01KFAO

      Install the shift fork shaft stopper to the No. 1 gear shift fork shaft.

    2. Using a pin punch (5 mm) and a hammer, install the slotted spring pin into the No. 1 gear shift fork shaft.

  31. INSTALL SHIFT DETENT BALL SPRING SEAT


    1. A01KI5G

      Install the 2 compression springs and 2 shift detent balls into the intermediate plate.

    2. A01KI1TE04

      Using a "TORX" socket wrench T40, install the 2 shift detent ball spring seats to the intermediate plate.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
    3. A01KFL7

      Install the shift detent ball and the compression spring into the intermediate plate.

    4. A01KINH

      Using a "TORX" socket wrench T40, install the shift detent ball spring seat to the intermediate plate.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

  32. INSTALL TRANSMISSION MAGNET


    1. A01KHL0

      Clean the transmission magnet, and install it to the intermediate plate.

  33. INSTALL MANUAL TRANSMISSION CASE


    1. A01KHJC

      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
    2. A01KFV2

      Using a plastic hammer, tap the manual transmission case to attach it to the intermediate plate.

  34. INSTALL COUNTER GEAR FRONT BEARING NO. 1 SNAP RING


    1. A01KHAO

      Using a snap ring expander, install the counter gear front bearing No. 1 snap ring to the transmission case.

  35. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A01KI4O

      Using a snap ring expander, install the front bearing shaft snap ring to the transmission case.

  36. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01KHN8E02

      Using SST and a hammer, install a new transmission front bearing retainer oil seal to the transmission front bearing retainer.

      SST
      09950-60010   ( 09951-00300, 09951-00520, 09952-06010, 09951-07100 )
      Drive in depth
      11.2 to 12.2 mm (0.4409 to 0.4803 in.)

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

  37. INSTALL FRONT BEARING RETAINER


    1. A01KI1B

      Apply seal packing to the bearing retainer front as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A01KF5I

      Install the front bearing retainer to the transmission case with the 8 bolts.

      Torque:
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }

    3. Check that the input shaft and output shaft rotate smoothly.

  38. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01KEN9E01

      Using SST and a hammer, install a new extension housing oil seal to the extension housing.

      SST
      09710-30050
      09950-70010   ( 09951-07100 )
      Drive in depth
      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

      Note

      Be careful not to damage the oil seal lip.

    2. Lightly apply MP grease to the tip of the oil seal.

  39. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE


    1. Install the oil receiver pipe with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  40. INSTALL NO. 1 EXTENSION HOUSING OIL RECEIVER


    1. A01KFXD

      Install the extension housing oil receiver to the extension housing.

  41. INSTALL EXTENSION HOUSING SUB-ASSEMBLY


    1. A01KGT9

      Apply seal packing to the extension housing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A01KI0C

      Install the extension housing to the transmission case with the 10 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  42. INSTALL SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A01KHJO

      Apply seal packing to the shift lever shaft housing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A01KF5Z

      Install the shift lever shaft housing to the transmission case with the 6 bolts.

      Torque:
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }

  43. INSTALL EXTENSION HOUSING DUST DEFLECTOR


    1. Using a plastic hammer, install the extension housing dust deflector to the extension housing.

  44. INSTALL EXTENSION HOUSING COVER


    1. A01KFRB

      Install the extension housing cover and a new gasket to the extension housing with the 6 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  45. INSTALL SPEEDOMETER DRIVEN GEAR


    1. Install a new O-ring to the speedometer driven gear.

    2. Install the speedometer driven gear with the bolt.

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }

  46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01KEQ0E01

      Using SST, install the back-up light switch assembly to the transmission case.

      SST
      09817-16011
      Torque:
      44 N*m  { 450 kgf*cm, 32 ft.*lbf }

  47. INSTALL CLUTCH HOUSING


    1. A01KF3J

      Install the clutch housing to the transmission case with the 9 bolts.

      Torque:
      36 N*m  { 370 kgf*cm, 27 ft.*lbf }

  48. INSTALL DRAIN PLUG SUB-ASSEMBLY


    1. A01KGK4

      Install the drain plug to the transmission case and a new gasket.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  49. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01KH0X

      Install the filler plug to the transmission case and a new gasket.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }