MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL SHIFT FORK SHAFT BEARING


    1. A004RYGE01

      Using SST and a press, press in 4 new shift fork shaft bearings.

      SST
      09820-00031
      Standard depth
      0 to 0.5 mm (0 to 0.0196 in.)

  2. INSTALL OUTPUT SHAFT COVER


    1. A004Q6EE05
      Text in Illustration
      *a Protrusion
      *b Groove

      Install the output shaft cover as shown in the illustration.

  3. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING OUTER RACE


    1. A004Q5RE01

      Using SST and a hammer, tap in the No. 2 output shaft front bearing outer race.

      SST
      09950-70010   ( 09951-07100, 09951-00710 )

  4. INSTALL OUTPUT SHAFT COVER


    1. A004SE9E04
      Text in Illustration
      *a Protrusion
      *b Groove

      Install the output shaft cover as shown in the illustration.

  5. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A004U7DE01

      Coat a new front bearing with gear oil. Then, using SST and a press, install the bearing to the front transaxle case.

      SST
      09223-15020
    2. A004TRP

      Install the bearing lock plate and bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  6. INSTALL TRANSAXLE CASE OIL SEAL


    1. A004NJ7E01

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

      SST
      09950-60010   ( 09951-00580 )
      Standard depth
      4.4 to 5.0 mm (0.174 to 0.196 in.)

    2. Coat the lip of the oil seal with MP grease.

  7. INSTALL INPUT SHAFT FRONT BEARING


    1. A004MNVE01

      Coat a new input shaft front bearing with gear oil. Then, using SST and a press, install the bearing to the front transaxle case.

      SST
      09223-00010
    2. A004MTH

      Install the bearing lock plate and bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  8. INSTALL INPUT AND OUTPUT SHAFT REAR BEARING SHAFT SNAP RING


    1. A004QKU

      Using snap ring expander, install the 2 snap rings.

  9. INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A004R38E03

      Using SST and a press, press in a new shift and select lever shaft needle roller bearing.

      SST
      09285-76010
      Clearance
      177.8 to 178.7 mm (7.00 to 7.03 in.)

  10. INSTALL SHIFT FORK SHAFT BEARING


    1. A004TTFE04

      Using SST and a press, press in 4 new shift fork shaft bearings.

      SST
      09307-12010
      09820-00031
      Clearance A
      168.2 to 169.3 mm (6.63 to 6.66 in.)
      Clearance B
      162.2 to 163.3 mm (6.39 to 6.42 in.)

  11. INSTALL FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE


    1. A004OIWE01

      Using SST and a hammer, tap in the front differential case front bearing outer race.

      SST
      09950-70010   ( 09951-00910, 09951-07150 )

  12. INSTALL FRONT DIFFERENTIAL CASE REAR BEARING OUTER RACE


    1. A004QIG

      Install the front differential case rear shim into the manual transmission case.

    2. A004S5DE01

      Using SST and a hammer, install the front differential case rear bearing outer race.

      SST
      09950-60010   ( 09951-00910 )
      09950-70010   ( 09951-07100 )

  13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A004NTT

      install the front differential case assembly to the front transaxle case

    2. A004Q1H

      Install the manual transmission case to the front transaxle case with the 12 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A004R6R

      Install the 6 bolts to the front transaxle case side.

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

    4. Turn the differential case in both directions and make sure it turns smoothly.

    5. A004PV7
      Text in Illustration
      *a Mark

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

      SST
      09564-33010
      New bearing preload
      1.00 to 2.49 N*m (10.2 to 25.3 kgf*cm, 8.85 to 22.03 in.*lbf)

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

      Standard Shim Thickness
      Mark Specified Condition Mark Specified Condition Mark Specified Condition
      0 1.99 to 2.01 mm (0.0783 to 0.0791 in.) 6 2.29 to 2.31 mm (0.0902 to 0.0909 in.) C 2.59 to 2.61 mm (0.1020 to 0.1027 in.)
      1 2.04 to 2.06 mm (0.0803 to 0.0811 in.) 7 2.34 to 2.36 mm (0.0921 to 0.0929 in.) D 2.64 to 2.66 mm (0.1040 to 0.1047 in.)
      2 2.09 to 2.11 mm (0.0823 to 0.0831 in.) 8 2.39 to 2.41 mm (0.0941 to 0.0949 in.) E 2.69 to 2.71 mm (0.1060 to 0.1066 in.)
      3 2.14 to 2.16 mm (0.0843 to 0.0850 in.) 9 2.44 to 2.46 mm (0.0961 to 0.0969 in.) F 2.74 to 2.76 mm (0.1079 to 0.1086 in.)
      4 2.19 to 2.21 mm (0.0862 to 0.0870 in.) A 2.49 to 2.51 mm (0.0981 to 0.0988 in.) G 2.79 to 2.81 mm (0.1099 to 0.1106 in.)
      5 2.24 to 2.26 mm (0.0882 to 0.0890 in.) B 2.54 to 2.56 mm (0.1000 to 0.1007 in.) H 2.84 to 2.86 mm (0.1119 to 0.1125 in.)

    6. Remove the 18 bolts and manual transmission case.

  14. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING OUTER RACE


    1. A004SALE02
      Text in Illustration
      *1 Mark

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

      Tech Tips

      When reusing the No. 2 output shaft rear bearing outer race, first install a shim of the same thickness as the original. When installing a new No. 2 output shaft rear bearing outer race, first select and install a shim which is thinner than the original.

    2. A004S0TE01

      Using SST and a press, press in the No. 2 output shaft rear bearing outer race.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07200 )

  15. ADJUST NO. 2 OUTPUT SHAFT REAR BEARING PRELOAD


    1. A004OW8

      Install the No. 2 output shaft and differential case to the front transaxle case.

    2. A004Q1H

      Install the manual transmission case to the front transaxle case with the 12 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A004R6R

      Install the 6 bolts to the front transaxle case side.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A004T0ME06

      Using SST and a torque wrench, measure the No. 2 output shaft rear bearing preload. Subtract the value of the differential side bearing preload from the measured No. 2 output shaft rear bearing preload.

      SST
      09564-33010
      New bearing preload
      3.89 to 5.51 N*m (40 to 56 kgf*cm, 35 to 48 in.*lbf)

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

      Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition Mark Specified Condition
      A 1.79 to 1.81 mm (0.0705 to 0.0712 in.) G 2.09 to 2.11 mm (0.0823 to 0.0830 in.) N 2.39 to 2.41 mm (0.0941 to 0.0948 in.)
      B 1.84 to 1.86 mm (0.0725 to 0.0732 in.) H 2.14 to 2.16 mm (0.0843 to 0.0850 in.) P 2.44 to 2.46 mm (0.0961 to 0.0968 in.)
      C 1.89 to 1.91 mm (0.0745 to 0.0751 in.) J 2.19 to 2.21 mm (0.0863 to 0.0870 in.) Q 2.49 to 2.51 mm (0.0981 to 0.0988 in.)
      D 1.94 to 1.96 mm (0.0764 to 0.0771 in.) K 2.24 to 2.26 mm (0.0882 to 0.0889 in.) R 2.54 to 2.56 mm (0.1000 to 0.1007 in.)
      E 1.99 to 2.01 mm (0.0784 to 0.0791 in.) L 2.29 to 2.31 mm (0.0902 to 0.0909 in.) S 2.59 to 2.61 mm (0.1020 to 0.1027 in.)
      F 2.04 to 2.06 mm (0.0804 to 0.0811 in.) M 2.34 to 2.36 mm (0.0922 to 0.0929 in.) T 2.64 to 2.66 mm (0.1040 to 0.1047 in.)

    5. Remove the 18 bolts and manual transmission case.

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

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

  16. INSTALL TRANSMISSION MAGNET


    1. A004P4G

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

  17. INSTALL FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A004NTT

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

  18. INSTALL TRANSMISSION OIL SEPARATOR


    1. A004N9P

      for Front Transaxle Case Side:

      Install the transmission oil separator to the front transaxle case with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  19. INSTALL INPUT SHAFT, NO. 1 OUTPUT SHAFT AND NO. 2 OUTPUT SHAFT


    1. A004S93

      Install the 3 shafts at the same time.

  20. INSTALL REVERSE IDLER GEAR


    1. A004O4W

      Coat the reverse idler gear, needle roller bearing and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.

      Tech Tips

      Make sure that the protruding part of the reverse idler thrust washer fits into the groove of the reverse idler shaft.

    2. A004OAZ

      Install the reverse idler gear shaft by sliding and lifting it.

    3. A004RQ4E03
      Text in Illustration
      *1 Alignment Mark

      Align the mark of the reverse idler gear shaft with the hole of the bolt.

  21. INSTALL REVERSE SHIFT FORK


    1. A004Q2O

      Install the reverse shift fork to the No. 2 output shaft.

  22. INSTALL NO. 3 GEAR SHIFT FORK


    1. A004QBY

      Install the No. 3 gear shift fork to the No. 2 output shaft.

  23. INSTALL 5TH AND 6TH SHIFT FORK SHAFT


    1. A004O31

      Install the 5th and 6th shift fork shaft to the front transaxle case.

    2. Coat the bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A004R1C

      Install the bolt to the No. 3 gear shift fork.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  24. INSTALL REVERSE SHIFT FORK SHAFT


    1. A004NV3

      Install the reverse shift fork shaft to the front transaxle case.

    2. Coat the bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A004R7V

      Install the bolt to the reverse shift fork shaft.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  25. INSTALL SHIFT ARM


    1. A004PQV

      Install the shaft arm to the front transaxle case.

  26. INSTALL NO. 1 GEAR SHIFT FORK


    1. A004U93

      Install the No. 1 gear shift fork to the No. 1 output shaft.

  27. INSTALL NO. 5 GEAR SHIFT FORK SHAFT


    1. A004P7S

      Install the No. 3 gear shift head to the No. 5 gear shift fork shaft.

    2. Using a 5 mm pin punch and hammer, tap a new pin into the No. 3 gear shift head.

      Standard depth
      -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
    3. A004SV3

      Install the No. 5 gear shift fork shaft to the front transaxle case.

    4. A004QK4

      Connect the shift arm to the No. 5 gear shift fork shaft.

    5. A004TAI

      Install the shift arm pin to the shift arm.

    6. A004O8E

      Using a brass bar and hammer, tap a new E-ring to the shift arm pin.

  28. INSTALL NO. 2 GEAR SHIFT FORK


    1. A004RNW

      Install the No. 2 gear shift fork to the No. 1 output shaft.

  29. INSTALL 3RD AND 4TH SHIFT FORK SHAFT


    1. A004OAP

      Install the No. 2 gear shift head to the 3rd and 4th shift fork shaft.

    2. Install the 3rd and 4th shift fork shaft to the front transaxle case.

    3. A004NB9

      Using a 5 mm pin punch and hammer, tap a new pin into the No. 2 gear shift fork.

      Standard depth
      -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
    4. A004NNH

      Using a 5 mm pin punch and hammer, tap a new pin into the No. 2 gear shift head.

      Standard depth
      -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

  30. INSTALL 1ST AND 2ND SHIFT FORK SHAFT


    1. A004SPN

      Install the 1st and 2nd shift fork shaft to the front transaxle case.

    2. Coat the bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A004O99

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

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  31. INSTALL TRANSMISSION OIL SEPARATOR


    1. A004P30

      for Manual Transmission Case Side:

      Install the transmission oil separator to the manual transmission case with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  32. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A004SL5

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

      Note

      Do not damage the No. 1 oil receiver pipe.

  33. INSTALL MANUAL TRANSMISSION CASE


    1. A004R1Z

      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. A004MUX

      Using 2 pairs of snap ring pliers to keep the snap ring stretched, install the manual transmission case.

    3. A004OBXE01
      Text in Illustration
      *a 8.5 mm (0.335 in.) or less
      *b 9.3 mm (0.366 in.) or less

      Install a bolt to the No. 1 output shaft and lift bolt from the service hole. Make sure that the snap rings are positioned correctly in the bearing grooves by checking that the distances between the centers of snap ring holes are as shown in the illustration.

    4. A004Q1H

      Install the manual transmission case to the front transaxle case with the 12 bolts .

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    5. A004R6R

      Install the 6 bolts to the front transaxle case.

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

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A004MW1

      Coat the reverse idler gear shaft bolt with adhesive, and install a new gasket and the shaft bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

  35. INSTALL BALL


    1. A004QB5

      Coat the 4 detent ball plugs with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Using a 6 mm hexagon wrench, install the 4 balls, 4 springs, 4 spring seats and 4 detent ball plugs .

      Torque:
      22 N*m  { 228 kgf*cm, 17 ft.*lbf }

  36. INSTALL MANUAL TRANSMISSION CASE PLUG


    1. A004QXDE01
      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, Three Bond 1207B or equivalent

    2. Coat the transmission case plug with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the manual transmission case plug to the manual transmission case.

      Torque:
      for case plug A
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      for case plug B
      22 N*m  { 228 kgf*cm, 17 ft.*lbf }

  37. INSTALL O-RING


    1. A004RFE

      Coat a new O-ring with the MP grease, and install it to the shift and select pin.

  38. INSTALL SHIFT AND SELECT PIN


    1. A004Q1NE01

      Install the spring.

    2. While pressing in the shift and select pin *1 in as far as it will go, push in the shift and select pin *2 to install it.

  39. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A004OGC

      Install a new gasket and the manual transmission filler plug.

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

  40. INSTALL DRAIN PLUG


    1. A004OVH

      Install a new gasket and the drain plug.

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

  41. INSTALL FRONT DRIVE SHAFT OIL SEAL LH

    Click here

  42. INSTALL FRONT DRIVE SHAFT OIL SEAL RH

    Click here

  43. INSTALL SHIFT AND SELECT LEVER ASSEMBLY


    1. A004O34

      Align the 4 shift fork shafts as shown in the illustration.

    2. A004R07

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

      Seal packing
      Toyota Genuine Seal Packing, Three Bond 1207B or equivalent

      Note

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

    3. Coat the 4 bolts with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A004PUU

      Install the shift and select lever shaft to the manual transmission case with the 4 bolts.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  44. INSTALL SHIFT GATE PIN


    1. A004SYH

      Coat the shift gate pin with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the shift gate pin to the manual transmission case.

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

  45. INSTALL NO. 2 LOCK BALL ASSEMBLY


    1. A004OF6

      Coat the No. 2 lock ball with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the No. 2 lock ball to the manual transmission case.

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

  46. INSTALL NO. 1 LOCK BALL ASSEMBLY


    1. A004PTY

      Coat the No. 1 lock ball with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the No. 1 lock ball to the manual transmission case.

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

  47. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A004NGYE03

    1. Using SST, install a new gasket and the park/neutral position switch to the manual transmission case.

      SST
      09816-30010
      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }

  48. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A004OLIE02

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

      SST
      09816-30010
      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }

  49. INSTALL SELECTING BELLCRANK ASSEMBLY


    1. A004T8F

      Install the selecting bellcrank to the manual transmission case with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  50. INSTALL CONTROL CABLE BRACKET


    1. A004NKJ

      Install the control cable bracket to the manual transaxle with the 3 bolts.

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

  51. INSTALL RELEASE FORK SUPPORT

    Click here

  52. INSTALL CLUTCH RELEASE FORK BOOT


    1. A004S8S

      Install the clutch release fork boot to the front transaxle case.

  53. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

  54. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here