MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL SHIFT FORK SHAFT BEARING


    1. A002QW0E02

      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 0.0197 in.)

  2. INSTALL OUTPUT SHAFT COVER


    1. A002O7XE02
      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. A002M8RE02

      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. A002QS5E05
      Text in Illustration
      *a Protrusion
      *b Groove

      Install the output shaft cover as shown in the illustration.

  5. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A002M48E01

      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. A002LJH

      Install the bearing lock plate bolt.

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

  6. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A002NNEE01

      Using SST and a hammer, install a new front transaxle 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. A002O1SE01

      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. A002NGN

      Install the bearing lock plate bolt.

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

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


    1. A002MAJ

      Using snap ring expander, install the 2 snap rings.

  9. INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A002N6EE02

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

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

  10. INSTALL SHIFT FORK SHAFT BEARING


    1. A002O2ZE03

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

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

  11. INSTALL FRONT DIFFERENTIAL CASE FRONT BEARING OUTER RACE


    1. A002MDBE01

      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. A002NSC

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

    2. A002PIHE01

      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. A002MT1

      Install the differential case assembly to the front transaxle case.

    2. A002OJC

      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. A002N4Z

      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. A002O2XE01
      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 25.4 kgf*cm, 8.85 to 22.04 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. A002O6PE01
      Text in Illustration
      *a 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. A002O41E02

      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. A002PLH

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

    2. A002OJC

      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. A002N4Z

      Install the 6 bolts to the front transaxle case side.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A002QXZE05

      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
      3.9 to 5.5 N*m (40 to 56 kgf*cm, 35 to 49 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 Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition Mark Specified Condition
      A 1.79 to 1.81 mm (0.0705 to 0.0713 in.) G 2.09 to 2.11 mm (0.0823 to 0.0831 in.) N 2.39 to 2.41 mm (0.0941 to 0.0949 in.)
      B 1.84 to 1.86 mm (0.0724 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 0.0969 in.)
      C 1.89 to 1.91 mm (0.0744 to 0.0752 in.) J 2.19 to 2.21 mm (0.0862 to 0.0870 in.) Q 2.49 to 2.51 mm (0.0980 to 0.0988 in.)
      D 1.94 to 1.96 mm (0.0764 to 0.0772 in.) K 2.24 to 2.26 mm (0.0882 to 0.0890 in.) R 2.54 to 2.56 mm (0.1000 to 0.1007 in.)
      E 1.99 to 2.01 mm (0.0783 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 (0.0803 to 0.0811 in.) M 2.34 to 2.36 mm (0.0921 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. A002M6P

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

  17. INSTALL FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A002MT1

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

  18. INSTALL TRANSMISSION OIL SEPARATOR


    1. A002OR5

      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. A002PQJ

      Install the 3 shafts at the same time.

  20. INSTALL REVERSE IDLER GEAR


    1. A002LSR

      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. A002Q1W

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

    3. A002POLE02
      Text in Illustration
      *a Alignment Mark

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

  21. INSTALL REVERSE SHIFT FORK


    1. A002N33

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

  22. INSTALL NO. 3 GEAR SHIFT FORK


    1. A002O9N

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

  23. INSTALL 5TH AND 6TH SHIFT FORK SHAFT


    1. A002M53

      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. A002MF5

      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. A002NQH

      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. A002PZ3

      Install the bolt to the reverse shift fork shaft.

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

  25. INSTALL SHIFT ARM


    1. A002LI5

      Install the shaft arm to the front transaxle case.

  26. INSTALL NO. 1 GEAR SHIFT FORK


    1. A002OIH

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

  27. INSTALL NO. 5 GEAR SHIFT FORK SHAFT


    1. A002O9T

      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. A002QJK

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

    4. A002PGW

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

    5. A002QRX

      Install the shift arm pin to the shift arm.

    6. A002PYC

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

  28. INSTALL NO. 2 GEAR SHIFT FORK


    1. A002Q4U

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

  29. INSTALL 3RD AND 4TH SHIFT FORK SHAFT


    1. A002M5G

      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 transaxle case.

    3. A002PQE

      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. A002P6X

      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. A002P64

      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. A002OWV

      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. A002M3B

      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. A002OB0

      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. A002MJOE05

      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.)
      Text in Illustration
      *a Seal Packing

      Note

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

    2. A002N1Z

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

    3. A002MARE01
      Text in Illustration
      *a less than 8.5 mm (0.335 in.)
      *b less than 9.3 mm (0.366 in.)

      Install a bolt to the No. 1 output shaft assembly and lift the 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. A002OJC

      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. A002N4Z

      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. A002NIJ

      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. A002PB1

      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. A002NY9E01
      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. A002MFR

      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. A002P0QE01

      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. A002NP5

      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. A002Q9A

      Install a new gasket and the drain plug.

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

  41. INSTALL TRANSAXLE CASE OIL SEAL LH

    Click here

  42. INSTALL TRANSAXLE CASE OIL SEAL RH

    Click here

  43. INSTALL SHIFT AND SELECT LEVER ASSEMBLY


    1. A002MR0

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

    2. A002M6CE07

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

      Seal packing
      Toyota Genuine Seal Packing, Three Bond 1207B or equivalent
      Text in Illustration
      *a Seal Packing

      Note

      Assemble parts within 10 minutes of application otherwise, 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. A002QMN

      Install the shift and select lever assembly 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. A002LY2

      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. A002Q6T

      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 NEUTRAL POSITION SWITCH (w/ Stop And Start System)

    Click here

  47. INSTALL NO. 1 LOCK BALL ASSEMBLY


    1. A002N7A

      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 onto the manual transmission case.

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

  48. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

  49. INSTALL SELECTING BELLCRANK ASSEMBLY


    1. A002NRU

      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. A002NRS

      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

    Click here

  53. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

  54. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here