MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT ASSEMBLY


    1. A01BFCQ

      Install the output shaft assembly into the intermediate plate by pulling on the output shaft assembly and tapping on the intermediate plate with a plastic hammer.

    2. A01BE7P

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

      Tech Tips

      Be sure the output shaft bearing snap ring is flush with the intermediate plate surface.

  2. INSTALL INPUT SHAFT ASSEMBLY


    1. A01BB4A

      Coat the input shaft assembly and synchronizer ring No.1 with gear oil, and install them to the output shaft.

  3. INSTALL COUNTER GEAR


    1. A01BE3E

      Coat the input shaft and the synchronizer ring No.2 with gear oil.

    2. Temporarily install the counter gear assembly and a new counter shaft center bearing to the intermediate plate.

      Note

      Install the bearing (with snap ring) to the counter gear's rear side.

    3. A01BCY6

      Using a plastic hammer, install the counter shaft center bearing to the intermediate plate by tapping the outer race of the counter shaft center bearing.

      Tech Tips

      Hold the front side of the counter gear by hand.

  4. INSTALL OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A01BG27

      Using a "torx" socket wrench T40, install the output shaft rear bearing retainer to the intermediate plate with the 4 screws.

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

  5. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01BB1R

      Install the reverse idler gear shaft and reverse idler gear sub-assembly to the intermediate plate.

    2. A01BCWO

      Install the reverse idler gear shaft stopper to the intermediate plate with the bolt.

      Torque:
      17 N*m  { 175 kgf*cm, 12 ft.*lbf }

  6. INSTALL REVERSE SHIFT ARM


    1. A01BASA

      Install a new E-ring and the shift fork to the shift arm.

  7. INSTALL REVERSE SHIFT ARM BRACKET


    1. A01BH00

      Install the arm bracket with the shift arm to the intermediate plate.

    2. Install the 2 bolts.

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

  8. INSTALL 5TH GEAR BEARING INNER RACE LOCK BALL


    1. A01BAE1

      Install the 5th gear bearing inner race lock ball.

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A01BG71

      Install the 5th gear thrust washer.

  10. INSTALL COUNTER SHAFT 5TH GEAR


    1. A01BE2F

      Install the counter shaft 5th gear assembly to the counter gear.

    2. A01BH6X

      Temporarily install the synchronizer ring No.3 on the gear spline piece No.5.

    3. A01BBQK

      Dismount the intermediate plate from the vise.

    4. Stand the manual transmission as shown in the illustration.

    5. A01BFDY

      Using a press and 22 mm socket wrench, install the gear spline piece No.5 with the synchronizer ring No.3 slots aligned with the shifting keys.

    6. Mount the intermediate plate in a vise.

    7. A01BGPJ

      Select a counter gear rear shaft snap ring that will allow the minimum amount of axial play.

      Standard clearance
      0.1 mm (0.00390in.) or less
      Counter gear rear shaft snap ring thickness
      Mark Thickness: mm (in.)
      A 2.80 to 2.85 (0.110 to 0.112)
      B 2.85 to 2.90 (0.112 to 0.114)
      C 2.90 to 2.95 (0.114 to 0.116)
      D 2.95 to 3.00 (0.116 to 0.118)
      E 3.00 to 3.05 (0.118 to 0.120)
      F 3.05 to 3.10 (0.120 to 0.122)
      G 3.10 to 3.15 (0.122 to 0.124)
    8. A01BH2W

      Using a brass bar and a hammer, install the counter gear rear shaft snap ring to the counter gear.

  11. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01BCNN

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

      Standard clearance
      0.125 to 0.325 mm (0.0049 to 0.0128 in.)
      Maximum clearance
      0.325 mm (0.0128 in.)

  12. INSTALL GEAR SHIFT HEAD NO.1


    1. A01BBAW

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

    2. Using a pin punch and a hammer, drive in the slotted spring pin to the gear shift fork shaft No.1.

  13. INSTALL GEAR SHIFT FORK NO.2


    1. A01BBZD

      Coat the gear shift fork No.2 with gear oil, and install it to the transmission hub sleeve No.2.

  14. INSTALL GEAR SHIFT FORK SHAFT NO.1


    1. A01BEVL

      Coat the gear shift fork No.1 with gear oil, and install it to the reverse gear.

    2. Install the gear shift fork shaft No.1 through the gear shift fork No.2, gear shift fork No.1 and intermediate plate.

    3. A01BA49

      Tighten the shift fork bolt..

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }

  15. INSTALL SHIFT INTER LOCK PIN NO.2


    1. A01BBAS

      Coat the shift inter lock pin No.2 with MP grease, and install it into the gear shift fork shaft No.2.

  16. INSTALL GEAR SHIFT FORK SHAFT NO.2


    1. A01BCEQ

      Coat the shift inter lock pin No.1 with MP grease.

    2. Using a magnetic finger, install the shift inter lock pin No.1 to the intermediate plate.

    3. Install the gear shift fork shaft No.2 through the gear shift fork No.2 and intermediate plate.

    4. A01BE6X

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

    5. A01BBBV

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

  17. INSTALL SHIFT INTER LOCK PIN NO.2


    1. A01BEZN

      Coat the shift inter lock pin No.2 with MP grease, and install it into the reverse shift fork shaft.

  18. INSTALL REVERSE SHIFT FORK SHAFT


    1. A01BFTN

      Coat the shift inter lock pin No.1 with MP grease.

    2. Using a magnetic finger, install the shift inter lock pin No.1 to the intermediate plate.

    3. A01BAS0

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

    4. Using a screwdriver, install the reverse shift fork shaft by pushing the ball gently.

    5. A01BDXT

      Apply gear oil to the gear shift head No.3, and install it to the reverse shift fork shaft.

    6. Using a pin punch (5 mm) and a hammer, install the slotted spring pin to the reverse shift fork shaft.

  19. INSTALL REVERSE SHIFT HEAD


    1. A01BBBW

      Install the reverse shift head to the reverse shift fork shaft.

  20. INSTALL GEAR SHIFT FORK SHAFT NO.4


    1. A01BAUA

      Coat the reverse shift fork ball with MP grease.

    2. Using a magnetic finger, install the reverse shift fork ball to the reverse shift fork.

    3. Install the gear shift fork shaft No.4 through the reverse shift fork.

    4. A01BHKS

      Coat the shift inter lock ball No.1 with MP grease.

    5. Using a magnetic finger, install the shift inter lock ball No.1 to the intermediate plate.

    6. Install the gear shift fork shaft No.4 through the gear shift fork No.3 and intermediate plate.

    7. A01BD4X

      Install the shift fork bolt to the gear shift fork No.3.

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }
    8. A01BEQF

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

    9. A01BBR0

      Using a pin punch (5 mm) and a hammer, install the slotted spring pin to the gear shift fork shaft No.4.

  21. INSTALL SHIFT DETENT BALL NO.2


    1. A01BHFI

      Coat the shift detent ball No.2 with MP grease.

    2. Install the shift detent ball No.2 and shift detent ball compression spring to the intermediate plate.

    3. A01BA76

      Coat the shift detent ball spring seat No.2 with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. Using a "torx" socket wrench T40, install the shift detent ball spring seat No.2 to the intermediate plate.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  22. INSTALL SHIFT DETENT BALL


    1. A01BBFL

      Coat the 3 shift detent balls with MP grease, and install these balls and 3 compression springs to the intermediate plate.

    2. A01BG02

      Coat the 3 shift detent ball spring seats No.1 with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a "torx" socket wrench T40, install the 3 shift detent ball spring seats No.1 to the intermediate plate.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  23. INSTALL MANUAL TRANSMISSION CASE


    1. A01BDUOE01

      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. A01BHGG

      Stand the intermediate plate as shown in the illustration.

    3. Using a plastic hammer, install the manual transmission case to the intermediate plate as shown in the illustration.

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


    1. A01BFQ4

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

  25. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A01BA6P

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

  26. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01BGJ8E01

      Using SST, press in a new transmission front bearing retainer oil seal to the front bearing retainer.

      SST
      09950-60010   ( 09952-06010, 09951-00440 )
      Oil seal depth
      12.5 to 13.5 mm (0.492 to 0.531 in.)

  27. CHECK BEARING RETAINER FRONT(MTM)


    1. A01BDQSE01

      Check that "FIPG" is imprinted on the bearing retainer front.

  28. INSTALL BEARING RETAINER FRONT(MTM)


    1. A01BF5LE01

      w/o Gasket:


      1. 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. w/ Gasket:


      1. Install the bearing retainer front with gasket to the transmission case.

    3. w/o Gasket:


      1. Install the bearing retainer front to the transmission case.

    4. A01BGM7E01

      Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Install the 8 bolts to the manual transmission case.

      Torque:
      17 N*m  { 175 kgf*cm, 12 ft.*lbf }

  29. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01BH0LE01

      Using SST, drive in a new manual transmission extension housing oil seal to the extension housing.

      SST
      09325-20010

  30. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A01BCZ1

      Install the extension housing oil receiver pipe No.1 to the the extension housing.

  31. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE


    1. A01BC1W

      Install the extension housing oil receiver pipe to the extension housing with the bolt.

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

  32. INSTALL TRANSMISSION MAGNET


    1. A01BDH2

      Install the transmission magnet to the extension housing.

  33. INSTALL EXTENSION HOUSING DUST(MTM) DEFLECTOR


    1. A01BE8C

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

  34. INSTALL EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A01BDHEE01

      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. A01BBCN

      Install the extension housing to the manual transmission case with the 8 bolts.

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

  35. INSTALL SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A01BHZ2

      Shift the gear shift fork No.2, gear shift head and reverse shift head to the neutral position.

    2. A01BCB4E01

      Install a new shift lever shaft housing gasket to the manual transmission case.

    3. Apply sealant to the threads of the 4 yellow bolts and 2 bluish-silver bolts.

    4. Install the clamp and shift lever shaft housing assembly to the manual transmission case with the 6 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 12 ft.*lbf }

  36. INSTALL CLUTCH HOUSING


    1. A01BDHBE01

      Install the clutch housing.

    2. Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the 9 bolts to the clutch housing.

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

  37. INSTALL BACK UP LIGHT SWITCH ASSEMBLY


    1. A01BABEE01

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

      SST
      09817-16011
      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  38. INSTALL SPEEDOMETER SENSOR


    1. A01BBNG

      Install a new O-ring to the speedometer sensor.

    2. Install the speedometer sensor to the extension housing with the bolt.

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

  39. INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY


    1. A01BF91

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

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

  40. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01BEGO

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

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