MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A0052Y2E01

      Using SST and a press, press a new front differential case front tapered roller bearing onto the differential case.

      SST
      09316-20011
      09950-60010   ( 09951-00580, 09952-06010 )
      09950-60020   ( 09951-00910 )
      09950-40011   ( 09957-04010 )
      09950-70010   ( 09951-07100 )
    2. A00565AE01

      Using SST and a press, press the front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer into the front transaxle case.

      SST
      09950-60010   ( 09952-06010 )
      09950-60020   ( 09951-00780, 09951-00890 )
      09950-70010   ( 09951-07100 )

  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A00599UE01

      Using SST and a press, press a new front differential case rear tapered roller bearing onto the differential case.

      SST
      09316-20011
      09950-60010   ( 09951-00580, 09952-06010 )
      09950-60020   ( 09951-00910 )
      09950-40011   ( 09957-04010 )
      09950-70010   ( 09951-07100 )
    2. A005994E01

      Using SST, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer as shown in the illustration.

      SST
      09950-60020   ( 09951-00770, 09951-00890 )

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A0052S7

      Coat the differential case assembly with gear oil and install it to the front transaxle case.

    2. A0056NY

      Install the manual transmission case with the 17 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A00587CE01

      Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      SST
      09564-50010

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

      SST
      09564-50010
      Standard preload (at starting)
      New bearing
      1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)
      Used bearing
      0.24 to 0.37 N*m (2.44 to 3.77 kgf*cm, 2.12 to 3.27 in.*lbf)

      If the preload is not as specified, replace the front differential case rear shim with one of a different thickness. Use the table below to select a front differential case rear shim which will ensure that the preload is within the specification.

      Standard Shim Thickness
      Mark Specified Condition Mark Specified Condition
      A 2.05 mm (0.0807 in.) K 2.50 mm (0.0984 in.)
      B 2.10 mm (0.0827 in.) L 2.55 mm (0.100 in.)
      C 2.15 mm (0.0846 in.) M 2.60 mm (0.102 in.)
      D 2.20 mm (0.0866 in.) N 2.65 mm (0.104 in.)
      E 2.25 mm (0.0886 in.) P 2.70 mm (0.106 in.)
      F 2.30 mm (0.0906 in.) Q 2.75 mm (0.108 in.)
      G 2.35 mm (0.0925 in.) R 2.80 mm (0.110 in.)
      H 2.40 mm (0.0945 in.) S 2.85 mm (0.112 in.)
      J 2.45 mm (0.0965 in.) T 2.90 mm (0.114 in.)

      Tech Tips


      • Select a thicker plate washer to increase the preload, or a thinner plate washer to decrease the preload.

      • Make a memo as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.

    5. Remove the 17 bolts and manual transmission case.

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

    7. Replace the installed front differential case rear plate washer with the one selected above.

  4. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A0052FY

      Install the output shaft cover to the front transaxle case.

      Note

      Insert the output shaft cover key into the case groove.

    2. A005630E01

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

      SST
      09950-60010   ( 09951-00620, 09952-06010 )
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

  5. INSTALL REAR OUTPUT SHAFT BEARING


    1. A00565KE05

      Using SST and a press, press the rear output shaft bearing (outer race) together with the rear output shaft bearing shim into the manual transmission case.

      SST
      09950-60010   ( 09951-00490, 09951-00620, 09952-06010 )
      09950-70010   ( 09951-07150 )

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A0052S7

      Coat the differential case assembly with gear oil and install it to the front transaxle case.

    2. A0054B2

      Coat the output shaft assembly with gear oil and install it to the front transaxle case.

    3. A0056NY

      Install the manual transmission case with the 17 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A005591E01
      Text in Illustration
      *1 Bearing Shim

      Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      SST
      09564-50010

    5. Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing preload using the following formula.

      SST
      09564-50010
      Formula
      Value A - Differential side bearing preload = Output shaft bearing preload
      Preload (at starting)
      New bearing
      2.80 to 5.60 N*m (29 to 57 kgf*cm, 25 to 50 in.*lbf)
      Used bearing
      2.31 to 4.62 N*m (24 to 47 kgf*cm, 20 to 41 in.*lbf)

      If the preload is not as specified, replace the rear output shaft bearing shim with one of a different thickness. Use the table below to select a rear output shaft bearing shim which will ensure that the preload is within the specification.

      Standard Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition
      A 1.30 mm (0.511 in.) P 1.95 mm (0.768 in.)
      B 1.35 mm (0.531 in.) Q 2.00 mm (0.787 in.)
      C 1.40 mm (0.551 in.) R 2.05 mm (0.807 in.)
      D 1.45 mm (0.571 in.) S 2.10 mm (0.827 in.)
      E 1.50 mm (0.591 in.) T 2.15 mm (0.846 in.)
      F 1.55 mm (0.610 in.) U 2.20 mm (0.866 in.)
      G 1.60 mm (0.630 in.) V 2.25 mm (0.886 in.)
      H 1.65 mm (0.650 in.) W 2.30 mm (0.906 in.)
      J 1.70 mm (0.669 in.) X 2.35 mm (0.925 in.)
      K 1.75 mm (0.689 in.) Y 2.40 mm (0.945 in.)
      L 1.80 mm (0.709 in.) Z 2.45 mm (0.965 in.)
      M 1.85 mm (0.728 in.) 1 2.50 mm (0.984 in.)
      N 1.90 mm (0.748 in.) - -

      Tech Tips

      Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

    6. Remove the 17 bolts and manual transmission case.

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

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

    9. Replace the installed rear output shaft bearing shim with the one selected above.

  7. INSTALL OUTER SHIFT LEVER OIL SEAL


    1. A0056HWE01
      *1 Depth

      Using SST and a hammer, tap in a new outer shift lever oil seal to the manual transmission case.

      SST
      09950-60010   ( 09951-00280 )
      09950-70010   ( 09951-07100 )
      Standard depth
      0.5 to 1.0 mm (0.0197 to 0.0393 in.)

    2. Coat the lip of the outer shaft lever oil seal with MP grease.

  8. INSTALL OUTER NO. 1 SHIFT LEVER


    1. A0055U0E03
      *1 Depth

      Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.

    2. Using a 5 mm pin punch and hammer, tap in the inner shift lever slotted spring pin to the inner No. 1 shift lever.

      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  9. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A0058XM

      Install the No. 1 oil receiver pipe to the manual transmission case.

      Tech Tips

      Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

  10. INSTALL STRAIGHT PIN


    1. A0053XKE01

      Using a plastic-faced hammer, tap in 5 new straight pins to the specified protrusion height.

      Protrusion height
      10.5 to 11.5 mm (0.413 to 0.452 in.)
      Text in Illustration
      *1 10.5 to 11.5 mm

  11. INSTALL BREATHER PLUG


    1. A0054BRE01

      Using SST and a hammer, tap in the breather plug to the front transaxle case.

      SST
      09350-30020   ( 09350-07110 )

  12. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A00594VE01
      *1 Depth

      Using SST and a hammer, tap in a new front transaxle case oil seal to the front transaxle case.

      SST
      09612-22011
      Standard depth
      1.0 to 2.0 mm (0.0393 to 0.0787 in.)

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

  13. INSTALL TRANSMISSION MAGNET


    1. A0058R0

      Clean the transmission magnet and install it to the front transaxle case.

  14. INSTALL INPUT SHAFT COVER


    1. A005493

      Install the input shaft cover to the manual transmission case.

      Note

      Insert the input shaft cover key into the manual transmission case groove.

  15. INSTALL REAR INPUT SHAFT BEARING SHIM


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

      Note

      Apply grease allowed on shim, (to avoid) falling shim off, from case during assembly.

    2. A0052CAE01

      Measure the distance between the end of the manual transmission case and rear input shaft bearing shim (Dimension A).

      Text in Illustration
      *1 Manual Transmission Case
      *2 Input Shaft Assembly
      *3 Front Transaxle Case
      *4 Dimension A
      *5 Dimension C
      *6 Dimension B

    3. Measure the distance between the end of the front transaxle case and installation surface of the front input shaft bearing (Dimension B).

    4. Measure the distance between both input shaft bearing outer races (Dimension C).

      Note

      Measure Dimension C with each bearing having no axial clearance.

    5. Calculate the rear input shaft bearing shim clearance using the following formula.

      Formula
      (Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

      If the clearance is not as specified, replace the rear input shaft bearing shim with one of a different thickness. Use the table below to select a rear input shaft bearing shim which will ensure that the clearance is within the specification.

      Standard Rear Input Shaft Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition
      A 1.15 mm (0.0453 in.) H 1.50 mm (0.0591 in.)
      B 1.20 mm (0.0472 in.) J 1.55 mm (0.0610 in.)
      C 1.25 mm (0.0492 in.) K 1.60 mm (0.0630 in.)
      D 1.30 mm (0.0512 in.) L 1.65 mm (0.0650 in.)
      E 1.35 mm (0.0531 in.) M 1.70 mm (0.0669 in.)
      F 1.40 mm (0.0551 in.) N 1.75 mm (0.0689 in.)
      G 1.45 mm (0.0571 in.) P 1.80 mm (0.0709 in.)

    6. Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the one selected above.

      Note

      Apply grease to the shim to prevent it from falling off the case during assembly.

  16. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A0052S7

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

  17. INSTALL INPUT SHAFT ASSEMBLY


    1. Apply gear oil to all sliding and rotating parts.

    2. A0058DFE01
      Text in Illustration
      *1 No. 1 Gear Shift Fork Shaft
      *2 Output Shaft

      Coat the No. 1 gear shift fork shaft with gear oil and install it onto the output shaft assembly.

    3. A0055DIE01
      Text in Illustration
      *1 No. 2 Gear Shift Fork Shaft
      *2 Input Shaft

      Coat the No. 2 gear shift fork shaft with gear oil and install it onto the input shaft assembly.

    4. Temporarily install the output shaft with No. 1 gear shift fork shaft to the input shaft assembly, and tie them with a rope or string.

    5. A0059J1

      Install the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.

  18. INSTALL OUTER SELECT LEVER OIL SEAL


    1. A0058OGE08
      *1 Depth

      Using SST and a hammer, tap in a new oil seal to the front transaxle case.

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )
      Standard depth
      0.5 to 1.0 mm (0.0197 to 0.0393 in.)

    2. Coat the lip of the outer select lever oil seal with MP grease.

  19. INSTALL OUTER SELECT LEVER


    1. A005508E01
      Text in Illustration
      *1 Mark

      Install the outer select lever and inner select lever to the front transaxle case.

      Tech Tips

      Install the lever with its mark positioned outside of the front transaxle case.

    2. A0055JN

      Coat the threads of the inner select lever bolt with adhesive and install it.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  20. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A00573H

      Install the shift interlock plate and shift and select lever shaft assembly to the front transaxle case, and then turn them counterclockwise.

      Tech Tips

      When installing the shift interlock plate, make sure to engage it with the inner select lever.

  21. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A0057RN

      Coat the threads of the 2 bolts with adhesive, and then install the reverse shift arm bracket with the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  22. INSTALL REVERSE SHIFT FORK


    1. A0054WX

      Using a pin punch 5 mm and a hammer, install the reverse shift fork slotted pin onto the reverse shift fork shaft.

      Standard depth
      -0.5 to 1.0 mm (-0.0197 to 0.03934 in.)

      Note

      Confirm the installation direction.

  23. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A0052L6

      Coat the reverse shift fork shaft assembly with gear oil and install it onto the front transaxle case.

  24. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A0057JWE01
      Text in Illustration
      *1 Case Hole
      *2 I-groove mark of the reverse idler gear shaft

      Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

      Note

      Using the bolt hole of the case for reference, align the I-groove mark of the reverse idler gear shaft within the range shown (approximately 20°).

      Tech Tips

      Raise the edge of the reverse shift arm bracket assembly and connect the reverse shift arm bracket assembly to the reverse shift fork shaft assembly.

  25. INSTALL MANUAL TRANSMISSION CASE


    1. A00599J

      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 packing diameter
      1.2 mm (0.0472 in.)

      Note


      • Remove any oil from the contact surfaces.

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

    2. A0054IP

      Push the outer No. 1 shift lever and install the manual transmission case.

      Tech Tips

      Pushing the outer No. 1 shift lever allows the manual transmission case to be installed.

    3. A0059IM

      Turn the outer No. 1 shift lever counterclockwise and then pull it.

    4. A0056NY

      Install the manual transmission case with the 17 bolts.

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

  26. INSTALL OUTER SHIFT LEVER E-RING


    1. A0053NY

      Install the outer shift lever E-ring to the outer No. 1 shift lever.

  27. INSTALL FRONT DRIVE SHAFT OIL SEAL RH

    Click here

  28. INSTALL FRONT DRIVE SHAFT OIL SEAL LH

    Click here

  29. INSTALL SHIFT DETENT BALL


    1. Install the 2 shift detent balls and 2 compression springs to the manual transmission case.

      Note

      Be careful not to drop the ball into the manual transmission case.

    2. A0055LH

      Coat the threads of the 2 shift detent ball plugs with adhesive and install them using a 6 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    3. A00546S

      Install the shift detent ball and compression spring to the manual transmission case.

      Note

      Be careful not to drop the lock ball pin into the manual transmission case.

    4. Coat the threads of the shift detent ball plug with adhesive and install it using a 6 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  30. INSTALL LOCK BALL PIN


    1. Install the lock ball pin and compression spring to the manual transmission case.

      Note

      Be careful not to drop the lock ball pin into the manual transmission case.

    2. A0055UV

      Coat the threads of the plug with adhesive and install it using a 10 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Install the lock ball pin and compression spring to the manual transmission case.

      Note

      Be careful not to drop the lock ball pin into the manual transmission case.

    4. A0056JK

      Coat the threads of the plug with adhesive and install it using a 10 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  31. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A005697

      Install a new gasket and the reverse idler gear shaft bolt to the manual transmission case.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  32. INSTALL RELEASE CYLINDER BLEEDER PLUG


    1. Install the release cylinder bleeder plug to the clutch release bleeder.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  33. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP


    1. Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.

  34. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  35. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  36. INSTALL CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    Click here

  37. INSPECT CLUTCH PIPE LINE

    Click here

  38. INSTALL CONTROL CABLE BRACKET ASSEMBLY


    1. A0057KB

      Install the control cable bracket to the manual transmission case with the 3 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  39. INSTALL NEUTRAL POSITION SWITCH


    1. A00551J

      Using a 27 mm deep socket wrench, install a new gasket and the neutral position switch to the manual transmission case.

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

  40. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A0055H7

      Using a 27 mm deep socket wrench, install a new gasket and the back-up light switch to the manual transmission case.

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

  41. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A0057V2

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

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

  42. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    1. A00570W

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

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