MULTI-MODE MANUAL TRANSAXLE UNIT REASSEMBLY


  1. INSTALL TRANSAXLE CASE STRAIGHT PIN


    1. A0137VOE02
      Text in Illustration
      *a Standard Depth

      Install the transaxle case straight pin.

      Standard depth
      10.5 to 11.5 mm (0.4134 to 0.4528 in.)

  2. 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.

  3. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A0136O7E02

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

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

  4. INSTALL FR0NT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0136LJE02

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

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

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A01390CE02

      Install the shim onto the manual transmission case.

      Tech Tips

      When re-using the output shaft rear tapered roller bearing, first install a shim of the same thickness as before. If 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 FR differential case rear tapered roller bearing (outer race).

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

  6. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD


    1. A0138QQE02

      Coat the differential case assembly with gear oil, and install it onto 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

      Manual transmission case side: 8 bolts

      Front transaxle case side: 5 bolts

    3. A01381BE02

      Using SST and a torque wrench, turn the differential case assembly 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 preload.

      SST
      09564-32011
      Preload (at starting)
      New bearing
      0.78 to 1.57 N*m (7.95 to 16.00 kgf*cm, 6.9 to 13.89 in.*lbf)
      Used bearing
      0.49 to 0.98 N*m (5.00 to 9.99 kgf*cm, 4.3 to 8.67 in.*lbf)

    5. Select another shim.

      Shim Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      01 1.10 (0.433) 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 (0.04952) 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 assembly from the front transaxle case.

  7. INSTALL OUTPUT SHAFT REAR BEARING


    1. A0138I8E01

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

      Tech Tips

      When re-using the output shaft rear tapered roller bearing, first install a shim of the same thickness as before. If installing a new output shaft rear tapered roller bearing, first select and install a shim which is thinner than the original.

    2. A01362VE02

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

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

  8. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A0136YRE01

      Install the output shaft assembly and the differential case assembly 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 }
    3. A01381BE03

      Using SST and a torque wrench, turn the output shaft assembly and differential case assembly 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 preload.

      SST
      09564-32011
      Preload (at starting)
      New bearing
      2.79 to 5.56 N*m (28.4 to 56.7 kgf*cm, 24.7 to 49.2 in.*lbf)
      Used bearing
      1.73 to 3.47 N*m (17.6 to 35.4 kgf*cm, 15.3 to 30.7 in.*lbf)

    5. Select another output shaft rear bearing shim.

      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. A013906E01

      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 assembly from the front transaxle case.

  9. INSTALL 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 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.)
      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.

  10. INSTALL TRANSMISSION CASE OIL SEAL


    1. A01383FE02

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

      SST
      09950-60010   ( 09951-00370 )
      09950-70010   ( 09951-07150 )
      Drive in depth
      2.1 to 3.1 mm (0.083 to 0.122 in.)

    2. Coat the tip of the transmission oil seal with MP grease.

  11. INSTALL TRANSAXLE CASE OIL SEAL


    1. A01372SE02

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

      SST
      09316-60011   ( 09316-00011 )
      Drive in depth
      1.7 to 2.7 mm (0.067 to 0.106 in.)

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

  12. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A013758E04

      Using SST and a hammer, install the 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.

  13. INSTALL TRANSMISSION MAGNET


    1. A0138HOE01

      Clean the transmission magnet and then install it onto the front transaxle case.

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


    1. A0138KTE02

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

      Note

      Do not damage oil receiver pipe No. 2.

  15. INSTALL FRONT DIFFERENTIAL CASE


    1. A0138QQE01

      Coat the differential case tapered roller bearings with gear oil, and install them onto the front transaxle case.

  16. INSTALL OUTPUT SHAFT


    1. A0136YRE01

      Install the output shaft assembly onto the front transaxle case.

  17. INSTALL INPUT SHAFT


    1. A0138DPE01

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

  18. INSTALL GEAR SHIFT FORK SHAFT NO.2


    1. A0137VZ

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

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

    3. A0136F2

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

    4. Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft No. 2.

    5. A0137U5

      Shift hub sleeve No. 2 into the 3rd gear, as shown.

    6. A0137KD

      Install gear shift fork shaft No. 2 with the 2 snap rings.

    7. Install gear shift fork No.2 and reverse shift fork onto the transaxle case.

    8. Set gear shift fork No. 2 onto hub sleeve No. 2.

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

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }
    10. A0137D0E02
      Text in Illustration
      *1 Straight Pin
      *2 Gear Shift Fork Shaft No. 2

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

      Note

      Insert the straight pin along the groove on gear shift fork shaft No. 2, as shown in the illustration.

  19. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A0138OH

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

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

      Note

      Fit the edge of the reverse shift fork into the hole in the reverse shift arm bracket.

  20. INSTALL REVERSE IDLER GEAR SHAFT


    1. A013939

      Coat the reverse idler gear shaft with gear oil, and install it onto the transmission case.

      Note

      Set the top of the reverse shift arm bracket into the groove on the reverse idler gear, as shown in the illustration.

    2. A01367BE02
      Text in Illustration
      *a Align

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

  21. INSTALL GEAR SHIFT FORK SHAFT NO.3


    1. A013865

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

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

    3. Set gear shift fork No. 3 onto hub sleeve No. 3.

    4. Using a screwdriver and hammer, tap 2 new snap rings onto gear shift fork shaft No. 3.

    5. A0137WE

      Using a magnetic finger, install the straight pin onto gear shift fork No. 3.

  22. INSTALL GEAR SHIFT FORK SHAFT NO.1


    1. A0136Q4

      Using a screwdriver and hammer, install a new snap ring onto gear shift fork shaft No. 1.

    2. A01389M

      Set gear shift fork No. 1 onto the reverse gear.

    3. Set gear shift head No. 1 onto gear shift fork No. 1.

    4. Install gear shift fork shaft No. 1 onto the transaxle case with the snap ring.

      Note

      Insert the straight pin along the groove on gear shift fork shaft No. 1, as shown in the illustration.

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

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

  23. INSTALL SHIFT HEAD SET SLOTTED SPRING PIN


    1. A0138ZEE02
      Text in Illustration
      *a Drive in Depth

      Using a pin punch and hammer, tap the 2 slotted spring pins into the No. 1 and No. 3 gear shift heads.

      Drive in depth
      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

  24. INSTALL INPUT SHAFT REAR BEARING SHIM


    1. A0138W3

      Install the input shaft rear bearing shim onto the transmission case.

      Tech Tips

      Install the previously selected shim.

  25. INSTALL MANUAL TRANSMISSION CASE


    1. A0136POE02
      Text in Illustration
      *1 Seal Packing

      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 the parts within 10 minutes of application.

    2. A01367G

      Coat the 13 bolts with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

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

  26. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A0136H0

      Apply adhesive to the reverse idler gear shaft lock bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the reverse idler gear shaft lock bolt with a new gasket.

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

  27. INSTALL TRANSMISSION REVOLUTION SENSOR


    1. A0137KP

      Install a new O-ring onto the transmission revolution sensor.

    2. Install the transmission revolution sensor with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

    3. Install the transmission case protector with the bolt.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  28. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY


    1. A01373DE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the transmission case as shown.

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

    2. Apply adhesive to the actuator set bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A0137SQ

      Install the shift and select actuator with the 6 bolts and wire harness clamp.

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

  29. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A0137KXE01

      Using SST, install the park/neutral position switch with a new gasket onto the transaxle case.

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

  30. INSTALL LOCK BALL ASSEMBLY NO.1


    1. A0135YJ

      Apply adhesive to the lock ball assembly threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Using an 18 mm socket wrench, install the lock ball assembly onto the transmission case.

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

  31. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A0136BAE01

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

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

  32. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

    A0138TK

    1. Using SST, drive in the oil seal until its surface is flush with the transaxle housing.

      SST
      09950-60010
      09950-70010

  33. INSTALL CLUTCH RELEASE FORK

    A0137AA

    1. Apply release hub grease to the release fork, fork lever and fork lever bushings.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
    2. A0136QW

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
    3. A0137AY

      Install the fork lever and fork onto the transaxle housing.

    4. Install a new E-ring onto the fork lever.

    5. A0138HM

      Install the release bearing with the clip.

  34. INSTALL SHIFT STROKE SENSOR

    A01373GE01

    1. Apply MP grease to a new O-ring.

    2. Install the new O-ring onto the stroke sensor.

    3. Set the stroke senor so that the sensor side and the actuator side sensor arms are in the positions shown in the illustration.

    4. A0136N5

      Turn the stroke sensor clockwise and fix it with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    5. Connect the shift stroke sensor connector.