MANUAL TRANSMISSION UNIT(for 1KD-FTV) REASSEMBLY

PROCEDURE


  1. INSTALL NO. 1 RELEASE ARM


    1. Install the No. 1 release arm and shift arm pivot to the shift interlock bracket.

    2. Install a new E-ring to the shift arm pivot.

  2. INSTALL NO. 4 GEAR SHIFT FORK SHAFT


    1. A01XJ8E

      Install the compression spring and shift detent ball to the shift interlock bracket.

    2. Install the No. 4 gear shift fork shaft.

  3. INSTALL NO. 4 GEAR SHIFT FORK

    A01XIFA

    1. Install the No. 4 gear shift fork to the No. 4 gear shift fork shaft.

    2. Using a 5 mm pin punch and hammer, tap a new slotted spring pin into the No. 4 gear shift fork and No. 4 gear shift fork shaft.

      Standard depth
      0 to 0.5 mm (0 to 0.0196 in.)

  4. INSTALL NO. 1 GEAR SHIFT FORK

    A01XDM5

    1. Install the No. 1 gear shift fork and No. 2 gear shift head to the No. 4 gear shift fork shaft.

    2. Using a 5 mm pin punch and hammer, tap a new slotted spring pin into the No. 2 gear shift head and No. 4 gear shift fork shaft.

      Standard depth
      0 to 0.5 mm (0 to 0.0196 in.)

  5. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

    A01XMRD

    1. Install the compression spring and shift detent ball to the shift interlock bracket.

    2. Install the No. 1 gear shift fork shaft to the shift interlock bracket.

  6. INSTALL NO. 1 GEAR SHIFT HEAD

    A01XKZT

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

    2. Using a 5 mm pin punch and hammer, tap a new slotted spring pin into the No. 1 gear shift head and No. 1 gear shift fork shaft.

      Standard depth
      0 to 0.5 mm (0 to 0.0196 in.)

  7. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

    A01XGGN

    1. Install the compression spring and shift detent ball to the shift interlock bracket.

    2. Install the No. 2 gear shift fork shaft to the shift interlock bracket.

  8. INSTALL NO. 2 GEAR SHIFT FORK

    A01XCZ3

    1. Install the No. 2 gear shift fork with a new bolt.

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

  9. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

    A01XLV2

    1. Install the compression spring and shift detent ball to the shift interlock bracket.

    2. Install the No. 3 gear shift fork shaft to the shift interlock bracket.

  10. INSTALL NO. 3 GEAR SHIFT FORK

    A01XKRX

    1. Install the No. 3 gear shift fork with a new bolt.

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

  11. INSTALL TRANSMISSION CASE NEEDLE BEARING


    1. B001EP0E02
      Text in Illustration
      *a Front

      Using SST, install the transmission case needle bearing into the front transmission case so that dimension A in the illustration is as specified.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Dimension A
      0.50 to 1.50 mm (0.0197 to 0.0590 in.)

  12. INSTALL TRANSMISSION CASE OIL SEAL

    B001EXZE06

    1. Using SST and a hammer, tap a new transmission case oil seal into the front transmission case so that dimension A in the illustration is as specified.

      SST
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00470 )
      Dimension A
      60.0 to 60.8 mm (2.363 to 2.393 in.)

    2. Apply gear oil to the lip of the transmission case oil seal.

  13. INSTALL FRONT BEARING SHAFT SNAP RING

    A01XIWE

    1. Using snap ring pliers, install the 2 front bearing shaft snap rings.

  14. INSTALL NO. 3 OIL RECEIVER PIPE

    A01XFCB

    1. Install the No. 3 oil receiver pipe to the front transmission case.

      Tech Tips

      Align the protrusion of the No. 3 oil receiver pipe with the cutout of the front transmission case and install the No. 3 oil receiver pipe to the front transmission case.

  15. INSTALL FRONT TRANSMISSION CASE

    A01XG3C

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

    2. Temporarily install the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks, gear shift fork shafts, and tie them with a piece of rope or string.

    3. A01XH9H

      Using a snap ring expander, expand the 2 snap rings and install the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks, gear shift fork shafts.

      Tech Tips

      Make sure that the snap ring fits into the grooves of the input shaft and front bearing of the counter gear shaft.

    4. Untie the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks, gear shift fork shafts.

    5. A01XM7I

      Using a 27 mm hexagon wrench, install a new manual transmission case plug to the front transmission case.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
    6. A01XMFA

      Install the shift interlock bracket with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  16. INSTALL REVERSE IDLER GEAR

    B001IN8E03
    Text in Illustration
    *a 15°

    1. Install the reverse idler gear, reverse idler gear bearing and reverse idler gear shaft.

      Tech Tips

      Make sure that the reverse idler gear faces the correct direction as shown in the illustration.

      Note

      Make sure that the hole in the reverse idler gear shaft is in the position shown in the illustration.

  17. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    B001I1VE04

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

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

  18. INSTALL SHIFT AND SELECT LEVER


    1. Install the compression spring and lock ball pin to the shift and select lever.

    2. Install the shift and select lever, shift and select cam and shift interlock plate to the shift and select lever shaft.

    3. A01XFBT

      Using a 5 mm pin punch and hammer, tap in a new slotted pin to the shift and select lever shaft.

      Standard depth
      1.0 to 2.0 mm (0.0394 to 0.0787 in.)

    4. Install a new bolt to the shift and select lever.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    5. Install a new E-ring to the lever shaft.

  19. INSTALL SHIFT AND SELECT LEVER SHAFT

    A01XIT7

    1. Align the groove of the shift and select cam with the reverse idler shaft and the claw with the groove of the control assembly, and then install the shift and select lever shaft.

  20. INSTALL NO. 2 OIL RECEIVER PIPE


    1. Install the No. 2 oil receiver pipe to the transmission middle case.

  21. INSTALL DRAIN PLUG SUB-ASSEMBLY


    1. Install a new gasket and the drain plug sub-assembly to the transmission middle case.

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

  22. INSTALL TRANSMISSION MIDDLE CASE

    B001FGCE12

    1. Apply seal packing to the transmission middle case as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Text in Illustration
      *a Seal Packing

      Note

      Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

    2. B001HYVE02

      Install the transmission middle case with the 11 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      Bolt length
      for bolt A: 40 mm (1.57 in.)
      for bolt B: 80 mm (3.15 in.)

  23. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    A01XFFH

    1. Install a new gasket and the reverse idler gear shaft bolt to the reverse idler gear shaft.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  24. INSTALL TRANSMISSION OIL SEPARATOR

    A01XIVL

    1. Install the transmission oil separator with the 2 bolts.

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

  25. INSTALL TRANSFER ADAPTER NEEDLE ROLLER BEARING


    1. B001EC0E02
      Text in Illustration
      *a Front

      Using SST, install the transfer adapter needle roller bearing to the transfer adapter.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07150 )

  26. INSTALL COUNTER GEAR REAR RADIAL BALL BEARING


    1. B001CQAE02

      Coat a new counter gear rear radial ball bearing with gear oil, and then using SST and a press, install it to the transfer adapter.

      SST
      09950-70010   ( 09951-07360 )
      09950-60010   ( 09951-00650 )
    2. A01XE25

      Install the bearing lock plate with the bolt.

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

  27. INSTALL REAR OUTPUT SHAFT BEARING


    1. B001H0YE02

      Using SST and a press, press in 2 new rear output shaft bearings (outer race) to the transfer adapter.

      SST
      09950-70010   ( 09951-07100, 09951-07360 )
      09950-60020   ( 09951-00790 )

  28. INSTALL TRANSFER ADAPTER CASE PLUG


    1. A01XI2A

      Using a 14 mm hexagon socket wrench, install a new transfer adapter case plug to the transfer adapter.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  29. INSTALL OIL SEPARATOR PACKING SEAL

    A01XLL3

    1. Install the oil separator packing seal to the transfer adapter.

      Tech Tips

      Insert the protruding part of the oil separator packing seal into the groove of the transfer adapter.

  30. INSTALL NO. 1 OIL RECEIVER PIPE


    1. Install the No. 1 oil receiver pipe to the transfer adapter.

  31. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. Install 2 new gaskets and the 2 manual transmission filler plugs to the transfer adapter.

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

  32. INSTALL TRANSFER ADAPTER

    B001GQSE11
    Text in Illustration
    *a Seal Packing

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

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

      Note

      Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

    2. Install the transfer adapter and 2 brackets to the transmission middle case with the 10 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  33. INSTALL SHIFT DETENT BALL PLUG


    1. Install the ball and compression spring to the transfer adapter.

    2. Using a 10mm socket hexagon wrench, install a new shift detent ball plug to the transfer adapter.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  34. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. Using a belt and wooden block, securely fasten the transmission to the workbench.

    2. Install a new output shaft spacer and a new rear output shaft bearing (inner race).

    3. B001CILE02
      Text in Illustration
      *1 Output Shaft Spacer
      *2 Rear Output Shaft Bearing
      *3 Manual Transmission Output Shaft Rear Set Nut

      Temporarily install a new manual transmission output shaft rear set nut by hand.

      Tech Tips

      Fit the spacer and rear output shaft bearing securely.

    4. Move the shift and select lever shaft to N.

    5. Using SST, rotate the output shaft 15 times at a speed of 100 rpm or less in order to settle the bearing.

    6. B001CEUE02

      Using SST and a torque wrench, measure the output shaft preload.*1

      SST
      09326-35010   ( 09326-03010, 09326-03020 )
    7. B001GKJE05
      Text in Illustration
      *1 Input Shaft

      Engage 5th gear, and then secure the input shaft using SST.

      SST
      09322-35010   ( 09322-03010, 09322-03020, 09322-03030, 90105-12087, 90170-12030 )

      Tech Tips


      • Install SST securely so that (A) is in-line with the input shaft.

      • Make sure that (A) moves back and forth by hand after installing SST.

    8. B001EOEE02

      Using SST and a torque wrench, tighten the nut.

      Torque:
      580 N*m  { 5914 kgf*cm, 428 ft.*lbf }

    9. Move the shift and select lever shaft to N.

    10. Using SST, rotate the output shaft 15 times at a speed of 100 rpm or less in order to settle the bearing.

    11. B001CEUE02

      Using SST and a torque wrench, measure the output shaft preload.*2

      SST
      09326-35010   ( 09326-03010, 09326-03020 )

    12. Adjust the preload so that the difference between *1 and *2 is within the specified range.

      Standard Preload (at starting)
      *2 - *1 = 0.45 to 1.05 N*m (4.59 to 10.7 kgf*cm, 3.99 to 9.29 in.*lbf)

      • If the preload is more than the standard, replace the output shaft spacer.

    13. A01XCZ9

      Using a chisel and hammer, caulk the manual transmission output shaft rear set nut.

  35. INSTALL MANUAL TRANSMISSION CASE COVER

    B001DPNE07
    Text in Illustration
    *a Seal Packing

    1. Apply seal packing to the manual transmission case cover as shown in the illustration.

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

      Note

      Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

    2. Install the manual transmission case cover with 4 new bolts.

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

  36. INSTALL SHIFT LEVER HOUSING


    1. A01XI2N

      Install the shift lever housing with a new bolt.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

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

    B001CCBE03
    Text in Illustration
    *a Seal Packing

    1. Apply seal packing to the floor shift control shift lever retainer sub-assembly as shown in the illustration.

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

      Note

      Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

    2. Install the floor shift control shift lever retainer sub-assembly with the 4 bolts.

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

  38. INSTALL CLUTCH RELEASE FORK SUPPORT BOOT


    1. Install the clutch release fork support boot to the front transmission case.

  39. INSTALL RELEASE FORK SUPPORT

    Click here

  40. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  41. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

  42. INSTALL CLUTCH RELEASE FORK BOOT