MANUAL TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STRAIGHT PIN AND RING PIN

    Note

    It is not necessary to remove a straight pin and ring pin unless it is being replaced.


    1. A01SD86C01
      *a Protrusion Height

      Using a plastic-faced hammer, tap 4 new ring pins into the intermediate plate.

      Specified Condition
      Item Specified Condition
      A 5.5 to 7.5 mm (0.217 to 0.295 in.)
    2. A01SCFAC01
      *a Protrusion Height

      Using a plastic-faced hammer, tap 2 new straight pins into the manual transmission case.

      Specified Condition
      Item Specified Condition
      A 9.0 to 11.0 mm (0.355 to 0.433 in.)

  2. INSTALL OUTPUT SHAFT


    1. A01SCXE

      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.

  3. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01SB7J

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

  4. INSPECT NO. 2 SYNCHRONIZER RING

    Click here

  5. INSTALL INPUT SHAFT


    1. A01SB8H

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

      Note


      • When installing the input shaft to the output shaft, align the protrusion of the No. 2 synchronizer ring with the cutout of the transmission clutch hub.

      • Check that the input shaft rotates slightly.

  6. INSTALL COUNTER GEAR


    1. A01SBNB

      Temporarily install the counter gear to the intermediate plate.

  7. INSTALL COUNTER SHAFT REAR BEARING


    1. A01SAWQN02

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

      SST
      09316-60011   ( 09316-00011 )

      Tech Tips

      Install the counter shaft rear 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.

  8. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01SE5X

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

      Note

      Install the reverse idler shaft with its groove facing the rear side, and install it from the rear side.

  9. INSTALL OUTPUT SHAFT REAR BEARING RETAINER


    1. A01SB0Y

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

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

  10. INSTALL 5TH GEAR THRUST WASHER PIN


    1. A01SDSA

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

  11. INSTALL 5TH GEAR THRUST WASHER


    1. A01SE4H

      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 chamfer side faces forward.

  12. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


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

      Note

      Make sure that the No. 3 transmission hub sleeve and countershaft 5th gear are installed facing the correct direction.

    2. A01SDKKC01
      *a Cutout
      *b Protrusion

      Install the 2 No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring to the countershaft 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. A01SDWV

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

  13. INSTALL COUNTER 5TH GEAR BEARING


    1. A01SCN1

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

  14. INSTALL COUNTERSHAFT 5TH GEAR


    1. A01SEXP

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

  15. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01SEP3

      Apply gear oil to the No. 3 synchronizer ring, and install it to the countershaft 5th gear.

      Note

      Install the No. 3 synchronizer ring so that its protrusion fits between the 2 No. 3 synchromesh shifting keys.

  16. INSTALL NO. 5 GEAR SPLINE PIECE


    1. A01SD1WN03

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

      SST
      09316-60011   ( 09316-00011 )

      Note

      Check that the gear rotates freely.

  17. INSTALL COUNTER SHAFT REAR SNAP RING


    1. A01SAETC01
      *a Thrust Clearance

      Select a snap ring so that the thrust clearance between the No. 5 gear spline piece and snap ring is within the specification.

      Standard clearance
      0.10 mm (0.00393 in.) or less
      Snap Ring Thickness
      Thickness
      2.80 to 2.85 mm (0.111 to 0.112 in.)
      2.85 to 2.90 mm (0.113 to 0.114 in.)
      2.90 to 2.95 mm (0.115 to 0.116 in.)
      2.95 to 3.00 mm (0.117 to 0.118 in.)
      3.00 to 3.05 mm (0.119 to 0.120 in.)
      3.05 to 3.10 mm (0.121 to 0.122 in.)
      3.10 to 3.15 mm (0.123 to 0.124 in.)
    2. A01SDA4

      Using a brass bar and hammer, install the counter shaft rear snap ring.

  18. INSPECT COUNTERSHAFT 5TH GEAR THRUST CLEARANCE

    Click here

  19. INSPECT COUNTERSHAFT 5TH GEAR RADIAL CLEARANCE

    Click here

  20. INSTALL OUTPUT SHAFT REAR BEARING


    1. A01SEFEN02

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

      SST
      09309-35010

    2. Select a shaft snap ring so that the thrust clearance between the output shaft rear bearing and shaft snap ring is within the specification.

      Standard clearance
      0.10 mm (0.00393 in.) or less
      Snap Ring Thickness
      Thickness Thickness
      2.65 to 2.70 mm (0.105 to 0.106 in.) 3.10 to 3.15 mm (0.122 to 0.124 in.)
      2.70 to 2.75 mm (0.107 to 0.108 in.) 3.15 to 3.20 mm (0.124 to 0.126 in.)
      2.75 to 2.80 mm (0.109 to 0.110 in.) 3.20 to 3.25 mm (0.126 to 0.128 in.)
      2.80 to 2.85 mm (0.111 to 0.112 in.) 3.25 to 3.30 mm (0.128 to 0.129 in.)
      2.85 to 2.90 mm (0.113 to 0.114 in.) 3.30 to 3.35 mm (0.130 to 0.131 in.)
      2.90 to 2.95 mm (0.115 to 0.116 in.) 3.35 to 3.40 mm (0.132 to 0.133 in.)
      2.95 to 3.00 mm (0.117 to 0.118 in.) 3.40 to 3.45 mm (0.134 to 0.135 in.)
      3.00 to 3.05 mm (0.119 to 0.120 in.) 3.45 to 3.50 mm (0.136 to 0.137 in.)
      3.05 to 3.10 mm (0.121 to 0.122 in.) -
    3. A01SCCR

      Using a brass bar and hammer, install the shaft snap ring to the output shaft.

  21. INSTALL REVERSE SHIFT ARM BRACKET


    1. A01SETY

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

    2. A01SE0AC01
      *1 Reverse Idler Gear
      *2 Reverse Shift Arm

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

    3. A01SE82

      Install the reverse shift arm bracket with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. A01SAUI

      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.

  22. INSTALL REVERSE SHIFT FORK


    1. A01SC8S

      Install the reverse shift fork to the reverse shift arm.

  23. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A01SBR2

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

    2. A01SE18

      Install the No. 1 shift interlock roller to the reverse shift fork.

    3. A01SBMD

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

    4. A01SDY2

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

  24. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A01SETF

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

    2. A01SBO3

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

    3. A01SBHK

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

    4. A01SB7P

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

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
    5. A01SC3W

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

  25. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A01SCJ7C01
      *1 No. 1 Shift Interlock Roller
      *2 Shift Interlock Pin

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

    2. A01SBFZ

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

    3. A01SAAW

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

    4. A01SDAH

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

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }
    5. A01SE0U

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

  26. INSTALL SHIFT DETENT BALL PLUG


    1. A01SBPH

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

    2. A01SE0TC03
      *a for Type A
      *b for Type B

      Install 2 new shift detent ball plugs to the intermediate plate.


      1. for Type A:

        Using a T40 ''TORX'' socket wrench, install 2 new shift detent ball plugs to the intermediate plate.

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

      2. for Type B

        Using a 6 mm hexagon socket wrench, install 2 new shift detent ball plugs to the intermediate plate.

        Torque:
        18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }
    3. A01SCEB

      Install the shift detent ball and shift detent ball compression spring to the intermediate plate.

    4. A01SBXDC03
      *a for Type A
      *b for Type B

      Install a new shift detent ball plug to the intermediate plate.


      1. for Type A:

        Using a T40 ''TORX'' socket wrench, install a new shift detent ball plug to the intermediate plate.

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

      2. for Type B:

        Using a 6 mm hexagon socket wrench, install a new shift detent ball plug to the intermediate plate.

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

  27. INSTALL TRANSMISSION MAGNET


    1. A01SALF

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

  28. INSTALL MANUAL TRANSMISSION CASE


    1. A01SCKPC01
      *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
    2. A01SEDS

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

  29. INSTALL COUNTER GEAR FRONT BEARING SNAP RING


    1. A01SDHQ

      Using a snap ring expander, install the counter gear front bearing snap ring to the manual transmission case.

  30. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A01SE9C

      Using a snap ring expander, install the front bearing shaft snap ring to the manual transmission case.

  31. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    Click here

  32. INSTALL FRONT BEARING RETAINER


    1. Clean and degrease the contact surface of the front bearing retainer and manual transmission case.

    2. Clean and degrease the 8 bolts and the installation holes in the manual transmission case.

    3. A01SB10C01
      *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

      Note


      • Assemble the parts within 10 minutes of application. Otherwise, the seal packing material must be removed and reapplied.

      • Apply seal packing in a continuous line (width 1.2 mm (0.0472 in.)) a long the sealing surface of the manual transmission case

    4. A01SDN9

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

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

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

  33. INSTALL TRANSFER ADAPTER OIL SEAL

    Click here

  34. INSTALL REVERSE RESTRICT PIN


    1. A01SALD

      Install the reverse restrict pin to the transfer adapter sub-assembly.

    2. A01SEZX

      Using a 5 mm pin punch and hammer, tap in the slotted pin to the transfer adapter sub-assembly.

    3. A01SEOF

      Using a T40 ''TORX'' socket wrench, install a new plug to the transfer adapter sub-assembly.

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

  35. INSTALL TRANSFER OIL RECEIVER PIPE


    1. A01SAEI

      Install the transfer oil receiver pipe to the transfer adapter sub-assembly.

  36. INSTALL SHIFT AND SELECT LEVER


    1. A01SCOIC01
      *A w/ Console Box Lid
      *B w/o Console Box Lid

      Install the shift and select lever shaft and shift lever housing to the transfer adapter sub-assembly.

    2. A01SEFHC01
      *A w/ Console Box Lid
      *B w/o Console Box Lid

      Install a new bolt to the transfer adapter sub-assembly.

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

  37. INSTALL TRANSFER ADAPTER SUB-ASSEMBLY


    1. A01SCKPC01
      *a Seal Packing

      Apply seal packing to the transfer adapter sub-assembly as shown in the illustration.

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

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

    3. A01SDPC

      Install the transfer adapter sub-assembly to the manual transmission case with the 10 bolts and 2 wire harness brackets.

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

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


    1. Install a new control shift lever retainer gasket and the floor shift control shift lever retainer sub-assembly.

    2. A01SAYCC01
      *A w/o Console Box Lid
      *B w/ Console Box Lid

      Install the 4 bolts.

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

  39. INSTALL REVERSE RESTRICT PIN ASSEMBLY


    1. A01SESMC03
      *A w/o Console Box Lid
      *B w/ Console Box Lid
      *a Blue
      *b Red
      *c Gray
      *d Purple

      Install the 2 reverse restrict pin assemblies.

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

  40. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    Click here

  41. INSTALL CLUTCH HOUSING


    1. Clean the threads of the bolts and the manual transmission case with non-residue solvent.

    2. A01SBTUC01
      *a Precoated Bolt

      Install the clutch housing to the manual transmission case with the 7 bolts.

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

    3. Install 2 new bolts (labeled A).

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

  42. INSTALL RELEASE FORK SUPPORT

    Click here

  43. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    Click here

  44. INSTALL CLUTCH RELEASE FORK BOOT

  45. INSTALL DRAIN PLUG SUB-ASSEMBLY


    1. A01SC9X

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

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

  46. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01SDG0

      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 }