MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT ASSEMBLY


    1. A003HUP

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

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

  2. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A003DEI

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

  3. INSTALL INPUT SHAFT ASSEMBLY


    1. A003AV3

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

      Note


      • Make sure that the No. 2 synchromesh shifting key fits into the grooves of the No. 2 synchronizer ring.

      • Check that the input shaft assembly rotates smoothly.

  4. INSTALL COUNTER GEAR


    1. A003CFO

      Temporarily install the counter gear to the intermediate plate.

  5. INSTALL COUNTER SHAFT CENTER BEARING


    1. A003GDGE01

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

      SST
      09316-60011   ( 09316-00011 )

      Tech Tips

      Install the 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.

  6. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A003HTJE04

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

      Note

      Orient the groove side of the reverse idler shaft to the rear side and install it from the rear side.

  7. INSTALL OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A003DOQ

      Install the output shaft rear bearing (MTM) retainer into the groove of the reverse idler gear shaft with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
  8. INSTALL 5TH GEAR THRUST WASHER PIN


    1. A003DUM

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

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A003E95

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

      Note

      Install the thrust washer so that its chamfer side faces to the front side.

  10. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


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

      Note

      Be sure of the direction of the No. 3 transmission hub sleeve and the counter shaft 5th gear.

    2. A003BGCE01
      Text in Illustration
      *a Cutout
      *b Protrution

      Install the 2 No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring to the counter shaft 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. A003DNK

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

  11. INSTALL COUNTER 5TH GEAR BEARING


    1. A003F1EE02

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

  12. INSTALL COUNTER SHAFT 5TH GEAR


    1. A003F7W

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

  13. INSTALL OUTER NO.3 SYNCHRONIZER RING


    1. A003ASJ

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

      Note

      Make sure that the No. 3 synchromesh shifting key fits into the grooves of the outer No. 3 synchronizer ring.

  14. INSTALL No. 5 GEAR SPLINE PIECE


    1. A003GDTE01

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

      SST
      09316-60011   ( 09316-00011 )

      Note

      Check that the gear rotates smoothly.

  15. INSTALL COUNTER GEAR REAR SHAFT SNAP RING


    1. Select a counter gear rear shaft snap ring so that the thrust gap between the No. 5 gear spline piece and counter gear rear shaft snap ring is within the specified values. Use a brass bar and a hammer, install it to the counter gear.

      Standard clearance
      0.1 mm (0.0039 in.) or less
      Mark Thickness: mm (in.)
      A 2.80 to 2.85 (0.1102 to 0.1122)
      B 2.85 to 2.90 (0.1122 to 0.1141)
      C 2.90 to 2.95 (0.1141 to 0.1160)
      D 2.95 to 3.00 (0.1160 to 0.1181)
      E 3.00 to 3.05 (0.1181 to 0.1200)
      F 3.05 to 3.10 (0.1200 to 0.1220)
      G 3.10 to 3.15 (0.1220 to 0.1240)
  16. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A003CEY

      Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)
  17. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A003ESM

      Using a dial indicator, measure the radial clearance of the counter shaft 5th gear.

      Standard clearance
      0.015 to 0.068 mm (0.0059 to 0.0027 in.)

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

  18. INSTALL OUTPUT SHAFT REAR BEARING


    1. A003GFFE01

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

      SST
      09309-35010
  19. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. Select an output shaft bearing shaft snap ring so that the thrust gap between the snap ring and the bearing is within the specified values. Use a brass bar and a hammer to install it to the output shaft assembly.

      Standard clearance
      0.1 mm (0.0039 in.) or less
      Mark Thickness: mm (in.)
      A 2.65 to 2.70 (0.1043 to 0.1063)
      B 2.70 to 2.75 (0.1063 to 0.1083)
      C 2.75 to 2.80 (0.1083 to 0.1102)
      D 2.80 to 2.85 (0.1102 to 0.1122)
      E 2.85 to 2.90 (0.1122 to 0.1141)
      F 2.90 to 2.95 (0.1141 to 0.1160)
      G 2.95 to 3.00 (0.1160 to 0.1181)
      H 3.00 to 3.05 (0.1181 to 0.1200)
      J 3.05 to 3.10 (0.1200 to 0.1220)
      K 3.10 to 3.15 (0.1220 to 0.1240)
      L 3.15 to 3.20 (0.1240 to 0.1260)
      M 3.20 to 3.25 (0.1260 to 0.1280)
      N 3.25 to 3.30 (0.1280 to 0.1299)
      P 3.30 to 3.35 (0.1299 to 0.1319)
      Q 3.35 to 3.40 (0.1319 to 0.1339)
      R 3.40 to 3.45 (0.1339 to 0.1358)
      S 3.45 to 3.50 (0.1358 to 0.1378)
  20. INSTALL SPEEDOMETER DRIVE (MTM) GEAR


    1. A003EAP

      Using snap ring expander, install the snap ring.

    2. Install the steel ball and speedometer drive (MTM) gear.

    3. Using snap ring expander, install the snap ring.

  21. INSTALL REVERSE SHIFT ARM BRACKET


    1. A003DR7

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

    2. A003GMXE02
      Text in Illustration
      *1 Reverse Idler Gear
      *2 Reverse Shift Arm

      Insert the tip of the reverse shift arm into the reverse idler gear.

    3. A003GJ2

      Install the reverse shift arm bracket with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. A003AT2

      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.

  22. INSTALL REVERSE SHIFT FORK


    1. A003AM2

      Install the reverse shift fork to the reverse shift arm.

  23. INSTALL REVERSE SHIFT FORK SHAFT


    1. A003BJ9

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

    2. A003F36

      Install the straight pin to the reverse shift fork.

    3. A003FK3

      Using a brass bar and a hammer, install the snap ring to the reverse shift fork shaft.

    4. A003F5H

      Using a 5 mm pin punch and a hammer, install the slotted spring pin into the No. 3 gear shift fork.

  24. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A003DLC

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

    2. A003B4O

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

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

    4. A003I99

      Install the No. 2 gear shift head and No. 2 gear shift fork shaft to the intermediate plate from the front side.

    5. A003CNB

      Using a 5 mm pin punch and a hammer, install the slotted spring pin into the No. 2 gear shift fork shaft.

    6. A003EY7

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    7. A003E6P

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

  25. INSTALL SHIFT FORK SHAFT STOPPER


    1. A003F10

      Install the shift fork shaft stopper to the No. 2 gear shift fork shaft.

    2. Using a 5 mm pin punch and a hammer, install the slotted spring pin into the No. 2 gear shift fork shaft.

  26. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A003I4V

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

    2. A003CL0

      Apply gear oil to the No. 1 gear shift fork shaft, and install it to the intermediate plate from the front side.

    3. A003GL6

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    4. A003BIJ

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

  27. INSTALL SHIFT FORK SHAFT STOPPER


    1. A003HCK

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

    2. Using a 5 mm pin punch and a hammer, install the slotted spring pin into the No. 2 gear shift fork shaft.

  28. INSTALL NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A003GNX

      Install the 2 compression springs and 2 shift detent balls into the intermediate plate.

    2. A003HCX

      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 }
    3. A003C0R

      Install the shift detent ball and compression spring into the intermediate plate.

    4. A003AXS

      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 }
  29. INSTALL TRANSMISSION MAGNET


    1. A003GJU

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

  30. INSTALL MANUAL TRANSMISSION CASE


    1. A003EF3E02
      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. A003BOJ

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

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


    1. A003H72

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

  32. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A003CG3

      Using a snap ring expander, install the front bearing shaft snap ring to the manual transmission case.

  33. INSTALL FRONT TRANSMISSION BEARING RETAINER OIL SEAL


    1. A003BVRE02

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

      SST
      09950-60010   ( 09951-00300, 09951-00520, 09952-06010, 09951-07100 )
      Drive in depth
      11.2 to 12.2 mm (0.4409 to 0.4803 in.)
    2. Coat the lip of the transmission front bearing retainer oil seal with MP grease.

  34. INSTALL FRONT BEARING RETAINER (MTM)


    1. A003HLJE05
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the front bearing retainer (MTM) 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. Apply seal packing to the bolts.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    3. A003GT0

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

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

      Check that the input shaft and output shaft rotate smoothly.

  35. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A003FMWE01

      Using SST and a hammer, install a new manual transmission extension housing oil seal to the extension housing sub-assembly.

      SST
      09710-30050
      09950-70010   ( 09951-07100 )
      Drive in depth
      -0.5 to 0.5 mm (-0.020 to 0.020 in.)

      Note

      Be careful not to damage the oil seal lip.

    2. Lightly apply MP grease to the tip of the manual transmission extension housing oil seal.

  36. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE


    1. Install the extension housing oil receiver pipe with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
  37. INSTALL No. 1 EXTENSION HOUSING OIL RECEIVER PIPE


    1. A003FTU

      Install the No. 1 extension housing oil receiver pipe to the extension (MTM) housing sub-assembly.

  38. INSTALL EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A003AR3E16
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the extension (MTM) housing sub-assembly 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. A003DO9

      Install the extension (MTM) housing sub-assembly to the manual transmission case with the 10 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  39. INSTALL SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A003HOM

      Apply seal packing to the shift lever shaft housing sub-assembly as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A003BCE

      Install the shift lever shaft housing sub-assembly to the manual transmission case with the 6 bolts.

      Torque:
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }
  40. INSTALL EXTENSION HOUSING DUST(MTM) DEFLECTOR


    1. Using a plastic-faced hammer, install the extension housing dust (MTM) deflector to the extension (MTM) housing sub-assembly.

  41. INSTALL EXTENSION HOUSING(MTM) COVER


    1. A003FHJ

      Install the extension housing (MTM) cover and a new gasket to the extension (MTM) housing sub-assembly with the 6 bolts.

      Torque:
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }
  42. INSTALL SPEEDOMETER SENSOR


    1. Install a new O-ring to the speedometer sensor.

    2. Install the speedometer sensor with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
  43. INSTALL BACK UP LIGHT SWITCH ASSEMBLY


    1. A003CE0E01

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

      SST
      09817-16011
      Torque:
      44 N*m  { 448 kgf*cm, 32 ft.*lbf }
  44. INSTALL CLUTCH HOUSING


    1. A003HRG

      Install the clutch housing to the manual transmission case with the 9 bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
  45. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    1. A003E05

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

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  46. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A003ED8

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

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