MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT ASSEMBLY


    1. A01BCDR

      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. A01BHWQ

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

  3. INSTALL INPUT SHAFT ASSEMBLY


    1. A01BB8O

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

      Note


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

      • Check that the input shaft assembly rotates smoothly.

  4. INSTALL COUNTER GEAR


    1. A01BA8O

      Temporarily install the counter gear assembly to the intermediate plate.

  5. INSTALL COUNTER SHAFT CENTER BEARING


    1. A01BDNJE01

      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. A01BHT2E04

      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(MTM) RETAINER


    1. A01BD23

      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. A01BE8L

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

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A01BFGI

      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 to the front side.

  10. INSTALL TRANSMISSION HUB SLEEVE NO.3


    1. A01BAVJ

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

      Note

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

    2. Install the 2 synchromesh shifting keys No.3 and the 2 synchromesh shifting key springs to the counter shaft 5th gear.

    3. A01BAY8

      Using a snap ring expander, install the bearing shaft snap ring to the counter 5th gear.

  11. INSTALL COUNTER 5TH GEAR BEARING


    1. A01BCTOE02

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

  12. INSTALL COUNTER SHAFT 5TH GEAR


    1. A01BGCQ

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

  13. INSTALL SYNCHRONIZER RING OUTER NO.3


    1. A01BB86

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

      Note

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

  14. INSTALL GEAR SPLINE PIECE NO.5


    1. A01BAE4E01

      Using SST and a press, install the gear spline piece No.5 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. Use 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. A01BGP4

      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. A01BFJ5

      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. A01BGDZE01

      Using SST and a press, install a new spacer and 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 (MTM) GEAR


    1. Install the output shaft spacer.

    2. A01BAFN

      Using snap ring expander, install the snap ring.

    3. Install the ball and drive gear.

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

  21. INSTALL REVERSE SHIFT ARM BRACKET


    1. A01BGKR

      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. A01BD82

      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. A01BBU0

      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 GEAR SHIFT FORK SHAFT NO.4


    1. A01BGY8

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

    2. A01BH7T

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

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

    4. A01BBWM

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

  24. INSTALL GEAR SHIFT HEAD NO.1


    1. A01BDTR

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

  25. INSTALL REVERSE SHIFT FORK SHAFT


    1. A01BBW3

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

    2. A01BEPS

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

    3. A01BH7B

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

    4. A01BDFW

      Using a brass bar and a hammer, install the snap ring to the reverse shift fork shaft.

    5. A01BFLI

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

  26. INSTALL GEAR SHIFT FORK SHAFT NO.2


    1. A01BEPS

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

    2. A01BDR2

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

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

    4. A01BF9R

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

    5. A01BFHM

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

    6. A01BE3O

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

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }
    7. A01BBAB

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

  27. INSTALL SHIFT FORK SHAFT STOPPER


    1. A01BFCI

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

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

  28. INSTALL GEAR SHIFT HEAD NO.1


    1. A01BDTR

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

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

  29. INSTALL GEAR SHIFT FORK SHAFT NO.1


    1. A01BDTI

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

    2. A01BESW

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

    3. A01BH9Z

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

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }
    4. A01BC7X

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

  30. INSTALL SHIFT FORK SHAFT STOPPER


    1. A01BAWA

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

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

  31. INSTALL SHIFT DETENT BALL SPRING SEAT NO.1


    1. A01BE40

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

    2. A01BB6BE01

      Using a "torx" socket wrench T40, install the 2 shift detent ball spring seats No.1 to the intermediate plate.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }
    3. A01BDBD

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

    4. A01BDUZ

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

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

  32. INSTALL TRANSMISSION MAGNET


    1. A01BBVQ

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

  33. INSTALL MANUAL TRANSMISSION CASE


    1. A01BGHM

      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. A01BC1N

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

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


    1. A01BHZZ

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

  35. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A01BH1E

      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. A01BGZLE02

      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 BEARING RETAINER FRONT(MTM)


    1. A01BHXX

      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. A01BDNY

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

      Torque:
      17 N*m  { 170 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. A01BFYSE01

      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 EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A01BE3M

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

  41. INSTALL EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A01BCAZ

      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. A01BFQ0

      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. A01BE9K

      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. A01BCK6

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

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

  43. INSTALL EXTENSION HOUSING DUST(MTM) DEFLECTOR


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

  44. INSTALL EXTENSION HOUSING(MTM) COVER


    1. A01BD48

      Install the extension housing (MTM) 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 SENSOR


    1. Install a new O-ring to the speedometer sensor.

    2. Install the speedometer sensor with the bolt.

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

  46. INSTALL BACK UP LIGHT SWITCH ASSEMBLY


    1. A01BDDRE01

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

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

  47. INSTALL CLUTCH HOUSING


    1. A01BCT1

      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 (MTM) PLUG SUB-ASSEMBLY


    1. A01BB5E

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

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

  49. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01BC7V

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

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