MANUAL TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. INSTALL OUTPUT SHAFT


    1. A01XEMD

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

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

  2. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING (for Center Bearing Side)


    1. A01XCQU

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

  3. INSTALL INPUT SHAFT


    1. A01XDEU

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

      Note


      • Install the No. 2 synchronizer ring so that its groove fits onto the No. 2 synchromesh shifting key.

      • Check that the input shaft rotates smoothly.

  4. INSTALL COUNTER GEAR


    1. A01XDIO

      Install the counter gear to the intermediate plate.

  5. INSTALL COUNTER SHAFT CENTER BEARING


    1. A01XL3YE01

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

      SST
      09316-60011

      Tech Tips

      Install the counter shaft center 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 to the counter shaft center bearing.

  6. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01XJ9R

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

      Note

      Be sure to install the reverse idler gear shaft from the rear with the groove facing the rear side.

  7. INSTALL OUTPUT SHAFT REAR BEARING RETAINER


    1. A01XEOH

      Insert the protrusion of the output shaft rear bearing retainer into the groove of the reverse idler gear shaft. Then install the output shaft rear bearing retainer with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  8. INSTALL 5TH GEAR THRUST WASHER PIN


    1. A01XETW

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

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A01XGND

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

      Note

      Install the 5th gear thrust washer so that its chamfered side faces the front side.

  10. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


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

      Note

      Make sure that the No. 3 transmission hub sleeve and counter 5th gear are facing the proper direction.

    2. A01XJLLE05
      Text in Illustration
      *a Cutout
      *b Protrusion

      Install the 2 No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring to the counter 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. A01XL9C

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

  11. INSTALL COUNTER 5TH GEAR BEARING


    1. A01XCMK

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

  12. INSTALL COUNTER 5TH GEAR


    1. A01XJ6A

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

  13. INSTALL OUTER NO. 3 SYNCHRONIZER RING


    1. A01XGDP

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

      Note

      Install the outer No. 3 synchronizer ring so that its groove fits onto the No. 3 synchromesh shifting key.

  14. INSTALL NO. 5 GEAR SPLINE PIECE


    1. A01XHECE01

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

      SST
      09316-60011   ( 09316-00011 )

      Note

      Check that the counter 5th gear rotates freely.

  15. INSTALL COUNTER GEAR REAR SHAFT SNAP RING


    1. Select a counter gear rear shaft snap ring so that the thrust clearance between the No. 5 gear spline piece and counter gear rear shaft snap ring to be within the specification.

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Snap Ring Thickness
      Thickness
      2.85 mm (0.1122 in.)
      2.90 mm (0.1141 in.)
      2.95 mm (0.1161 in.)
      3.00 mm (0.1181 in.)
      3.05 mm (0.1200 in.)
      3.10 mm (0.1220 in.)
      3.15 mm (0.1240 in.)

    2. Secure the intermediate plate in a vise between aluminum plates.

    3. A01XK6M

      Using a brass bar and hammer, tap on the counter gear rear shaft snap ring.

  16. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE

    Click here

  17. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE

    Click here

  18. INSTALL OUTPUT SHAFT REAR BEARING


    1. A01XKSRE01

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

      SST
      09309-35010

  19. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING (for Rear Bearing Side)


    1. Select a output shaft bearing shaft snap ring so that the thrust clearance between the output shaft bearing shaft and output shaft bearing shaft snap ring to be within the specification.

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Snap Ring Thickness
      Thickness Thickness
      2.65 mm (0.1043 in.) 3.10 mm (0.1220 in.)
      2.70 mm (0.1063 in.) 3.15 mm (0.1240 in.)
      2.75 mm (0.1083 in.) 3.20 mm (0.1260 in.)
      2.80 mm (0.1102 in.) 3.25 mm (0.1280 in.)
      2.85 mm (0.1122 in.) 3.30 mm (0.1299 in.)
      2.90 mm (0.1142 in.) 3.35 mm (0.1319 in.)
      2.95 mm (0.1161 in.) 3.40 mm (0.1339 in.)
      3.00 mm (0.1181 in.) 3.45 mm (0.1358 in.)
      3.05 mm (0.1200 in.) -
    2. A01XGN5

      Using a brass bar and hammer, tap on the output shaft bearing shaft snap ring.

  20. INSTALL REVERSE SHIFT ARM BRACKET


    1. A01XCKY

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

    2. A01XJU9E02
      Text in Illustration
      *1 Reverse Idler Gear Sub-assembly
      *2 Reverse Shift Arm

      Insert the tip of the reverse shift arm into the reverse idler gear sub-assembly.

    3. A01XLA0

      Install the reverse shift arm bracket with the 2 bolts.

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

    4. 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.

  21. INSTALL REVERSE SHIFT FORK


    1. A01XMA7

      Install the reverse shift fork to the reverse shift arm.

  22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A01XIHB

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

    2. A01XFT8

      Install the straight pin to the reverse shift fork.

    3. A01XF0A

      Using a brass bar and hammer, tap on the snap ring to the No. 3 gear shift fork shaft.

    4. A01XKD4

      Using a 5 mm pin punch and hammer, tap on the shift fork set slotted spring pin to the No. 3 shift fork.

  23. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A01XDLF

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

    2. A01XEIX

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

    3. A01XEAI

      Install the No. 1 gear shift fork shaft to the intermediate plate from the rear side.

    4. A01XCOQ

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    5. A01XFWE

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

  24. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A01XIOR

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

    2. A01XCDY

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

    3. A01XIM8

      Apply gear oil to the No. 2 gear shift fork shaft and install it to the intermediate plate from the rear side.

    4. A01XK6N

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    5. A01XM4Q

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

  25. INSTALL NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A01XI4F

      Install the 2 detent balls and 2 compression springs to the intermediate plate.

    2. for Type A:

      Apply adhesive to 2 or 3 threads of the 2 No. 1 shift detent ball spring seats.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A01XJTE

      for Type A:

      Using a 6 mm hexagon 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 }
    4. A01XF5G

      for Type B:

      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 }
    5. A01XJ1S

      Install the detent ball and low side compression spring to the intermediate plate.

    6. for Type A:

      Apply adhesive to 2 or 3 threads of the No. 1 shift detent ball spring seat.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    7. A01XDG4

      for Type A:

      Using a 6 mm hexagon socket wrench, install the No. 1 shift detent ball spring seat to the intermediate plate.

    8. A01XCH7

      for Type B:

      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 }

  26. INSTALL TRANSMISSION MAGNET


    1. A01XCKQ

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

  27. INSTALL MANUAL TRANSMISSION CASE


    1. A01XKYUE17
      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. A01XI7M

      Place the manual transmission case on wooden blocks.

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

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


    1. A01XLAF

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

  29. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A01XCTK

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

  30. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A01XIQZE01

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

      SST
      09950-60010   ( 09951-00300, 09951-00520, 09952-06010 )
      09950-70010   ( 09951-07100 )
      Standard oil seal depth
      11.20 to 12.20 mm (0.441 to 0.480 in.)

    2. Apply a light coat of MP grease to the lip of the transmission front bearing retainer oil seal.

  31. INSTALL FRONT BEARING RETAINER


    1. A01XEXGE06
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the front bearing retainer 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. A01XMLH

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

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

    3. Check that the input shaft and output shaft rotate smoothly.

  32. INSTALL TRANSFER ADAPTER OIL SEAL


    1. A01XL5OE02

      Using SST and a hammer, tap in a new transfer adapter oil seal to the transfer adapter.

      SST
      09710-30050
      09950-70010   ( 09951-07100 )
      Standard oil seal depth
      45.4 to 46.4 mm (1.79 to 1.82 in.)

    2. Apply a light coat of MP grease to the lip of the transfer adapter oil seal.

  33. INSTALL REVERSE RESTRICT PIN ASSEMBLY


    1. A01XH4U

      Install the reverse restrict pin assembly to the transfer adapter.

    2. A01XDSG

      Using a 5 mm pin punch and hammer, tap in the reverse restrict pin slotted spring pin to the transfer adapter.

    3. A01XILH

      Using a T40 "TORX" socket wrench, install the reverse restrict pin plug to the transfer adapter.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

  34. INSTALL TRANSFER OIL RECEIVER PIPE


    1. A01XI31

      Install the transfer oil receiver pipe to the transfer adapter.

  35. INSTALL TRANSFER ADAPTER


    1. A01XKYUE19
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the transfer adapter 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. A01XISV

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

    3. A01XJA0

      Install the transfer adapter to the manual transmission case with the 10 bolts.

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

  36. INSTALL SHIFT AND SELECT LEVER


    1. A01XM4VE01
      Text in Illustration
      *1 Shift Lever Housing
      *2 Shift and Select Lever

      Install the shift and select lever with the shift lever housing to the transfer adapter.

    2. A01XD8G

      Install the bolt to the shift lever housing.

      Torque:
      33 N*m  { 340 kgf*cm, 25 ft.*lbf }

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


    1. A01XCXD

      Install the floor shift control shift lever retainer sub-assembly and a new gasket with the 4 bolts.

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

  38. INSTALL RESTRICT PIN


    1. A01XDZQ

      Install the 2 restrict pins.

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

  39. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01XK73E12

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

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

  40. INSTALL CLUTCH HOUSING

    A01XFUPE03

    1. Temporarily install the clutch housing with the 7 bolts labeled A.

    2. Apply adhesive to the 2 bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Temporarily install the 2 bolts labeled B.

    4. Tighten the 9 bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  41. INSTALL RELEASE FORK SUPPORT

    Click here

  42. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  43. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

  44. INSTALL CLUTCH RELEASE FORK BOOT


    1. Install the release fork boot to the clutch housing.

  45. INSTALL DRAIN PLUG


    1. A01XL7X

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

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

  46. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01XC9M

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

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