MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL SHIFT FORK SHAFT BEARING


    1. A01GA9PN01

      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 0.0196 in.)

  2. INSTALL OUTPUT SHAFT COVER


    1. A01GA9EC03
      *a Protrusion
      *b Groove

      Install the output shaft cover as shown in the illustration.

  3. INSTALL FRONT NO. 2 OUTPUT SHAFT BEARING OUTER RACE


    1. A01GBWSN02

      Using SST and a hammer, tap in the front No. 2 output shaft bearing outer race.

      SST
      09950-60020   ( 09951-00720 )
      09950-70010   ( 09951-07100 )

  4. INSTALL OUTPUT SHAFT COVER


    1. A01GBRBC03
      *a Protrusion
      *b Groove

      Install the output shaft cover as shown in the illustration.

  5. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A01GAQNN02

      Using SST and a press, install a new front output shaft bearing to the front transaxle case.

      SST
      09223-15020
    2. A01KB2K

      Install the bearing lock plate and bolt.

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

    3. Coat a front output shaft bearing with gear oil.

  6. INSTALL TRANSAXLE CASE OIL SEAL


    1. A01GBMQN01

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

      SST
      09950-60010   ( 09951-00420 )
      Standard depth
      4.4 to 5.0 mm (0.174 to 0.196 in.)

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

  7. INSTALL FRONT INPUT SHAFT BEARING


    1. A01GDHWN02

      Using SST and a press, install a new front input shaft bearing to the front transaxle case.

      SST
      09223-00010
    2. A01KCHW

      Install the bearing lock plate and bolt.

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

    3. Coat the front input shaft bearing with gear oil.

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


    1. A01KAY5

      Using a snap ring expander, install the 2 rear input and output shaft bearing shaft snap rings.

  9. INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A01GA95N01

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

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

  10. INSTALL SHIFT FORK SHAFT BEARING


    1. A01GD7ZN01

      Using SST and a press, press in 4 new shift fork shaft bearings to the manual transmission case.

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

  11. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01GD3QN02

      Using SST and a hammer, tap in the front differential case front tapered roller bearing.

      SST
      09950-70010   ( 09951-07150 )
      09951-00900

  12. INSTALL FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING


    1. A01GA4S

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

    2. A01GAUSN02

      Using SST and a hammer, install the front differential case rear outer race bearing.

      SST
      09950-70010   ( 09951-07100 )
      09951-00900

  13. INSTALL MANUAL TRANSMISSION CASE STRAIGHT PIN

    A01GBICC01
    *a Protrusion

    1. Using a plastic-faced hammer, tap in the 4 new straight pins to the front transaxle case.

      Protrusion height
      10.5 to 11.5 mm (0.414 to 0.452 in.)

  14. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01KAW8

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

    2. A01KCOX

      Install the manual transmission case to the front transaxle case with the 12 bolts.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A01KD5H

      Install the 6 bolts to the front transaxle case side.

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

    4. Turn the differential case in both directions and make sure it turns smoothly.

    5. A01GAI6C01
      *a Mark

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

      SST
      09564-33010
      Standard Preload (at starting)
      1.0 to 2.49 N*m (11 to 26 kgf*cm, 9 to 22 in.*lbf)

      • If the preload is not as specified, replace the front differential case rear shim with one of a different thickness. Use the table below to select a front differential case rear shim which will ensure that the preload is within the specification.

      Standard Shim Thickness
      Mark Specified Condition Mark Specified Condition
      0 2.00 mm (0.0787 in.) 9 2.45 mm (0.0965 in.)
      1 2.05 mm (0.0807 in.) A 2.50 mm (0.0984 in.)
      2 2.10 mm (0.0827 in.) B 2.55 mm (0.1004 in.)
      3 2.15 mm (0.0846 in.) C 2.60 mm (0.1024 in.)
      4 2.20 mm (0.0866 in.) D 2.65 mm (0.1043 in.)
      5 2.25 mm (0.0886 in.) E 2.70 mm (0.1063 in.)
      6 2.30 mm (0.0906 in.) F 2.75 mm (0.1083 in.)
      7 2.35 mm (0.0925 in.) G 2.80 mm (0.1102 in.)
      8 2.40 mm (0.0945 in.) H 2.85 mm (0.1122 in.)

    6. Remove the 18 bolts and manual transmission case.

  15. INSTALL REAR NO. 2 OUTPUT SHAFT BEARING OUTER RACE


    1. A01GCGOC01
      *a Mark

      Install the rear output shaft bearing shim to the manual transmission case.

      Tech Tips

      When reusing the output shaft rear tapered roller bearing, first install a shim of the same thickness as the original. When installing a new output shaft front bearing, first select and install a rear output shaft bearing shim which is thinner than the original.

    2. A01GBDHN02

      Using SST and a hammer, install the rear No. 2 output shaft bearing outer race.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07200 )

  16. ADJUST REAR NO. 2 OUTPUT SHAFT BEARING PRELOAD


    1. A01GAY1

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

    2. A01KCOX

      Install the manual transmission case to the front transaxle case with the 12 bolts.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A01KD5H

      Install the 6 bolts to the front transaxle case side.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A01GC0PN02

      Using SST and a torque wrench, measure the rear No. 2 output shaft bearing preload. Subtract the value of the differential side bearing preload from the measured rear No. 2 output shaft bearing preload.

      SST
      09564-33010
      Standard Preload ( at starting)
      4.14 to 5.87 N*m (43 to 59 kgf*cm, 37 to 51 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.

      Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition
      A 1.80 mm (0.0709 in.) K 2.25 mm (0.0866 in.)
      B 1.85 mm (0.0723 in.) L 2.30 mm (0.0906 in.)
      C 1.90 mm (0.0748 in.) M 2.35 mm (0.0925 in.)
      D 1.95 mm (0.0768 in.) N 2.40 mm (0.0945 in.)
      E 2.00 mm (0.0787 in.) P 2.45 mm (0.0965 in.)
      F 2.05 mm (0.0809 in.) Q 2.50 mm (0.0984 in.)
      G 2.10 mm (0.0827 in.) R 2.55 mm (0.1004 in.)
      H 2.15 mm (0.0846 in.) S 2.60 mm (0.1024 in.)
      J 2.20 mm (0.0866 in.) T 2.65 mm (0.1043 in.)

    5. Remove the 18 bolts and manual transmission case.

    6. Remove the No. 2 output shaft assembly from the front transaxle case.

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

  17. INSTALL TRANSMISSION MAGNET


    1. A01KBKD

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

  18. INSTALL FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A01KAW8

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

  19. INSTALL TRANSMISSION OIL SEPARATOR


    1. A01KAY8

      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 }

  20. INSTALL INPUT SHAFT, NO. 1 OUTPUT SHAFT ASSEMBLY AND NO. 2 OUTPUT SHAFT ASSEMBLY


    1. A01KCC8

      Install the 3 shafts at the same time.

  21. INSTALL REVERSE IDLER GEAR


    1. A01KC57

      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. A01GA5Q

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

    3. A01GBR4C02
      *a Align the Mark

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

  22. INSTALL REVERSE SHIFT FORK


    1. A01KCS3

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

  23. INSTALL NO. 3 GEAR SHIFT FORK


    1. A01KC73

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

  24. INSTALL 5TH AND 6TH SHIFT FORK SHAFT


    1. A01KCN9

      Install the 5th and 6th shift fork shaft to the front transaxle case.

    2. Coat the threads of the bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond1344 or equivalent
    3. A01KCY5

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

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

  25. INSTALL REVERSE SHIFT FORK SHAFT


    1. A01KCY1

      Install the reverse shift fork shaft to the front transaxle case.

    2. Coat the threads of the bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond1344 or equivalent
    3. A01KCK7

      Install the bolt to the reverse gear shift fork.

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

  26. INSTALL SHIFT ARM


    1. A01KCBZ

      Install the shift arm to the front transaxle case.

  27. INSTALL NO. 1 GEAR SHIFT FORK


    1. A01KD9R

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

  28. INSTALL NO. 5 GEAR SHIFT FORK SHAFT


    1. A01GAWS

      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 (-0.0197 to 0.0196 in.)
    3. A01KDT7

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

    4. A01GBDE

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

    5. A01KCWZ

      Install the pin to the shift arm.

    6. A01GBIP

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

  29. INSTALL NO. 2 GEAR SHIFT FORK


    1. A01KB6D

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

  30. INSTALL 3RD AND 4TH SHIFT FORK SHAFT


    1. A01KD5N

      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 front transaxle case.

    3. A01GBX7

      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 (-0.0197 to 0.0196 in.)
    4. A01GAQB

      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 (-0.0197 to 0.0196 in.)

  31. INSTALL 1ST AND 2ND SHIFT FORK SHAFT


    1. A01KDQC

      Install the 1st and 2nd shift fork shaft to the front transaxle case.

    2. Coat the threads of the bolt with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond1344 or equivalent
    3. A01KBQB

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

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

  32. INSTALL TRANSMISSION OIL SEPARATOR


    1. A01KBFJ

      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 }

  33. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A01KDC5

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

      Note

      Do not damage the No. 1 oil receiver pipe.

  34. INSTALL MANUAL TRANSMISSION CASE


    1. Clean the contact surface of the manual transmission case and front transaxle case with non-residue solvent.

    2. A01GBC7C02
      *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 seal packing must be removed and reapplied.

    3. A01KDGK

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

    4. A01GCDFC01
      *a 8.5 mm (0.3346 in.)
      *b 9.3 mm (0.3661 in.)

      Install a bolt to the No. 1 output shaft assembly and lift the No. 1 output shaft assembly from the service hole. Make sure that the output shaft rear bearing shaft snap ring and input shaft bearing shaft snap ring 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.

    5. A01KCOX

      Install the manual transmission case to the front transaxle case with the 12 bolts.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    6. A01KD5H

      Install the 6 bolts to the front transaxle case.

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

  35. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A01KBW1

      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 }

  36. INSTALL SHIFT DETENT BALL


    1. Clean the threads of the 4 detent ball plugs.

    2. A01KCNM

      Apply a few drops of adhesive to 2 or 3 threads of each of the 4 detent ball plugs.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a 6 mm hexagon wrench, install the 4 shift detent balls, 4 shift detent ball compression springs, 4 No. 1 shift ball spring seats and 4 detent ball plugs.

      Torque:
      22.4 N*m  { 228 kgf*cm, 17 ft.*lbf }

  37. INSTALL MANUAL TRANSMISSION CASE PLUG


    1. Clean the contact surface of the manual transmission case and manual transmission case plug.

    2. A01GAUCC01
      *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

    3. Apply a few drop of the adhesive to 2 or 3 threads of the manual transmission case plug.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. Install the manual transmission case plug to the manual transmission case.

      Torque:
      for case plug*1
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      for case plug*2
      22.4 N*m  { 228 kgf*cm, 17 ft.*lbf }

  38. INSTALL O-RING


    1. A01KCEC

      Coat a new O-ring with MP grease, and install it to the shift and select lever shaft straight pin (B).

  39. INSTALL SHIFT AND SELECT LEVER SHAFT STRAIGHT PIN


    1. A01GBT8N01

      Install the spring.

    2. While pressing in the shift and select lever shaft straight pin (A) in as far as it will go, push in the shift and select lever shaft straight pin (B) to install it.

  40. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01KDA6

      Install a new gasket and the manual transmission filler plug.

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

  41. INSTALL DRAIN PLUG


    1. A01KBNM

      Install a new gasket and the drain plug.

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

  42. INSTALL TRANSMISSION CASE OIL SEAL

    Click here

  43. INSTALL TRANSAXLE CASE OIL SEAL

    Click here

  44. INSTALL SHIFT AND SELECT LEVER ASSEMBLY


    1. A01GCDQ

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

    2. Clean the contact surface of the manual transmission case and shift and select lever assembly.

    3. Clean the threads of the bolts with non-residue solvent.

    4. A01GA3GC03
      *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

    5. Apply a few drops of adhesive to 2 or 3 threads of the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A01KDEI

      Install the shift and select lever assembly to the manual transmission case with the 4 bolts.

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

  45. INSTALL SHIFT GATE PIN


    1. A01KBVM

      Apply a few drops of the adhesive to 2 or 3 threads of the shift gate pin.

      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 }

  46. INSTALL NO. 2 LOCK BALL ASSEMBLY


    1. Clean the threads of the No. 2 lock ball assembly with non-residue solvent.

    2. A01KCRX

      Apply a few drops of the adhesive to 2 or 3 threads of the No. 2 lock ball assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the No. 2 lock ball assembly to the manual transmission case.

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

  47. INSTALL NO. 1 LOCK BALL ASSEMBLY


    1. Clean the threads of the No. 1 lock ball assembly with non-residue solvent.

    2. A01KDFR

      Apply a few drops of the adhesive to 2 or 3 threads of the No. 1 lock ball assembly.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the No. 1 lock ball assembly to the manual transmission case.

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

  48. INSTALL NEUTRAL POSITION SWITCH


    1. A01KD0D

      Using SST, 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 }

  49. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01GAJUN03

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

      SST
      09817-16011
      Torque:
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }

  50. INSTALL FLOOR SHIFT SELECTING BELL CRANK ASSEMBLY


    1. A01KB1D

      Install the floor shift selecting bell crank assembly to the manual transmission case with the 2 bolts.

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

  51. INSTALL CONTROL CABLE BRACKET


    1. A01GB8L

      Install the control cable bracket to the manual transaxle assembly with the 3 bolts.

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

  52. INSTALL RELEASE FORK SUPPORT

    Click here

  53. INSTALL CLUTCH RELEASE FORK BOOT


    1. A01KDSG

      Install the clutch release fork boot to the front transaxle assembly.

  54. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  55. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here