INPUT SHAFT REASSEMBLY


  1. INSTALL INPUT SHAFT FRONT BEARING

    A0138A6E02

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

      SST
      09515-10010

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

    A01360C

    1. Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input shaft.

  3. INSTALL 3RD GEAR

    A0136X3

    1. Coat the 3rd gear with gear oil, and install it onto the input shaft.

  4. INSTALL 3RD GEAR SYNCHRONIZER RING

    A0138E8

    1. Coat the 3rd gear synchronizer ring with gear oil, and install it onto the 3rd gear.

  5. INSTALL TRANSMISSION CLUTCH HUB NO. 2

    A0136P7

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

      Note

      Assemble transmission hub sleeve No. 2 and transmission clutch hub No. 2 in the correct orientations, as shown in the illustration.

    2. A0138EME02

      Using SST and a press, install transmission clutch hub sleeve No. 2 onto the input shaft.

      SST
      09506-35010

  6. INSTALL CLUTCH HUB NO. 2 SETTING SHAFT SNAP RING

    A0136IDE03

    1. Select a snap ring that allows the minimum axial play.

      Text in Illustration
      *a Mark
      Standard clearance
      0.1 mm (0.0039 in.) or less.
      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. A01369C

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

      Note

      Do not damage the journal surface of the input shaft.

  7. INSPECT 3RD GEAR THRUST CLEARANCE

    A0137QR

    1. Using a feeler gauge, measure the 3rd gear thrust clearance.

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

  8. INSPECT 3RD GEAR RADIAL CLEARANCE

    A01378F

    1. Using a dial indicator, measure the 3rd gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)

      If the clearance is outside the standard, replace the 3rd gear needle roller bearing.

  9. INSTALL 4TH GEAR SYNCHRONIZER RING

    A0137LX

    1. Coat the 4th gear synchronizer ring with gear oil, and install it onto transmission clutch hub No. 2.

  10. INSTALL 4TH GEAR BEARING SPACER

    A0137ZY

    1. Coat the 4th gear bearing spacer with gear oil, and install it onto the input shaft.

  11. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

    A0136PL

    1. Coat the 4th gear needle roller bearing with gear oil, and install it onto the input shaft.

  12. INSTALL 4TH GEAR

    A0138HK

    1. Coat the 4th gear with gear oil, and install it onto the input shaft.

  13. INSTALL 5TH GEAR THRUST WASHER BALL

    A0135ZC

    1. Install the 5th gear thrust washer ball onto the input shaft.

  14. INSTALL 5TH GEAR THRUST WASHER

    A0136F5

    1. Coat the 5th gear thrust washer with gear oil, and install it onto the input shaft.

  15. INSTALL 5TH GEAR SHAFT SNAP RING

    A0138BSE03

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

      Text in Illustration
      *a Mark
      Snap Ring Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      1 2.28 (0.0898) 4 2.46 (0.0969)
      2 2.34 (0.0921) 5 2.52 (0.0992)
      3 2.40 (0.0945) 6 2.58 (0.1016)
    2. A0136AK

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

      Note

      Do not damage the journal surface of the input shaft.

  16. INSPECT 4TH GEAR THRUST CLEARANCE

    A0138BD

    1. Using a dial indicator, measure the 4th gear thrust clearance.

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

  17. INSPECT 4TH GEAR RADIAL CLEARANCE

    A013612

    1. Using a dial indicator, measure the 4th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance exceeds the maximum, replace the 4th gear needle roller bearing or the shaft.

  18. INSTALL 5TH GEAR BEARING SPACER

    A0138A1

    1. Coat the 5th gear bearing spacer with gear oil, and install it onto the input shaft.

  19. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

    A0136ZC

    1. Coat the 5th gear needle roller bearing with gear oil, and install it onto the input shaft.

  20. INSTALL 5TH GEAR

    A0135TQ

    1. Coat the 5th gear with gear oil, and install it onto the input shaft.

  21. INSTALL 5TH GEAR SYNCHRONIZER RING

    A0136NK

    1. Coat the 5th gear synchronizer ring with gear oil, and install it onto the 5th gear.

  22. INSTALL TRANSMISSION CLUTCH HUB NO. 3

    A01373Y

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

      Note

      Assemble transmission hub sleeve No. 3 and transmission clutch hub No. 3 in the correct orientations, as shown in the illustration.

    2. Place the 5th gear synchronizer ring on the 5th gear, and align the synchronizer ring slots with shifting keys No. 3.

    3. A0136CJE02

      Using SST and a press, press No. 3 hub sleeve into the input shaft.

      SST
      09515-10010

      Note

      Install transmission hub sleeve No. 3 in the correct orientation, as shown in the illustration.

  23. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

    A0137KHE02

    1. Using SST and a press, install a new input shaft rear radial ball bearing onto the input shaft.

      SST
      09515-10010

  24. INSPECT 5TH GEAR THRUST CLEARANCE

    A0137MU

    1. Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.50 mm (0.0039 to 0.0197 in.)
      Maximum clearance
      0.50 mm (0.0197 in.)

  25. INSPECT 5TH GEAR RADIAL CLEARANCE

    A0137C1

    1. Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance exceeds the maximum, replace the 5th gear needle roller bearing.

  26. INSTALL OUTPUT SHAFT COVER

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

    1. Install the output shaft cover, as shown in the illustration.

  27. 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 )

  28. INSTALL FRONT DIFFERENTIAL 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 )

  29. 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 before.

      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 )

  30. 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 the manual transmission case from the front transaxle case.

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

  31. 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 before.

      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 )

  32. 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 the 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.

  33. ADJUST INPUT SHAFT REAR BEARING SHIM

    A01388VE03
    Text in Illustration
    *1 Input Shaft Rear Bearing Shim

    1. 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.

  34. INSTALL TRANSMISSION CASE OIL SEAL

  35. INSTALL TRANSAXLE CASE OIL SEAL

  36. 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.

  37. INSTALL TRANSMISSION MAGNET

    A0138HO

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

  38. INSTALL OIL RECEIVER PIPE NO. 2

    A0138KT

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

      Note

      Do not damage oil receiver pipe No. 2.

  39. INSTALL DIFFERENTIAL CASE ASSEMBLY

    A0138QQ

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

  40. INSTALL OUTPUT SHAFT ASSEMBLY

    A0136YR

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

  41. 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.

  42. INSTALL GEAR SHIFT FORK SHAFT NO. 2

    A0138CQ

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

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

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

    4. A0136B7

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

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

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

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

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

    9. A0138MO

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

  43. INSTALL GEAR SHIFT FORK SHAFT NO. 3

    A0137HS

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

    2. A01383O

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

    3. A0136GP

      Install gear shift fork shaft No. 3, the 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 gear shift head No. 3.

    5. A01373J

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

    6. A01365U

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

  44. INSTALL GEAR SHIFT FORK SHAFT NO. 1

    A01361A

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

    2. A01383O

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

    3. A0136BU

      Install 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 gear shift head No. 1.

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

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

      Install the bolt onto gear shift fork No. 1.

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

  45. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

    A0136S9

  46. INSTALL REVERSE IDLER GEAR SHAFT


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

    2. A0137Z6E02
      Text in Illustration
      *a Mark

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

  47. INSTALL REVERSE SHIFT 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 }

  48. 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. A01382O

      Install the 8 bolts onto the manual transmission side.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A01361H

      Install the 5 bolts onto the manual transaxle side.

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

  49. 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 }

  50. 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 }

  51. INSTALL LOCK BALL ASSEMBLY NO. 1


    1. Coat lock ball No. 1 with adhesive.

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

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

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

  52. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A0136ENE01

      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. A0136NDE02
      Text in Illustration
      *A for Bend Type
      *B for Clamp Type
      *1 Wire Harness

      Install the back-up light switch wire harness into the clamp bracket.

      Tech Tips


      • For bend type :

        Fit the wire harness into the bracket and push it closed with your finger.

      • For clamp type :

        Insert the wire harness into the clamp of the bracket.

  53. INSTALL MANUAL TRANSAXLE CASE PLUG


    1. A0136MB

      Install the manual transaxle case plug with a new gasket.

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

  54. 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 }

  55. INSTALL CLUTCH HOUSING COVER NO. 1

    A013662

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

  56. 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.

  57. INSTALL CLUTCH RELEASE FORK LEVER

    A01385M

    1. 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. A01389B

      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.

  58. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A0138DD

    1. Install the release bearing onto the transaxle case.

  59. 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 }