БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ ПОВТОРНАЯ СБОРКА


  1. INSTALL OUTPUT SHAFT ASSEMBLY


    1. A003F2M

      Install the output shaft assembly into the intermediate plate by pulling on the output shaft assembly and tapping on the intermediate plate with a plastic hammer.

    2. A003ET4

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

      Tech Tips

      Be sure the output shaft bearing snap ring is flush with the intermediate plate surface.

  2. INSTALL INPUT SHAFT ASSEMBLY


    1. A003DKJ

      Coat the input shaft assembly and synchronizer ring No.1 with gear oil, and install them to the output shaft.

  3. INSTALL COUNTER GEAR


    1. A003CFZ

      Coat the input shaft and the synchronizer ring No.2 with gear oil.

    2. Temporarily install the counter gear assembly and a new counter shaft center bearing to the intermediate plate.

      Note

      Install the bearing (with snap ring) to the counter gear's rear side.

    3. A003BQG

      Using a plastic hammer, install the counter shaft center bearing to the intermediate plate by tapping the outer race of the counter shaft center bearing.

      Tech Tips

      Hold the front side of the counter gear by hand.

  4. INSTALL OUTPUT SHAFT REAR BEARING(MTM) RETAINER


    1. A003F5Y

      Using a "torx" socket wrench T40, install the output shaft rear bearing retainer to the intermediate plate with the 4 screws.

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

  5. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A003C15

      Install the reverse idler gear shaft and reverse idler gear sub-assembly to the intermediate plate.

    2. A003FRO

      Install the reverse idler gear shaft stopper to the intermediate plate with the bolt.

      Torque:
      17 N*m  { 175 kgf*cm, 12 ft.*lbf }

  6. INSTALL REVERSE SHIFT ARM


    1. A003I4Q

      Install a new E-ring and the shift fork to the shift arm.

  7. INSTALL REVERSE SHIFT ARM BRACKET


    1. A003EXJ

      Install the arm bracket with the shift arm to the intermediate plate.

    2. Install the 2 bolts.

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

  8. INSTALL 5TH GEAR BEARING INNER RACE LOCK BALL


    1. A003C7T

      Install the 5th gear bearing inner race lock ball.

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A003C3A

      Install the 5th gear thrust washer.

  10. INSTALL COUNTER SHAFT 5TH GEAR


    1. A003BMR

      Install the counter shaft 5th gear assembly to the counter gear.

    2. A003GFC

      Temporarily install the synchronizer ring No.3 on the gear spline piece No.5.

    3. A003H3R

      Dismount the intermediate plate from the vise.

    4. Stand the manual transmission as shown in the illustration.

    5. A003BA5

      Using a press and 22 mm socket wrench, install the gear spline piece No.5 with the synchronizer ring No.3 slots aligned with the shifting keys.

    6. Mount the intermediate plate in a vise.

    7. A003GW5

      Select a counter gear rear shaft snap ring that will allow the minimum amount of axial play.

      Standard clearance
      0.1 mm (0.00390in.) or less
      Counter gear rear shaft snap ring thickness
      Mark Thickness: mm (in.)
      A 2.80 to 2.85 (0.110 to 0.112)
      B 2.85 to 2.90 (0.112 to 0.114)
      C 2.90 to 2.95 (0.114 to 0.116)
      D 2.95 to 3.00 (0.116 to 0.118)
      E 3.00 to 3.05 (0.118 to 0.120)
      F 3.05 to 3.10 (0.120 to 0.122)
      G 3.10 to 3.15 (0.122 to 0.124)
    8. A003G13

      Using a brass bar and a hammer, install the counter gear rear shaft snap ring to the counter gear.

  11. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A003G3Q

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

      Standard clearance
      0.125 to 0.325 mm (0.0049 to 0.0128 in.)
      Maximum clearance
      0.325 mm (0.0128 in.)

  12. INSTALL GEAR SHIFT HEAD NO.1


    1. A003CNW

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

    2. Using a pin punch and a hammer, drive in the slotted spring pin to the gear shift fork shaft No.1.

  13. INSTALL GEAR SHIFT FORK NO.2


    1. A003EL8

      Coat the gear shift fork No.2 with gear oil, and install it to the transmission hub sleeve No.2.

  14. INSTALL GEAR SHIFT FORK SHAFT NO.1


    1. A003IDZ

      Coat the gear shift fork No.1 with gear oil, and install it to the reverse gear.

    2. Install the gear shift fork shaft No.1 through the gear shift fork No.2, gear shift fork No.1 and intermediate plate.

    3. A003I29

      Tighten the shift fork bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }

  15. INSTALL SHIFT INTER LOCK PIN NO.2


    1. A003I3W

      Coat the shift inter lock pin No.2 with MP grease, and install it into the gear shift fork shaft No.2.

  16. INSTALL GEAR SHIFT FORK SHAFT NO.2


    1. A003F84

      Coat the shift inter lock pin No.1 with MP grease.

    2. Using a magnetic finger, install the shift inter lock pin No.1 to the intermediate plate.

    3. Install the gear shift fork shaft No.2 through the gear shift fork No.2 and intermediate plate.

    4. A003EAY

      Using a pin punch (5 mm) and a hammer, Install the slotted spring pin to the gear shift fork No.2.

    5. A003DQC

      Install the shift fork shaft snap ring to the gear shift fork shaft No.2.

  17. INSTALL SHIFT INTER LOCK PIN NO.2


    1. A003BW5

      Coat the shift inter lock pin No.2 with MP grease, and install it into the reverse shift fork shaft.

  18. INSTALL REVERSE SHIFT FORK SHAFT


    1. A003I39

      Coat the shift inter lock pin No.1 with MP grease.

    2. Using a magnetic finger, install the shift inter lock pin No.1 to the intermediate plate.

    3. A003GGU

      Install the ball and compression spring to the reverse shift fork.

    4. Using a screwdriver, install the reverse shift fork shaft by pushing the ball gently.

    5. A003GGL

      Apply gear oil to the gear shift head No.3, and install it to the reverse shift fork shaft.

    6. Using a pin punch (5 mm) and a hammer, install the slotted spring pin to the reverse shift fork shaft.

  19. INSTALL REVERSE SHIFT HEAD


    1. A003HGW

      Install the reverse shift head to the reverse shift fork shaft.

  20. INSTALL GEAR SHIFT FORK SHAFT NO.4


    1. A003C0W

      Coat the reverse shift fork ball with MP grease.

    2. Using a magnetic finger, install the reverse shift fork ball to the reverse shift fork.

    3. Install the gear shift fork shaft No.4 through the reverse shift fork.

    4. A003BL0

      Coat the shift inter lock ball No.1 with MP grease.

    5. Using a magnetic finger, install the shift inter lock ball No.1 to the intermediate plate.

    6. Install the gear shift fork shaft No.4 through the gear shift fork No.3 and intermediate plate.

    7. A003B2C

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

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }
    8. A003AZJ

      Using a brass bar and a hammer, install the snap ring to the gear shift fork shaft No.4.

    9. A003DQT

      Using a pin punch (5 mm) and a hammer, install the slotted spring pin to the gear shift fork shaft No.4.

  21. INSTALL SHIFT DETENT BALL NO.2


    1. A003HFQ

      Coat the shift detent ball No.2 with MP grease.

    2. Install the shift detent ball No.2 and shift detent ball compression spring to the intermediate plate.

    3. A003D4U

      Coat the shift detent ball spring seat No.2 with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. Using a "torx" socket wrench T40, install the shift detent ball spring seat No.2 to the intermediate plate.

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

  22. INSTALL SHIFT DETENT BALL


    1. A003HB3

      Coat the 3 shift detent balls with MP grease, and install these balls and 3 compression springs to the intermediate plate.

    2. A003EFH

      Coat the 3 shift detent ball spring seats No.1 with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a "torx" socket wrench T40, install the 3 shift detent ball spring seats No.1 to the intermediate plate.

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

  23. INSTALL MANUAL TRANSMISSION CASE


    1. A003CV5E01

      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
    2. A003H4L

      Stand the intermediate plate as shown in the illustration.

    3. Using a plastic hammer, install the manual transmission case to the intermediate plate as shown in the illustration.

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


    1. A003CDJ

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

  25. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A003EUN

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

  26. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A003C49E01

      Using SST, press in a new transmission front bearing retainer oil seal to the front bearing retainer.

      SST
      09950-60010   ( 09952-06010, 09951-00440 )
      Oil seal depth
      12.5 to 13.5 mm (0.492 to 0.531 in.)

  27. CHECK BEARING RETAINER FRONT(MTM)


    1. A003FOGE01

      Check that "FIPG" is imprinted on the bearing retainer front.

  28. INSTALL BEARING RETAINER FRONT(MTM)


    1. A003AT3E01

      w/o Gasket:


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

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

    2. w/ Gasket:


      1. Install the bearing retainer front with gasket to the transmission case.

    3. w/o Gasket:


      1. Install the bearing retainer front to the transmission case.

    4. A003DKME01

      Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Install the 8 bolts to the manual transmission case.

      Torque:
      17 N*m  { 175 kgf*cm, 12 ft.*lbf }

  29. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A003H5AE01

      Using SST, drive in a new manual transmission extension housing oil seal to the extension housing.

      SST
      09325-20010

  30. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE NO.1


    1. A003GA9

      Install the extension housing oil receiver pipe No.1 to the the extension housing.

  31. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE


    1. A003FPM

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

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }

  32. INSTALL TRANSMISSION MAGNET


    1. A003CTC

      Install the transmission magnet to the extension housing.

  33. INSTALL EXTENSION HOUSING DUST(MTM) DEFLECTOR


    1. A003AM1

      Using a plastic hammer, install the extension housing dust deflector to the extension housing.

  34. INSTALL EXTENSION (MTM) HOUSING SUB-ASSEMBLY


    1. A003DQJE01

      Apply seal packing to the extension housing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A003DY5

      Install the extension housing to the manual transmission case with the 8 bolts.

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

  35. INSTALL SHIFT LEVER SHAFT HOUSING SUB-ASSEMBLY


    1. A003EVR

      Shift the gear shift fork No.2, gear shift head and reverse shift head to the neutral position.

    2. A003EPWE01

      Install a new shift lever shaft housing gasket to the manual transmission case.

    3. Apply sealant to the threads of the 4 yellow bolts and 2 bluish-silver bolts.

    4. Install the clamp and shift lever shaft housing assembly to the manual transmission case with the 6 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 12 ft.*lbf }

  36. INSTALL CLUTCH HOUSING


    1. A003EYPE01

      Install the clutch housing.

    2. Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the 9 bolts to the clutch housing.

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

  37. INSTALL BACK UP LIGHT SWITCH ASSEMBLY


    1. A003GLGE01

      Using SST, install the back up light switch assembly to the manual transmission case.

      SST
      09817-16011
      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  38. INSTALL SPEEDOMETER SENSOR


    1. A003D5B

      Install a new O-ring to the speedometer sensor.

    2. Install the speedometer sensor to the extension housing with the bolt.

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }

  39. INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY


    1. A003D5QE01
      Text in Illustration
      *1 Gasket
      *2 Drain Plug

      Using a 10 mm hexagon socket wrench, install a new gasket and the drain plug to the manual transmission case.

      Torque:
      44 N*m  { 450 kgf*cm, 33 ft.*lbf }

  40. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A003FOS

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

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