MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT


    1. A01DPV3

      Apply gear oil to the sliding part of the output shaft.

    2. Using a plastic-faced hammer, install the output shaft by tapping the intermediate plate.

  2. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING (for Center Bearing Side)


    1. A01DOXL

      Using a snap ring expander, install the output shaft bearing shaft snap ring to the output shaft center bearing.

  3. INSTALL INPUT SHAFT


    1. A01DTDA

      Apply gear oil to the input shaft and No. 2 synchronizer ring, and install them to the output shaft.

      Note


      • Install the No. 2 synchronizer ring so that its groove fits onto the No. 2 synchromesh shifting key.

      • Check that the input shaft rotates smoothly.

  4. INSTALL COUNTER GEAR


    1. A01DMF0

      Install the counter gear to the intermediate plate.

  5. INSTALL COUNTER SHAFT CENTER BEARING


    1. A01DMQDE01

      Using SST and a hammer, tap in a new counter shaft center bearing to the intermediate plate.

      SST
      09316-60011

      Tech Tips

      Install the counter shaft center bearing while tapping the tip of the counter gear with a plastic-faced hammer so that the counter gear does not hit the side wall of the output shaft gear by being pushed forward.

    2. Using a snap ring expander, install the snap ring to the counter shaft center bearing.

  6. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01DQDME02

      Apply gear oil to the sliding parts of the reverse idler gear sub-assembly and reverse idler gear shaft, and install the reverse idler gear sub-assembly and reverse idler shaft to the intermediate plate.

      Note

      Be sure to install the reverse idler gear shaft from the rear with the groove facing the rear side.

  7. INSTALL OUTPUT SHAFT REAR BEARING RETAINER


    1. A01DOJGE02

      Insert the protrusion of the output shaft rear bearing retainer into the groove of the reverse idler gear shaft. Then install the output shaft rear bearing retainer with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  8. INSTALL 5TH GEAR THRUST WASHER PIN


    1. A01DMKC

      Apply MP grease to the 5th gear thrust washer pin and install it to the counter gear.

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A01DOO9

      Apply gear oil to the 5th gear thrust washer and install it to the counter gear.

      Note

      Install the 5th gear thrust washer so that its chamfered side faces the front side.

  10. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


    1. Apply gear oil to the sliding part of No. 3 transmission hub sleeve and install it to the counter 5th gear.

      Note

      Make sure that the No. 3 transmission hub sleeve and counter 5th gear are facing the proper direction.

    2. A01DPPLE01
      Text in Illustration
      *a Cutout
      *b Protrusion

      Install the 2 No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring to the counter 5th gear as shown in the illustration.

      Tech Tips

      When installing the No. 3 synchromesh shifting key spring, make sure the protrusion fits into the cutout.

    3. A01DOK4

      Using a snap ring expander, install the snap ring to the counter 5th gear.

  11. INSTALL COUNTER 5TH GEAR BEARING


    1. A01DUR4E01

      Apply gear oil to the counter 5th gear bearing and install it to the counter 5th gear.

  12. INSTALL COUNTER 5TH GEAR


    1. A01DLUK

      Apply gear oil to the counter 5th gear and No. 3 transmission hub sleeve, and install the counter 5th gear to the counter gear.

  13. INSTALL OUTER NO. 3 SYNCHRONIZER RING


    1. A01DNVI

      Apply gear oil to the outer No. 3 synchronizer ring and install it to the counter gear.

      Note

      Install the outer No. 3 synchronizer ring so that its groove fits onto the No. 3 synchromesh shifting key.

  14. INSTALL NO. 5 GEAR SPLINE PIECE


    1. A01DNSOE01

      Using SST and a press, press in the No. 5 gear spline piece to the counter gear.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Check that the counter 5th gear rotates freely.

  15. INSTALL COUNTER GEAR REAR SHAFT SNAP RING


    1. Select a counter gear rear shaft snap ring so that the thrust clearance between the No. 5 gear spline piece and counter gear rear shaft snap ring to be within the specification.

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Snap Ring Thickness
      Thickness
      2.85 mm (0.1122 in.)
      2.90 mm (0.1141 in.)
      2.95 mm (0.1161 in.)
      3.00 mm (0.1181 in.)
      3.05 mm (0.1200 in.)
      3.10 mm (0.1220 in.)
      3.15 mm (0.1240 in.)

    2. Secure the intermediate plate in a vise between aluminum plates.

    3. A01DT9VE01

      Using a brass bar and hammer, tap on the counter gear rear shaft snap ring.

  16. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE


    1. A01DNY8E01

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      • If the clearance is not as specified, replace the counter 5th gear.

  17. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE


    1. A01DT3RE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

      • If the clearance is not as specified, replace the counter 5th gear bearing with a new one.

  18. INSTALL OUTPUT SHAFT REAR BEARING


    1. A01DSQZE01

      Using SST and a hammer, press in the output shaft spacer and a new output shaft rear bearing to the output shaft.

      SST
      09309-35010

  19. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING (for Rear Bearing Side)


    1. Select a output shaft bearing shaft snap ring so that the thrust clearance between the output shaft bearing shaft and output shaft bearing shaft snap ring to be within the specification.

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Snap Ring Thickness
      Thickness Thickness
      2.65 mm (0.1043 in.) 3.10 mm (0.1220 in.)
      2.70 mm (0.1063 in.) 3.15 mm (0.1240 in.)
      2.75 mm (0.1083 in.) 3.20 mm (0.1260 in.)
      2.80 mm (0.1102 in.) 3.25 mm (0.1280 in.)
      2.85 mm (0.1122 in.) 3.30 mm (0.1299 in.)
      2.90 mm (0.1142 in.) 3.35 mm (0.1319 in.)
      2.95 mm (0.1161 in.) 3.40 mm (0.1339 in.)
      3.00 mm (0.1181 in.) 3.45 mm (0.1358 in.)
      3.05 mm (0.1200 in.) -
    2. A01DRJ2E01

      Using a brass bar and hammer, tap on the output shaft bearing shaft snap ring.

  20. INSTALL REVERSE SHIFT ARM BRACKET


    1. A01DLXG

      Install the reverse shift arm to the reverse shift arm bracket with a new snap ring.

    2. A01DP1KE02
      Text in Illustration
      *1 Reverse Idler Gear Sub-assembly
      *2 Reverse Shift Arm

      Insert the tip of the reverse shift arm into the reverse idler gear sub-assembly.

    3. A01DQHA

      Install the reverse shift arm bracket with the 2 bolts.

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

    4. Install the torsion spring to the reverse shift arm bracket.

      Note

      Make sure that the torsion spring is securely installed to the reverse shift arm.

  21. INSTALL REVERSE SHIFT FORK


    1. A01DMH9

      Install the reverse shift fork to the reverse shift arm.

  22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A01DOIM

      Install the No. 3 shift fork to the No. 3 transmission hub sleeve and the No. 3 gear shift fork shaft to the intermediate plate from the front side.

    2. A01DPC1

      Install the straight pin to the reverse shift fork.

    3. A01DSO5

      Using a brass bar and hammer, tap on the snap ring to the No. 3 gear shift fork shaft.

    4. A01DRC6

      Using a 5 mm pin punch and hammer, tap on the shift fork set slotted spring pin to the No. 3 shift fork.

  23. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A01DTCXE04

      Install the No. 1 shift interlock roller to the intermediate plate.

    2. A01DPWJ

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

    3. A01DTVB

      Install the No. 1 gear shift fork shaft to the intermediate plate from the rear side.

    4. A01DSOT

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    5. A01DNMB

      Using a brass bar and hammer, tap in the snap ring to the No. 1 gear shift fork shaft.

  24. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A01DN6ME02

      Install the shift interlock pin and No. 1 shift interlock roller to the intermediate plate.

    2. A01DOV4

      Install the No. 2 shift fork to the No. 2 transmission hub sleeve.

    3. A01DS95E02

      Apply gear oil to the No. 2 gear shift fork shaft and install it to the intermediate plate from the rear side.

    4. A01DR8S

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    5. A01DLUL

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

  25. INSTALL NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A01DSZ0

      Install the 2 detent balls and 2 compression springs to the intermediate plate.

    2. for Type A:

      Apply adhesive to 2 or 3 threads of the 2 No. 1 shift detent ball spring seats.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A01DOA2

      for Type A:

      Using a 6 mm hexagon socket wrench, install the 2 No. 1 shift detent ball spring seats to the intermediate plate.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
    4. A01DSVV

      for Type B:

      Using a T40 "TORX" socket wrench, install the 2 No. 1 shift detent ball spring seats to the intermediate plate.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
    5. A01DS14E02

      Install the detent ball and low side compression spring to the intermediate plate.

    6. for Type A:

      Apply adhesive to 2 or 3 threads of the No. 1 shift detent ball spring seat.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    7. A01DQSF

      for Type A:

      Using a 6 mm hexagon socket wrench, install the No. 1 shift detent ball spring seat to the intermediate plate.

    8. A01DPI8E02

      for Type B:

      Using a T40 "TORX" socket wrench, install the No. 1 shift detent ball spring seat to the intermediate plate.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

  26. INSTALL TRANSMISSION MAGNET


    1. A01DMG7E02

      Clean the transmission magnet and install it to the intermediate plate.

  27. INSTALL MANUAL TRANSMISSION CASE


    1. A01DSNFE16
      Text in Illustration
      *a Seal Packing

      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
      Seal diameter
      1.2 mm (0.0472 in.)

      Note

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

    2. A01DTINE01

      Place the manual transmission case on wooden blocks.

    3. Using a plastic-faced hammer, tap the intermediate plate to install the manual transmission case.

  28. INSTALL NO. 1 COUNTER GEAR FRONT BEARING SNAP RING


    1. A01DOV0E02

      Using a snap ring expander, install the No. 1 counter gear front bearing snap ring to the counter gear front bearing.

  29. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A01DO4LE02

      Using a snap ring expander, install the front bearing shaft snap ring to the input shaft front bearing.

  30. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01DNNBE01

      Using SST and a hammer, tap in a new transmission front bearing retainer oil seal to the front bearing retainer.

      SST
      09950-60010   ( 09951-00300, 09951-00520, 09952-06010 )
      09950-70010   ( 09951-07100 )
      Standard oil seal depth
      11.20 to 12.20 mm (0.441 to 0.480 in.)

    2. Apply a light coat of MP grease to the lip of the transmission front bearing retainer oil seal.

  31. INSTALL FRONT BEARING RETAINER


    1. A01DTNDE05
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the front bearing retainer as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal diameter
      1.2 mm (0.0472 in.)

      Note

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

    2. A01DNI0E02

      Install the front bearing retainer to the manual transmission case with the 8 bolts.

      Torque:
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }

    3. Check that the input shaft and output shaft rotate smoothly.

  32. INSTALL TRANSFER ADAPTER OIL SEAL


    1. A01DSZOE02

      Using SST and a hammer, tap in a new transfer adapter oil seal to the transfer adapter.

      SST
      09710-30050
      09950-70010   ( 09951-07100 )
      Standard oil seal depth
      45.4 to 46.4 mm (1.79 to 1.82 in.)

    2. Apply a light coat of MP grease to the lip of the transfer adapter oil seal.

  33. INSTALL REVERSE RESTRICT PIN ASSEMBLY


    1. A01DR9OE02

      Install the reverse restrict pin assembly to the transfer adapter.

    2. A01DTG7E02

      Using a 5 mm pin punch and hammer, tap in the reverse restrict pin slotted spring pin to the transfer adapter.

    3. A01DOGRE02

      Using a T40 "TORX" socket wrench, install the reverse restrict pin plug to the transfer adapter.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

  34. INSTALL TRANSFER OIL RECEIVER PIPE


    1. A01DPR3E02

      Install the transfer oil receiver pipe to the transfer adapter.

  35. INSTALL TRANSFER ADAPTER


    1. A01DSNFE16
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the transfer adapter as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal diameter
      1.2 mm (0.0472 in.)

      Note

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

    2. A01DMFCE01

      Using a plastic-faced hammer, tap the transfer adapter to attach it to the manual transmission case.

    3. A01DMBNE03

      Install the transfer adapter to the manual transmission case with the 10 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  36. INSTALL SHIFT AND SELECT LEVER


    1. A01DT9FE01
      Text in Illustration
      *1 Shift Lever Housing
      *2 Shift and Select Lever

      Install the shift and select lever with the shift lever housing to the transfer adapter.

    2. A01DP45

      Install the bolt to the shift lever housing.

      Torque:
      33 N*m  { 340 kgf*cm, 25 ft.*lbf }

  37. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY


    1. A01DN86

      Install the floor shift control shift lever retainer sub-assembly and a new gasket with the 4 bolts.

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

  38. INSTALL RESTRICT PIN


    1. A01DPMN

      Install the 2 restrict pins.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  39. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01DPILE09

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

      SST
      09817-16011
      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  40. INSTALL CLUTCH HOUSING

    A01DOWOE01

    1. Temporarily install the clutch housing with the 7 bolts labeled A.

    2. Apply adhesive to the 2 bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Temporarily install the 2 bolts labeled B.

    4. Tighten the 9 bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  41. INSTALL RELEASE FORK SUPPORT


    1. Install the release fork support to the manual transmission unit.

      Torque:
      47 N*m  { 479 kgf*cm, 34 ft.*lbf }

  42. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A01DPCCE02
    Text in Illustration
    *1 Release hub grease

    1. Apply release hub grease to the clutch release bearing, and then install it to the clutch release fork with the clip.

      Grease
      Toyota Genuine Release Hub Grease or equivalent

  43. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. Install the clutch release fork.

      Note

      After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

    2. A01DQKYE01
      Text in Illustration
      *1 Clutch spline grease

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

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  44. INSTALL CLUTCH RELEASE FORK BOOT


    1. Install the release fork boot to the clutch housing.

  45. INSTALL DRAIN PLUG


    1. A01DQHW

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

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  46. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01DP0NE01

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

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }