MANUAL TRANSAXLE UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT COVER


    1. A01378HE06
      Text in Illustration
      *a Protrusion
      *b Align
      *c Groove

      Install the output shaft cover to the front transaxle case as shown in the illustration.

  2. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A0136O7E01

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

      SST
      09950-60010   ( 09951-00510 )
      09950-70010   ( 09951-07150 )

  3. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0135VBE01

      Using SST and a press, press in the front differential case front tapered roller bearing (outer race) to the front transaxle case.

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07150 )

  4. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01390CE01

      Install the differential case shim to the manual transmission case.

      Tech Tips

      When reusing the front differential case rear tapered roller bearing, reuse the original shim.

      When installing a new front differential case rear tapered roller bearing, first select and install a shim which is thinner than the original.

    2. Using SST and a press, press in the front differential case rear tapered roller bearing (outer race) to the manual transmission case.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

  5. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A0138QQE01

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

    2. A013906E01

      Install the manual transmission case with the 13 bolts.

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

      Tech Tips

      From manual transmission case side: 8 bolts

      From front transaxle case side: 5 bolts

    3. A01381BE01

      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 starting preload.

      SST
      09564-32011
      Standard preload (at starting)
      New bearing
      0.78 to 1.57 N*m (7.96 to 16.00 kgf*cm, 6.91 to 13.89 in.*lbf)
      Used bearing
      0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.34 to 8.67 in.*lbf)

    5. If the preload is not as specified, replace the differential case shim with one of a different thickness. Use the table below to select a differential case shim which will ensure that the preload is within the specification.

      Differential Case Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)

      		 Part No. Mark

      Thickness

      mm (in.)
      90564-41065 01 1.10 (0.0433) 90564-41075 11 1.60 (0.0630)
      90564-41066 02 1.15 (0.0453) 90564-41076 12 1.65 (0.0650)
      90564-41067 03 1.20 (0.0472) 90564-41077 13 1.70 (0.0669)
      90564-41068 04 1.25 (0.0492) 90564-41078 14 1.75 (0.0689)
      90564-41069 05 1.30 (0.0512) 90564-41079 15 1.80 (0.0709)
      90564-41070 06 1.35 (0.0531) 90564-41080 16 1.85 (0.0728)
      90564-41071 07 1.40 (0.0551) 90564-41081 17 1.90 (0.0748)
      90564-41072 08 1.45 (0.0571) 90564-41082 18 1.95 (0.0768)
      90564-41073 09 1.50 (0.0591) 90564-41083 19 2.00 (0.0787)
      90564-41074 10 1.55 (0.0610) - - -

    6. Remove the 13 bolts and the manual transmission case from the front transaxle case.

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

  6. INSTALL OUTPUT SHAFT REAR BEARING


    1. A0137B0E01

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

      Tech Tips

      When reusing the output shaft rear bearing, reuse the original shim.

      When installing a new output shaft rear bearing, first select and install a shim which is thinner than the original.

    2. A01362VE01

      Using SST and a press, press in the output shaft rear bearing (outer race) to the manual transmission case.

      SST
      09950-60010   ( 09951-00570 )
      09950-70010   ( 09951-07200 )

  7. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A0136YRE01

      Install the output shaft assembly and the differential case assembly to the front transaxle case.

    2. A013906E01

      Install the manual transmission case to the front transaxle case with the 13 bolts.

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

      Tech Tips

      From manual transmission case side: 8 bolts

      From front transaxle case side: 5 bolts

    3. A0136E8E01

      Using SST and a torque wrench, turn the differential case assembly and the output shaft 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 starting preload. Calculate the output shaft rear bearing shim value using the following formula.

      SST
      09564-32011
      Formula
      (Differential side bearing preload + Output shaft bearing preload) - Differential side bearing preload = Output shaft bearing preload
      Preload (at starting)
      New bearing
      2.79 to 5.56 N*m (28.5 to 56.6 kgf*cm, 24.7 to 49.2 in.*lbf)
      Used bearing
      1.73 to 3.47 N*m (17.7 to 35.3 kgf*cm, 15.4 to 30.7 in.*lbf)

    5. If the preload is not as specified, replace the output shaft rear bearing shim with one of a different thickness. Use the table below to select a output shaft rear bearing shim which will ensure that the reload is within the specification.

      Output Shaft Rear Bearing Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)

      		 Part No. Mark

      Thickness

      mm (in.)
      90564-38001 A 1.55 (0.0610) 90564-38009 J 1.95 (0.0768)
      90564-38002 B 1.60 (0.0630) 90564-38010 K 2.00 (0.0787)
      90564-38003 C 1.65 (0.0650) 90564-38011 L 2.05 (0.0807)
      90564-38004 D 1.70 (0.0669) 90564-38012 M 2.10 (0.0827)
      90564-38005 E 1.75 (0.0689) 90564-38013 N 2.15 (0.0846)
      90564-38006 F 1.80 (0.0709) 90564-38014 P 2.20 (0.0866)
      90564-38007 G 1.85 (0.0728) 90564-38015 Q 2.25 (0.0886)
      90564-38008 H 1.90 (0.0748) - - -

    6. Remove the 13 bolts and the manual transmission case from the front transaxle case.

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

  8. ADJUST INPUT SHAFT REAR BEARING SHIM


    1. A01388VE03
      Text in Illustration
      *1 Input Shaft Rear Bearing Shim

      Using a vernier caliper, accurately measure dimensions A and B shown in the illustration.

    2. Select an input shaft rear bearing shim that brings the value to within the specifications.

      Standard
      Shim thickness (B - A) should be more than 0 mm (0 in.) and less than 0.1 mm (0.00393 in.)
      Input Shaft Rear Bearing Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)

      		 Part No. Mark

      Thickness

      mm (in.)
      90564-38006 F 1.80 (0.0709) 90564-38013 N 2.15 (0.0846)
      90564-38007 G 1.85 (0.0728) 90564-38014 P 2.20 (0.0866)
      90564-38008 H 1.90 (0.0748) 90564-38015 Q 2.25 (0.0886)
      90564-38009 J 1.95 (0.0768) 90564-38016 R 2.30 (0.0906)
      90564-38010 K 2.00 (0.0787) 90564-38017 S 2.35 (0.0925)
      90564-38011 L 2.05 (0.0807) 90564-38018 T 2.40 (0.0945)
      90564-38012 M 2.10 (0.0827) - - -

    3. Install the input shaft rear bearing shim.

  9. INSTALL TRANSMISSION CASE OIL SEAL


    1. Coat the lip of a new transmission case oil seal with MP grease.

    2. A0138QBE01

      Using SST and a hammer, tap in the transmission case oil seal to the manual transmission case.

      SST
      09316-60011   ( 09316-00011 )
      Standard depth
      2.1 to 3.1 mm (0.0827 to 0.122 in.)

      Note

      Do not damage the lip of the transmission case oil seal.

  10. INSTALL TRANSAXLE CASE OIL SEAL


    1. Coat the lip of a new transaxle case oil seal with MP grease.

    2. A013878E01

      Using SST and a hammer, tap in the transaxle case oil seal to the front transaxle case.

      SST
      09636-20010
      Standard depth
      1.7 to 2.7 mm (0.0670 to 0.106 in.)

      Note

      Do not damage the lip of the transaxle case oil seal.

  11. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. Coat the lip of a new front transaxle case oil seal with MP grease.

    2. A013758E04

      Using SST and a hammer, tap in the front transaxle case oil seal to the front transaxle case.

      SST
      09950-60010   ( 09951-00360 )
      09950-70010   ( 09951-07150 )
      Standard depth
      14.4 to 15.4 mm (0.567 to 0.606 in.)

      Note

      Do not damage the lip of the front transaxle case oil seal.

  12. INSTALL TRANSMISSION MAGNET


    1. A0138HOE01

      Clean and reinstall the transmission magnet to the transaxle case.

  13. INSTALL NO. 2 OIL RECEIVER PIPE


    1. A0136GW

      Align the 2 protrusions with the 2 holes of the manual transmission case and install the No. 2 oil receiver pipe to the manual transmission case as shown in the illustration.

  14. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A0138QQE01

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

  15. INSTALL OUTPUT SHAFT ASSEMBLY


    1. A0136YRE01

      Install the output shaft assembly to the front transaxle case.

  16. INSTALL INPUT SHAFT ASSEMBLY


    1. A0138DPE01

      Coat sliding and rotating surfaces of the input shaft assembly and the output shaft assembly with gear oil, and install them to the front transaxle case.

  17. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A0138CQE01

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

    2. Using a plastic hammer, install a new snap ring to the No. 2 gear shift fork shaft.

    3. Install the reverse shift fork to the No. 2 gear shift fork shaft.

    4. A0136B7E01

      Shift the No. 2 transmission hub sleeve to the 4th gear position.

    5. Install the No. 2 gear shift fork shaft, No. 2 gear shift fork and the reverse shift fork to the front transaxle case.

    6. A0136DAE01

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

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }
    7. A0138FAE01

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

    8. A0138MOE01

      Using a magnet hand, install the straight pin to the reverse shift fork.

  18. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A0137HSE01

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

    2. A01383OE01

      Using a plastic hammer, install a new snap ring to the No. 3 gear shift fork shaft.

    3. A0136GPE01

      Pass the No. 3 gear shift fork shaft through the No. 3 gear shift fork, compression spring and the No. 3 gear shift head, and then install them to the front transaxle case.

    4. A0136BKE01

      Using a pin punch 5 mm and a hammer, tap in the slotted spring pin into the No. 3 gear shift head to secure the No. 3 gear shift head to the No. 3 gear shift fork shaft.

    5. A01373JE01

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

    6. A01365UE01

      Install the straight pin to the No. 3 gear shift fork.

  19. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A01361AE01

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

    2. A01383OE01

      Using a plastic hammer, install a new snap ring to the No. 1 gear shift fork shaft.

    3. A0136BUE01

      Pass the No. 1 gear shift fork shaft through the No. 1 gear shift head and the No. 1 gear shift fork, and then install them to the front transaxle case.

    4. A0136O9E01

      Using a pin punch 5 mm and a hammer, tap in the slotted spring pin into the No. 1 gear shift head to secure the No. 1 gear shift head to the No. 1 gear shift fork shaft.

    5. A0138EBE01

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

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }

  20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. Install the reverse idler gear sub-assembly to the front transaxle case.

  21. INSTALL REVERSE IDLER GEAR SHAFT


    1. Coat the reverse idler gear shaft with gear oil.

    2. Pass the reverse idler gear shaft through the reverse idler gear sub-assembly, and then install it to the front transaxle case.

    3. A0137Z6E04
      Text in Illustration
      *a Mark

      Align the mark on the reverse idler gear shaft with the bolt hole, as shown in the illustration.

  22. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A0137UTE01

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

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  23. INSTALL MANUAL TRANSMISSION CASE


    1. A01363V

      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 seal packing must be removed and reapplied.

    2. Install the manual transmission case to the front transaxle case.

    3. A0137UP

      Install the 8 bolts to the manual transmission case side.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A013689

      Install the 5 bolts to the front transaxle case side.

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

  24. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A0136JQ

      Coat the threads of the reverse idler gear shaft bolt with adhesive, and install it to the manual transmission case with a new gasket.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  25. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. Install the select return compression spring to the manual transmission case.

    2. A0136XD

      Apply seal packing to the control shaft cover of the shift and select lever shaft assembly as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    3. Coat the threads of bolt A with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A0136GUE01

      Install the shift and select lever shaft assembly and 2 clamps to the manual transmission case with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  26. INSTALL NO. 1 LOCK BALL ASSEMBLY


    1. Coat the threads of the No. 1 lock ball assembly with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A0136U5

      Install the No. 1 lock ball assembly to the manual transmission case.

      Torque:
      37 N*m  { 375 kgf*cm, 27 ft.*lbf }

  27. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A0136ENE01

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

      SST
      09817-16011
      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }
    2. A01379K

      Install the back-up light switch wire harness to the 2 clamps.

  28. INSTALL MANUAL TRANSAXLE FILLER PLUG


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

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

  29. INSTALL MANUAL TRANSAXLE DRAIN PLUG


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

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

  30. INSTALL MANUAL TRANSAXLE CASE PLUG


    1. A0136MB

      Install a new gasket and the manual transaxle case plug to the front transaxle case.

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

  31. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET


    1. A01365I

      Install the floor shift control lever housing support bracket to the front transaxle case with the 2 bolts.

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

  32. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover onto the transaxle case.

  33. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

    A0138FCE01

    1. Using SST and a hammer, tap in a new select lever shaft oil seal until its surface is flush with the manual transaxle case.

      SST
      09950-60010   ( 09951-00290 )
      09950-70010   ( 09951-07150 )

  34. INSTALL CLUTCH RELEASE FORK LEVER


    1. A01385M

      Apply release hub grease to the contact surface between the release bearing and the release fork, the rotating and sliding parts of the release lever and the spline coupling part.

      Text in Illustration
      A0137RP Release hub grease
      Grease
      Toyota Genuine Release Hub Grease or equivalent

      Note

      Apply grease uniformly to the rotating and sliding parts of the release lever and spline coupling part. Remove any grease extending beyond the release lever joining part.

    2. A01379J

      Install the release fork lever onto the transaxle case together with the torsion spring, spring stopper and the release fork.

    3. A013754

      Using a screwdriver and hammer, install a new E-ring.

    4. A01387T

      Secure the torsion spring to the release fork.

      Note

      Hold the spring and spring stopper up to the upper end of the release fork lever first, and then secure the spring.

  35. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


    1. Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

    2. Install the release bearing onto the transaxle case.

  36. INSTALL RELEASE FORK RETRACTING SPRING HANGER


    1. Install the release fork retracting spring hanger onto the release fork lever with the bolt.

      Torque:
      33 N*m  { 336 kgf*cm, 24 ft.*lbf }