MULTI-MODE MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A00Y4WYN06

      Using SST and a press, install a new front differential case front tapered roller bearing to the differential case.

      SST
      09309-37010
      09506-35010
    2. A00Y4W6N06

      Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer to the front transaxle case.

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07200 )

  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A00Y8W9N06

      Using SST and a press, install a new front differential case rear tapered roller bearing to the differential case.

      SST
      09636-20010
      09726-40010
    2. A00Y7Z9N06

      Using SST and a press, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer to the manual transmission case.

      SST
      09309-36010
      09950-60020   ( 09951-00730 )
      09950-70010   ( 09951-07100 )

      Tech Tips

      Use a plate washer of the same thickness as the removed one.

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A00YACE

      Coat the differential case assembly with gear oil and install it to the front transaxle case.

    2. A00YB1D

      Install the manual transmission case with the 16 bolts.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A00Y6JRC02
      *1 Front Differential Case Rear Plate Washer

      Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      SST
      09564-32011

    4. Using SST and a torque wrench, measure the preload.

      SST
      09564-32011
      Preload (at starting)
      New bearing
      1.0 to 1.6 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf)
      Used bearing
      0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 12 in.*lbf)

      If the preload is out of specification, select a proper front differential case rear plate washer.

      Front Differential Case Rear Plate Washer Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      10 2.100 (0.0827) 26 2.500 (0.0984)
      11 2.125 (0.0837) 27 2.525 (0.0994)
      12 2.150 (0.0846) 28 2.550 (0.1004)
      13 2.175 (0.0856) 29 2.575 (0.1014)
      14 2.200 (0.0866) 30 2.600 (0.1024)
      15 2.225 (0.0876) 31 2.625 (0.1033)
      16 2.250 (0.0886) 32 2.650 (0.1043)
      17 2.275 (0.0896) 33 2.675 (0.1053)
      18 2.300 (0.0906) 34 2.700 (0.1063)
      19 2.325 (0.0915) 35 2.725 (0.1073)
      20 2.350 (0.0925) 36 2.750 (0.1083)
      21 2.375 (0.0935) 37 2.775 (0.1093)
      22 2.400 (0.0945) 38 2.800 (0.1102)
      23 2.425 (0.0955) 39 2.825 (0.1112)
      24 2.450 (0.0965) 40 2.850 (0.1122)
      25 2.475 (0.0974) - -

      Tech Tips


      • Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

      • Make a memo as the torque values will be needed for adjusting output shaft bearing preload.

    5. Remove the 16 bolts and manual transmission case.

    6. Remove the differential case assembly from the front transaxle case.

  4. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A00Y8AV

      Install the output shaft cover to the front transaxle case.

      Note

      Insert the output shaft cover key into the case groove.

    2. A00Y8KZN03

      Using SST and a press, install the front output shaft bearing (outer race) to the front transaxle case.

      SST
      09950-60010   ( 09951-00630 )
      09950-70010
      09950-70010

  5. INSTALL REAR OUTPUT SHAFT BEARING


    1. A00YB4MN06

      Using SST and a press, install the rear output shaft bearing (outer race) with the rear output shaft bearing shim to the manual transmission case.

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07200 )

      Tech Tips

      Use a plate washer of the same thickness as the removed one.

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A00YACE

      Coat the differential case assembly with gear oil and install it to the front transaxle case.

    2. A00Y5ZA

      Coat the output shaft assembly with gear oil and install it to the front transaxle case.

    3. A00YB1D

      Install the manual transmission case with the 16 bolts.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A00YB6VC02
      *1 Rear Output Shaft Bearing Shim

      Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      SST
      09564-32011

    5. Using SST and a torque wrench, measure the preload. Calculate the rear output shaft bearing shim value using the following formula.

      SST
      09564-32011
      Formula
      (Differential side bearing preload + Output shaft bearing preload) - Differential side bearing preload = Output shaft bearing preload
      Preload (at starting)
      New Bearing
      4.0 to 6.9 N*m (41 to 70 kgf*cm, 35 to 61 in.*lbf)
      Used Bearing
      2.6 to 4.4 N*m (27 to 45 kgf*cm, 23 to 39 in.*lbf)

      If the preload is out of specification, select a proper rear output shaft bearing shim.

      Rear Output Shaft Bearing Shim
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      50 1.750 (0.0689) 72 2.300 (0.0906)
      51 1.775 (0.0699) 73 2.325 (0.0915)
      52 1.800 (0.0709) 74 2.350 (0.0925)
      53 1.825 (0.0719) 75 2.375 (0.0935)
      54 1.850 (0.0728) 76 2.400 (0.0945)
      55 1.875 (0.0738) 77 2.425 (0.0955)
      56 1.900 (0.0748) 78 2.450 (0.0965)
      57 1.925 (0.0758) 79 2.475 (0.0974)
      58 1.950 (0.0768) 80 2.500 (0.0984)
      59 1.975 (0.0778) 81 2.525 (0.0994)
      60 2.000 (0.0787) 82 2.550 (0.1004)
      61 2.025 (0.0797) 83 2.575 (0.1014)
      62 2.050 (0.0807) 84 2.600 (0.1024)
      63 2.075 (0.0817) 85 2.625 (0.1033)
      64 2.100 (0.0827) 86 2.650 (0.1043)
      65 2.125 (0.0837) 87 2.675 (0.1053)
      66 2.150 (0.0846) 88 2.700 (0.1063)
      67 2.175 (0.0856) 89 2.725 (0.1073)
      68 2.200 (0.0866) 90 2.750 (0.1083)
      69 2.225 (0.0876) 91 2.775 (0.1093)
      70 2.250 (0.0886) 92 2.800 (0.1102)
      71 2.275 (0.0896) - -

      Tech Tips

      Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

    6. Remove the 16 bolts and manual transmission case.

    7. Remove the output shaft assembly from the front transaxle case.

    8. Remove the differential case assembly from the front transaxle case.

  7. INSTALL TRANSMISSION CASE GASKET


    1. A00YBAHC01
      *a Depth

      Using SST and a hammer, install a new transmission case gasket to the manual transmission case.

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )
      Drive in Depth
      0 to 1.0 mm (0 to 0.0394 in.)

  8. INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A00Y5IZ

      Install the manual transmission oil separator sub-assembly to the manual transmission case with the 4 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Make sure that the end tabs of the manual transmission oil separator sub-assembly are inserted into the grooves of the manual transmission case.

  9. INSTALL TRANSMISSION OIL SEPARATOR


    1. A00Y6LZ

      Install the transmission oil separator to the manual transmission case with the 2 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Make sure that the tip of the transmission oil separator is inserted into the groove of the transmission case.

  10. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A00Y7G2

      Install the No. 1 oil receiver pipe to the manual transmission case.

      Tech Tips

      Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

  11. INSTALL STRAIGHT PIN


    1. A00Y6E8C02
      *a Depth

      Using a plastic hammer, tap in 5 new straight pins to the specified protrusion height.

      Protrusion Height (A)
      8.5 to 9.5 mm (0.335 to 0.374 in.)
      Protrusion Height (B)
      8.5 to 9.5 mm (0.335 to 0.374 in.)

  12. INSTALL BREATHER PLUG


    1. A00Y4YDN01

      Using SST and a hammer, install the breather plug to the front transaxle case.

      SST
      09350-30020   ( 09350-07110 )

  13. INSTALL TRANSMISSION OIL SEPARATOR


    1. A00Y6WE

      Install the transmission oil separator to the front transaxle case with the 4 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  14. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A00Y8CXC02
      *a Depth

      Using SST and a hammer, install a new front transaxle case oil seal to the front transaxle case.

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )
      Driven in Depth
      0.9 to 1.9 mm (0.0354 to 0.0748 in.)

    2. Coat the lip of the front transaxle case oil seal with MP grease.

  15. INSTALL TRANSMISSION MAGNET


    1. A00YA6A

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

  16. INSTALL INPUT SHAFT COVER


    1. A00Y9VS

      Install the input shaft cover to the manual transmission case.

      Note

      Insert the output shaft cover key into the manual transmission case groove.

  17. INSTALL REAR INPUT SHAFT BEARING SHIM


    1. The rear input shaft bearing shim should be washed before assembly.

      Note

      Apply grease to the shim to prevent it from falling off from the case during reassembly.

    2. Measure the area between the end of the manual transmission case and the rear input shaft bearing shim (Dimension A).

      A00Y79RC02
      *1 Manual Transmission Case *2 Input Shaft Assembly
      *3 Front Transaxle Case - -
      *a Dimension A *b Dimension B
      *c Dimension C - -

    3. Measure the area between the end of the front transaxle case and the installation surface of the front input shaft bearing (Dimension B).

    4. Measure the area between both input shaft bearing outer races (Dimension C).

      Note

      Measure Dimension C with each bearing having no axial clearance.

    5. Calculate the rear input shaft bearing shim value using the following formula.

      Formula
      (Dimension A + Dimension B) - Dimension C - rear input shaft bearing shim thickness = Between 0 mm and 0.14 mm (0.00551 in.)

      If the thickness is out of specification, select a proper rear output shaft bearing shim.

      Rear Input Shaft Bearing Shim Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      08 1.30 (0.0512) 14 1.60 (0.0630)
      09 1.35 (0.0531) 15 1.65 (0.0650)
      10 1.40 (0.0551) 16 1.70 (0.0669)
      11 1.45 (0.0571) 17 1.75 (0.0689)
      12 1.50 (0.0591) 18 1.80 (0.0709)
      13 1.55 (0.0610) 19 1.85 (0.0728)

    6. Coat the rear input shaft bearing shim with MP grease and install it to the manual transmission case.

      Note

      Do not apply MP grease to the oil grooves.

  18. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A00YACE

      Coat the differential case tapered roller bearing with gear oil and install the differential case assembly to the front transaxle case.

  19. INSTALL INPUT SHAFT ASSEMBLY


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

    2. A00YAFGC01
      *1 No. 1 Gear Shift Fork Shaft Assembly

      Coat the No. 1 gear shift fork shaft assembly with gear oil and install it.

    3. A00Y76ZC01
      *1 No. 2 Gear Shift Fork Shaft Assembly
      *2 No. 3 Gear Shift Fork Shaft Assembly

      Coat the No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly with gear oil and install them.

    4. Provisionally install the output shaft assembly, input shaft assembly and 3 gear shift fork shaft assemblies, and tie them with a rope or string.

    5. A00YAZX

      Install the input shaft assembly, output shaft assembly and 3 gear shift fork shaft assemblies to the front transaxle case.

  20. INSTALL SHIFT INTER LOCK PLATE


    1. A00Y9XT

      Install the shift inter lock plate to the front transaxle case.

  21. INSTALL SHIFT AND SELECT LEVER SHAFT


    1. A00Y5PDC02
      *a 5 mm Pin Punch
      *b Depth

      Using a 5 mm pin punch and hammer, install the slotted spring pin and shift and select lever shaft head to the shift and select lever shaft.

      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  22. INSTALL INNER SELECT LEVER


    1. A00Y91OC02
      *a 5 mm Pin Punch
      *b Depth

      Using a 5 mm pin punch and hammer, install the slotted spring pin to the inner select lever.

      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  23. INSTALL INNER NO. 1 SHIFT LEVER


    1. Using a 5 mm pin punch and hammer, install the slotted spring pin to the inner No. 1 shift lever.

      A00Y5RWC02
      *a 5 mm Pin Punch *b Depth
      *c Plane - -
      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Tech Tips

      The inner No. 1 shift lever can be installed in either direction.

  24. INSTALL FRONT INNER SHIFT LEVER


    1. A00Y7TBC02
      *a 5 mm Pin Punch
      *b Depth

      Using a 5 mm pin punch and hammer, install the slotted spring pin to the front inner shift lever.

      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Check the installation direction.

  25. INSTALL INNER NO. 2 SHIFT LEVER


    1. A00Y8XZC02
      *a 5 mm Pin Punch
      *b Depth

      Using a 5 mm pin punch and hammer, install the slotted spring pin to the inner No. 2 shift lever.

      Driven in Depth
      0 to 0.6 mm (0 to 0.0236 in.)

      Note

      Check the installation direction.

  26. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A00Y7Z0

      Turn the shift and select lever shaft assembly and the inner select lever counterclockwise, and install them to the front transaxle case.

      Tech Tips

      When installing the inner select lever, make sure to engage it with the shift inter lock plate.

  27. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A00Y6AA

      Install the reverse shift arm bracket assembly to the front transaxle case with the 2 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  28. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A00Y6OV

      Coat the reverse shift fork shaft assembly with gear oil and install it.

  29. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A00Y9JEC03
      *a Parallel

      Coat the reverse idler gear sub-assembly, revers idler thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

      Note

      Make sure that the reverse idler gear shaft bolt installation surface is parallel to the screw hole on the front transaxle case.

      Tech Tips

      Raise the edge of the reverse shift arm bracket assembly and install it to the reverse shift fork shaft assembly.

  30. INSTALL MANUAL TRANSMISSION CASE


    1. A00YB9GC02
      *a FIPG
      *b Seal Diameter 1.2 mm (0.0472 in.)

      Apply FIPG to the manual transmission case as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

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

    2. A00YB1D

      Install the 16 bolts to the manual transmission case.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }

  31. INSTALL TRANSMISSION CASE OIL SEAL

    Click here

  32. INSTALL TRANSAXLE CASE OIL SEAL

    Click here

  33. INSTALL SHIFT DETENT BALL


    1. A00Y5A5

      Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.

    2. Coat the threads of the 2 shift detent ball plugs with sealant.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a 6 mm hexagon socket wrench, install the 2 shift detent ball plugs.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    4. A00Y9KU

      Install the shift detent ball and shift detent ball compression spring to the manual transmission case.

    5. Coat the threads of the shift detent ball plug with sealant.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Using a 6 mm hexagon socket wrench, install the shift detent ball plugs.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A00Y6EN

      Coat the threads of the reverse idler gear shaft bolt with sealant.

      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install a new gasket and the reverse idler gear shaft bolt to the manual transmission case.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  35. INSTALL TRANSMISSION CASE PLUG


    1. A00Y7AW

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

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

  36. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP


    1. Install the release cylinder bleeder plug cap to the release clutch bleeder plug.

  37. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  38. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  39. INSPECT CLUTCH PIPE LINE

    Click here

  40. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  41. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover to the front transaxle case.

  42. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY


    1. A00YAJJ

      Install the breather plug cap to the shift and select actuator assembly.

    2. A00Y70Y

      Install the breather protector to the shift and select actuator assembly with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    3. A00YAUT

      Using a plastic hammer, tap in 2 new ring pins to the specified protrusion height.

      Protrusion Height
      5.2 to 5.8 mm (0.205 to 0.228 in.)
    4. A00Y9UFC04
      *a FIPG
      *b Seal Diameter 1.2 mm (0.0472 in.)

      Apply FIPG to the shift and select actuator assembly as shown in the illustration.

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

      Note


      • Remove any oil from the contact surfaces.

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

    5. When replacing the shift and select actuator with a new one:


      1. A00Y8K7

        Move the select inner lever as shown in the illustration.

      2. A00Y6MWC03
        *a Shift and Select Lever Shaft Head
        *b Shift Actuator Plate
        *c Select Actuator Plate
        *d Inner Select Lever

        Install the shift and select actuator and wire harness clamp bracket to the transaxle case with the 6 bolts.

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

        Note


        • Securely engage the shift actuator plate to the shift and select lever shaft head.

        • Securely engage the select actuator plate to the inner select lever.

    6. When reusing the shift and select actuator:


      1. A00YBGWC03
        *a Shift and Select Lever Shaft Head
        *b Shift Actuator Plate
        *c Select Actuator Plate
        *d Inner Select Lever

        Install the shift and select actuator to the transaxle case with the 6 bolts.

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

        Note


        • Securely engage the shift actuator plate to the shift and select lever shaft head.

        • Securely engage the select actuator plate to the inner select lever.

  43. INSTALL NEUTRAL POSITION SWITCH


    1. A00Y6RTC02
      *a 27 mm Deep Socket Wrench

      Using a 27 mm deep socket wrench, install a new gasket and the neutral position switch to the manual transmission case.

      Torque:
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }

  44. INSTALL TRANSMISSION REVOLUTION SENSOR


    1. Install a new O-ring to the transmission revolution sensor.

    2. A00Y84Z

      Install the transmission revolution sensor with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  45. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00Y6CPC03
      *a 27 mm Deep Socket Wrench

      Using a 27 mm deep socket wrench, install a new gasket and the back-up light switch to the manual transmission case.

      Torque:
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }

  46. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A00Y5E3

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

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

  47. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    1. A00Y7K7

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

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }