MANUAL TRANSAXLE UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT COVER

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

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

  2. 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 )

  3. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    A0135VBE01

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

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

  4. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    A01390CE01

    1. Install the differential case shim onto the 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   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

  5. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

    A0138QQ

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

    2. A013906

      Install the transmission case with the 13 bolts.

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

      Tech Tips

      Transmission case side: 8 bolts

      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 (7.96 to 16.00 kgf*cm, 6.91 to 13.89 in.*lbf)
      Used bearing preload
      0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.34 to 8.67 in.*lbf)

    5. Select a new differential case shim.

      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 transmission case from the transaxle case.

    7. Remove the differential case from the transaxle case.

  6. INSTALL OUTPUT SHAFT REAR BEARING

    A0138I8

    1. Install the output shaft rear bearing shim onto the 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 )

  7. ADJUST OUTPUT SHAFT BEARING PRELOAD

    A0136YR

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

    2. A013906

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

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

      Tech Tips

      Transmission case side: 8 bolts

      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. 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
      New bearing preload
      2.79 to 5.56 N*m (28.5 to 56.6 kgf*cm, 24.7 to 49.2 in.*lbf)
      Used bearing preload
      1.73 to 3.47 N*m (17.7 to 35.3 kgf*cm, 15.4 to 30.7 in.*lbf)

    5. Select a new output shaft rear bearing shim.

      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. A013906

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

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

    8. Remove the differential case from the transaxle case.

  8. ADJUST INPUT SHAFT REAR BEARING SHIM

    A01388VE03
    Text in Illustration
    *1 Input Shaft Rear Bearing Shim

    1. Using a vernier caliper, 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 (0.00393 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 a new oil seal lip with MP grease.

    2. A0137J0E01

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

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

      Note

      Do not damage the oil seal lip.

  10. INSTALL TRANSAXLE CASE OIL SEAL


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

    2. A0137VJE01

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

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

      Note

      Do not damage the oil seal lip.

  11. INSTALL FRONT TRANSAXLE CASE OIL SEAL

    A013758E04

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

      SST
      09950-60010   ( 09951-00360 )
      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.

  12. INSTALL TRANSMISSION MAGNET

    A0138HO

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

  13. INSTALL NO. 2 OIL RECEIVER PIPE

    A0138KT

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

      Note

      Do not damage the No. 2 oil receiver pipe.

  14. INSTALL DIFFERENTIAL CASE ASSEMBLY

    A0138QQ

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

  15. INSTALL OUTPUT SHAFT ASSEMBLY

    A0136YR

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

  16. 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 transaxle case.

  17. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

    A0138CQ

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

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

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

    4. A0136B7

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

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

    6. A0136DA

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

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

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

    8. A0138MO

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

  18. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

    A0137HS

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

    2. A01383O

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

    3. A0136GP

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

    4. A0136BK

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

    5. A01373J

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

    6. A01365U

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

  19. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

    A01361A

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

    2. A01383O

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

    3. A0136BU

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

    4. A0136O9

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

    5. A0138EB

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

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

  20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

    A0136S9

  21. 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.

  22. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

    A0137UT

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

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

  23. INSTALL MANUAL TRANSMISSION CASE

    A01363V

    1. Apply seal packing to the 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. A013689

      Install the 5 bolts onto the manual transaxle side.

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

  24. 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 }

  25. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


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

    2. A013784

      Apply seal packing to the transmission case, as shown in the illustration.

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

    3. Coat bolt A with adhesive.

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

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

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

  27. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A0136ENE01

      Using SST, install the back-up light switch with a new gasket onto the 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 into the 2 clamps.

  28. 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 }

  29. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET

    A01365I

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

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

  30. INSTALL NO. 1 CLUTCH HOUSING COVER


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

  31. 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 )

  32. 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.

  33. 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.

  34. 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 }