OUTPUT SHAFT REASSEMBLY


  1. INSTALL OUTPUT SHAFT FRONT BEARING

    A0136AEE01

    1. Using SST and a press, install the output shaft front bearing onto the output shaft.

      SST
      09710-22021   ( 09710-01051 )

  2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

    A0137E1

    1. Coat the 1st gear needle roller bearing with gear oil, and install it onto the output shaft.

  3. INSTALL 1ST GEAR

    A0137MJ

    1. Coat the 1st gear with gear oil, and install it onto the output shaft.

  4. INSTALL 1ST GEAR SYNCHRONIZER RING

    A0137UL

    1. Coat the 1st gear synchronizer ring with gear oil, and install it onto the 1st gear.

  5. INSTALL TRANSMISSION CLUTCH HUB NO.1

    A0137BC

    1. Install 2 shifting key springs No. 1, 3 shifting keys No. 1 and the reverse gear onto the transmission clutch hub No. 1.

    2. A0137L0E01

      Using SST and a press, install the transmission clutch hub No. 1 onto the output shaft.

      SST
      09316-60011   ( 09316-00011, 09316-00071 )

      Note

      Install the reverse gear assembly in the correct orientation, as shown in the illustration.

  6. INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING


    1. A0136R8E01
      Text in Illustration
      *a Mark

      Select a snap ring that allows the minimum axial play.

      Standard clearance
      0 to 0.1 mm (0 to 0.0039 in.)
      Snap Ring Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      A 2.28 (0.0898) D 2.46 (0.0969)
      B 2.34 (0.0921) E 2.52 (0.0992)
      C 2.40 (0.0945) F 2.58 (0.1016)
    2. A01370L

      Using a snap ring expander, install the new snap ring onto the output shaft.

  7. INSPECT 1ST GEAR THRUST CLEARANCE

    A01370R

    1. Using a feeler gauge, measure the 1st gear thrust clearance.

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

  8. INSPECT 1ST GEAR RADIAL CLEARANCE

    A0136PD

    1. Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance
      0.015 to 0.056 mm (0.0006 to 0.0022 in.)
      Maximum clearance
      0.056 mm (0.0022 in.)

      If the clearance exceeds the maximum, replace the 1st gear needle roller bearing.

  9. INSTALL 2ND GEAR BEARING SPACER

    A0136R0

    1. Coat the 2nd gear bearing spacer with gear oil and install it onto the output shaft.

  10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

    A0136T6

    1. Coat the 2nd gear needle roller bearing with gear oil, and install it onto the output shaft.

  11. INSTALL 2ND GEAR SYNCHRONIZER RING

    A0137ES

    1. Coat the 2nd synchronizer ring with gear oil, and install it onto the reverse gear.

  12. INSTALL 2ND GEAR

    A01368N

    1. Coat the 2nd gear with gear oil, and install it onto the output shaft.

  13. INSTALL 3RD DRIVEN GEAR

    A0135TZE01

    1. Using SST and a press, install the 3rd driven gear onto the output shaft.

      SST
      09316-60011   ( 09316-00041 )

  14. INSPECT 2ND GEAR THRUST CLEARANCE

    A01391R

    1. Using a feeler gauge, measure the 2nd gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.0039 to 0.0217 in.)

  15. INSPECT 2ND GEAR RADIAL CLEARANCE

    A0138M5

    1. Using a dial indicator, measure the 2nd gear radial clearance between the gear and shaft.

      Standard clearance
      0.015 to 0.056 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.056 mm (0.0006 in.)

      If the clearance exceeds the maximum, replace the 2nd gear needle roller bearing.

  16. INSTALL OUTPUT SHAFT SPACER

    A01369A

    1. Install the output shaft spacer onto the output shaft.

  17. INSTALL 4TH DRIVEN GEAR

    A0137KAE01

    1. Using SST and a press, install the 4th driven gear onto the output shaft.

      SST
      09223-00010
      09316-60011   ( 09316-00021 )

  18. INSTALL 5TH DRIVEN GEAR

    A0137ICE01

    1. Using SST and a press, install the 5th driven gear onto the output shaft.

      SST
      09223-00010
      09316-60011   ( 09316-00021 )

  19. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING


    1. A0136Z9E03
      Text in Illustration
      *a Mark

      Select a snap ring, using the table below, that makes the thrust clearance of the 5th driven gear less than 0.1 mm (0.0039 in.).

      Snap Ring Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      A 2.22 (0.0874) F 2.52 (0.0992)
      B 2.28 (0.0898) G 2.58 (0.1016)
      C 2.34 (0.0921) H 2.64 (0.1039)
      D 2.40 (0.0945) J 2.70 (0.1063)
      E 2.46 (0.0969) - -
    2. A0137O6

      Using a brass bar and hammer, tap the new snap ring onto the output shaft.

  20. INSTALL OUTPUT SHAFT REAR BEARING

    A0138SME02

    1. Using SST and a press, install the output shaft rear bearing onto the output shaft.

      SST
      09950-60010   ( 09951-00370 )

  21. INSTALL OUTPUT SHAFT(MTM) COVER


    1. A01378HE05
      Text in Illustration
      *a Hole
      *b Align
      *c Groove

      Install the output shaft (MTM) cover, as shown in the illustration.

  22. INSTALL OUTPUT SHAFT FRONT BEARING

    A0136O7E01

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

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

  23. INSTALL FRONT DOFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    A0136LJE01

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

      SST
      09350-32014   ( 09351-32111, 09351-32130 )

  24. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    A01390CE01

    1. Install the shim onto the manual transmission case.

      Tech Tips

      When reusing the output shaft rear tapered roller bearing, first install a shim of the same thickness as the original.

      When installing a new output shaft 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).

      SST
      09950-60010   ( 09951-00620 )
      09950-70010   ( 09951-07100 )

  25. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

    A0138QQ

    1. Coat the differential case with gear oil, and install it onto the front transaxle case.

    2. A013906

      Install the manual transmission case with the 13 bolts.

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

      Tech Tips

      Manual transmission case side: 8 bolts

      Front transaxle case side: 5 bolts

    3. A01381BE01

      Using SST and a torque wrench, turn the differential case right and left 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
      New bearing preload
      0.78 to 1.57 N*m (7.95 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf)
      Used bearing preload
      0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.3 to 8.67 in.*lbf)

    5. Select a new shim.

      Differential Case Shim Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      01 1.10 (0.0433) 08 1.45 (0.0571) 15 1.80 (0.0709)
      02 1.15 (0.0453) 09 1.50 (0.0591) 16 1.85 (0.0728)
      03 1.20 (0.0472) 10 1.55 (0.0610) 17 1.90 (0.0748)
      04 1.25 (0.0492) 11 1.60 (0.0630) 18 1.95 (0.0768)
      05 1.30 (0.0512) 12 1.65 (0.0650) 19 2.00 (0.0787)
      06 1.35 (0.0531) 13 1.70 (0.0669) - -
      07 1.40 (0.0551) 14 1.75 (0.0689) - -

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

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

  26. INSTALL OUTPUT SHAFT REAR BEARING

    A0138I8

    1. Install the output shaft rear bearing shim onto the manual transmission case.

      Tech Tips

      When reusing the output shaft rear tapered roller bearing, first install a shim of the same thickness as the original.

      When installing a new output shaft rear tapered roller 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).

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

  27. ADJUST OUTPUT SHAFT BEARING PRELOAD

    A0136YR

    1. Install the output shaft assembly and the differential case onto the front transaxle case.

    2. A013906

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

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

      Tech Tips

      Manual transmission case side: 8 bolts

      Front transaxle case side: 5 bolts

    3. A01381BE01

      Using SST and a torque wrench, turn the output shaft assembly and the differential case right and left 2 or 3 times to allow the bearings to settle.

      SST
      09564-32011

    4. Using SST and a torque wrench, measure the starting preload.

      New bearing preload
      2.79 to 5.56 N*m (28.4 to 56.7 kgf*cm, 24.7 to 49.2 in.*lbf)
      Used bearing preload
      1.73 to 3.47 N*m (17.6 to 35.4 kgf*cm, 15.3 to 30.7 in.*lbf)

    5. Select a new output shaft rear bearing shim.

      Output Shaft Rear Bearing Shim Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      A 1.55 (0.0610) J 1.95 (0.0768)
      B 1.60 (0.0630) K 2.00 (0.0787)
      C 1.65 (0.0650) L 2.05 (0.0807)
      D 1.70 (0.0669) M 2.10 (0.0827)
      E 1.75 (0.0689) N 2.15 (0.0846)
      F 1.80 (0.0709) P 2.20 (0.0866)
      G 1.85 (0.0728) Q 2.25 (0.0886)
      H 1.90 (0.0748) - -
    6. A013906

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

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

    8. Remove the differential case from the front transaxle case.

  28. ADJUST INPUT SHAFT REAR BEARING SHIM


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

      Using vernier calipers, accurately measure dimensions A and B.

    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 (0.0039 in.)
      Input Shaft Rear Bearing Shim Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      F 1.80 (0.0709) N 2.15 (0.0846)
      G 1.85 (0.0728) P 2.20 (0.0866)
      H 1.90 (0.0748) Q 2.25 (0.0886)
      J 1.95 (0.0768) R 2.30 (0.0906)
      K 2.00 (0.0787) S 2.35 (0.0925)
      L 2.05 (0.0807) T 2.40 (0.0945)
      M 2.10 (0.0827) - -

    3. Install the input shaft rear bearing shim.

  29. INSTALL TRANSMISSION CASE OIL SEAL


    1. Coat a new oil seal lip with MP grease.

    2. A0137J0E01

      Using SST and a hammer, install the manual transmission case oil seal.

      SST
      09316-60011   ( 09316-00011 )
      Drive in depth
      2.1 to 3.1 mm (0.083 to 0.122in.)

      Note

      Do not damage the oil seal lip.

  30. INSTALL TRANSAXLE CASE OIL SEAL


    1. Coat a new oil seal lip with MP grease.

    2. A0137VJE01

      Using SST and a hammer, install the manual transaxle case oil seal.

      SST
      09636-20010
      Drive in depth
      1.7 to 2.7 mm (0.067 to 0.106 in.)

      Note

      Do not damage the oil seal lip.

  31. INSTALL FRONT TRANSAXLE CASE OIL SEAL

    A013758E04

    1. Using SST and a hammer, install a new front transaxle case oil seal into the front transaxle case.

      SST
      09710-20011   ( 09710-06071 )
      09950-70010   ( 09951-07150 )
      Drive in depth
      14.4 to 15.4 mm (0.567 to 0.606 in.)

    2. Coat the tip of the front transaxle case oil seal with MP grease.

  32. INSTALL TRANSMISSION MAGNET

    A0138HO

    1. Clean and reinstall the transmission magnet onto the front transaxle case.

  33. INSTALL OIL RECEIVER PIPE NO.2(MTM)

    A0138KT

    1. Install the oil receiver pipe No. 2 onto the manual transmission case.

      Note

      Do not damage the oil receiver pipe No. 2.

  34. INSTALL DIFFERENTIAL CASE ASSEMBLY

    A0138QQ

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

  35. INSTALL OUTPUT SHAFT ASSEMBLY

    A0136YR

    1. Install the output shaft assembly onto the front transaxle case.

  36. INSTALL INPUT SHAFT ASSEMBLY

    A0138DP

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

  37. INSTALL GEAR SHIFT FORK SHAFT NO.2

    A0138CQ

    1. Install the gear shift fork No. 2 onto the gear shift fork shaft No. 2.

    2. Using a hammer, tap a new snap ring onto the gear shift fork shaft No. 2.

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

    4. A0136B7

      Shift the gear shift fork No. 2 to the 4th gear range.

    5. Install the gear shift fork shaft No. 2, gear shift fork No. 2 and reverse shift fork.

    6. Coat the gear shift fork No. 2 bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    7. A0136DA

      Install the gear shift fork No. 2 bolt onto the gear shift fork No. 2.

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }
    8. A0138FA

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

    9. A0138MO

      Using a magnetic finger, install the straight pin onto the reverse shift fork.

  38. INSTALL GEAR SHIFT FORK SHAFT NO.3

    A0137HS

    1. Install the gear shift fork No. 3 onto the hub sleeve No. 3.

    2. A01383O

      Using a hammer, tap a new snap ring onto the gear shift fork shaft No. 3.

    3. A0136GP

      Install the gear shift fork shaft No. 3, compression spring, gear shift head No. 3 and gear shift fork No. 3 onto the front transaxle case.

    4. A0136BK

      Using a pin punch and hammer, drive the slotted spring pin into the gear shift head No. 3.

    5. A01373J

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

    6. A01365U

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

  39. INSTALL GEAR SHIFT FORK SHAFT NO.1

    A01361A

    1. Install the gear shift fork No. 1 onto the hub sleeve No. 1.

    2. A01383O

      Using a hammer, tap a new snap ring onto the gear shift fork shaft No. 1.

    3. A0136BU

      Install the gear shift fork shaft No. 1, gear shift head No. 1 and gear shift fork No. 1.

    4. A0136O9

      Using a pin punch and hammer, drive the slotted spring pin into the gear shift head No. 1.

    5. Coat the gear shift fork No. 1 bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A0138EB

      Install the bolt onto the gear shift fork No. 1.

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

  40. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

    A0136S9

  41. INSTALL REVERSE IDLER GEAR SHAFT


    1. Coat the reverse idler gear shaft with gear oil, and install it as shown.

    2. A0137Z6

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

  42. INSTALL REVERSE SHAFT ARM BRACKET ASSEMBLY

    A0137UT

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

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

  43. INSTALL MANUAL TRANSMISSION CASE

    A01363V

    1. 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

      Assemble parts within 10 minutes of application. Otherwise, the packing material must be removed and reapplied.

    2. A0137UP

      Install the 8 bolts onto the manual transmission side.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A0137FO

      Install the 5 bolts onto the manual transaxle side.

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

  44. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    A0136JQ

    1. Coat the reverse idler gear shaft bolt with adhesive, and install it with a new gasket.

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

  45. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


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

    2. A013784

      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

    3. Coat the 4 bolts with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A0136GU

      Install the shift and select lever shaft, wire harness clamp bracket and release fork retracting spring hanger onto the manual transmission case with the 4 bolts.

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

  46. INSTALL LOCK BALL ASSEMBLY NO. 1


    1. Coat the lock ball No. 1 with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A0136BH

      Install the lock ball No. 1 onto the manual transmission case.

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

  47. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    A0136ENE01

    1. Using SST, install the back-up light switch with a new gasket onto the manual transmission case.

      SST
      09817-16011
      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }
    2. A0136YL

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

  48. INSTALL MANUAL TRANSMISSION CASE PLUG

    A0136MB

    1. Install the manual transaxle case plug with a new gasket.

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

  49. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET

    A01365I

    1. Install the floor shift control lever housing support bracket onto the manual transaxle case with the 2 bolts.

      Torque:
      11 N*m  { 115 kgf*cm, 8.3 ft.*lbf }

  50. INSTALL CLUTCH HOUSING COVER NO.1

    A013662

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

  51. 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 )

  52. INSTALL CLUTCH RELEASE FORK LEVER


    1. A01385M

      Apply clutch release 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.

      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.

  53. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A0138DD

    1. Install the release bearing onto the transaxle case.

  54. INSTALL RELEASE FORK RETRACTING SPRING HANGER

    A01367T

    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 }