MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT ASSEMBLY

    A01595H

    1. Install the output shaft by lightly tapping on the back side of the intermediate plate with a plastic-faced hammer.

  2. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING

    A015BZH

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

  3. INSTALL NO. 2 SYNCHRONIZER RING


    1. Install the No. 2 synchronizer ring to the input shaft.

  4. INSTALL INPUT SHAFT ASSEMBLY

    A015D29E01

    1. Install the input shaft to the output shaft.

      Tech Tips

      Align the shifting key of the synchronizer ring with the groove of the clutch hub.

    2. Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.

  5. INSTALL COUNTER GEAR


    1. Install the counter gear to the intermediate plate.

    2. A0158TO

      Install the center bearing to the counter gear.

    3. A0158UX

      Using a snap ring expander, install the snap ring to the outer race.

    4. A015AFH

      Using a brass bar and hammer, lightly tap the bearing outer race uniformly to install it.

      Note

      Do not drop the counter gear. Hold the front side of the counter gear.

  6. INSTALL OUTPUT SHAFT REAR BEARING(MTM) RETAINER

    A01581A

    1. Install the output shaft rear bearing retainer to the intermediate plate with the 4 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  7. INSTALL NO. 1 TRANSMISSION HUB SLEEVE


    1. Apply a light coat of gear oil to the sleeve and hub.

    2. A015AB3E01
      A0156R6E01

      Install the No. 1 transmission hub sleeve, 3 shifting keys and 3 springs to the No. 4 transmission clutch hub.

      Note

      Do not mistake the installation direction of the No. 1 transmission hub sleeve, No. 4 transmission clutch hub, and shifting keys.

  8. INSTALL REVERSE GEAR BEARING


    1. Coat the reverse gear bearing with gear oil, and install it to the reverse gear.

  9. INSTALL REVERSE SYNCHRONIZER RING SET


    1. Coat the reverse synchronizer ring set with gear oil, and install it to the reverse gear.

  10. INSTALL REVERSE GEAR

    A015E1U

    1. Coat the reverse gear with gear oil, and install it to the output shaft.

  11. INSTALL NO. 4 TRANSMISSION CLUTCH HUB

    A015879E01

    1. Using SST and a hammer, install the No. 4 transmission clutch hub.

      SST
      09316-60011   ( 09316-00011 )

      Tech Tips

      Align the shifting key of the synchronizer ring with the groove of the clutch hub.

    2. Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.

  12. INSTALL NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING

    A015CMS

    1. Select a new snap ring that will allow minimum clearance.

      Standard Clearance
      0.1 mm (0.00393 in.) or less
      Snap Ring Thickness
      Part No. Thickness Mark
      90520-34018

      2.40 to 2.45 mm

      (0.0945 to 0.0965 in.)

      		 A
      90520-34019

      2.45 to 2.50 mm

      (0.0965 to 0.0984 in.)

      		 B
      90520-34020

      2.50 to 2.55 mm

      (0.0984 to 0.100 in.)

      		 C
      90520-34021

      2.55 to 2.60 mm

      (0.100 to 0.102 in.)

      		 D
      90520-34022

      2.60 to 2.65 mm

      (0.102 to 0.104 in.)

      		 E
      90520-34023

      2.65 to 2.70 mm

      (0.104 to 0.106 in.)

      		 F
    2. A01573B

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

  13. INSPECT REVERSE GEAR THRUST CLEARANCE

    A01578W

    1. Using a feeler gauge, measure the reverse gear thrust clearance.

      Standard Clearance
      0.15 to 0.52 mm (0.00591 to 0.0204 in.)

      If the clearance is outside the specification, replace the defective gear or shaft.

  14. INSTALL NO. 2 GEAR SHIFT FORK


    1. Install the No. 2 gear shift fork.

  15. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

    A0156VF

    1. Install the No. 2 gear shift fork shaft to the No. 2 gear shift fork and intermediate plate with the bolt.

      Torque:
      46 N*m  { 472 kgf*cm, 34 ft.*lbf }

  16. INSTALL NO. 1 GEAR SHIFT FORK


    1. Install the No. 1 gear shift fork.

  17. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

    A0156AO

    1. Using a magnet hand, install the interlock pin to the intermediate plate.

    2. A0157QS

      Apply MP grease to the interlock pin.

    3. Install the interlock pin to the No. 1 gear shift fork shaft.

    4. A0159KY

      Install the No. 1 gear shift fork shaft to the No. 2 gear shift fork and intermediate plate with the bolt.

      Torque:
      46 N*m  { 472 kgf*cm, 34 ft.*lbf }

  18. INSTALL NO. 3 GEAR SHIFT FORK


    1. Install the No. 3 gear shift fork.

  19. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

    A015A5V

    1. Using a magnet hand, install the interlock pin to the intermediate plate.

    2. A015D68

      Apply MP grease to the interlock pin.

    3. Install the interlock pin to the No. 3 gear shift fork shaft.

    4. A0159TU

      Install the No. 3 gear shift fork shaft to the No. 3 gear shift fork and intermediate plate with the bolt.

      Torque:
      46 N*m  { 472 kgf*cm, 34 ft.*lbf }

  20. INSTALL REVERSE SHIFT FORK


    1. Install the reverse shift fork.

  21. INSTALL NO. 4 GEAR SHIFT FORK SHAFT

    A0155WO

    1. Using a magnet hand, install the ball to the intermediate plate.

    2. A015B63

      Using a magnet hand, install the ball to the reverse shift head.

    3. A0157CQ

      Install the No. 4 gear shift fork shaft to the reverse gear shift fork and intermediate plate with the bolt.

      Torque:
      34 N*m  { 350 kgf*cm, 25 ft.*lbf }

  22. INSTALL SHIFT FORK SHAFT SNAP RING

    A015C0U

    1. Using a brass bar and hammer, install the 4 snap rings.

  23. INSTALL SHIFT DETENT BALL PLUG

    A015D9F

    1. Install the 4 balls and 4 springs to the intermediate plate.

    2. Apply adhesive to 2 or 3 threads of the 4 detent ball plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a T40 "TORX" socket wrench, install the 4 detent ball plugs.

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

  24. INSTALL MANUAL TRANSMISSION CASE RECEIVER

    A015DDR

    1. Install the transmission case receiver to the intermediate plate with the 3 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  25. INSTALL INTERMEDIATE PLATE STRAIGHT PIN

    A0158YVE02

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

      Standard Protrusion Height
      7.0 to 9.0 mm (0.276 to 0.354 in.)

  26. INSTALL TRANSFER ADAPTER STRAIGHT PIN

    A015CNXE02

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

      Standard Protrusion Height
      4.0 to 6.0 mm (0.158 to 0.236 in.)
    2. A015B1FE02

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

      Standard Protrusion Height
      9.0 to 11.0 mm (0.355 to 0.433 in.)

  27. INSTALL NO. 1 OIL RECEIVER PIPE (MTM)

    A015C3AE01

    1. Install the oil receiver pipe to the transmission case with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  28. INSTALL MANUAL TRANSMISSION CASE SUB-ASSEMBLY

    A015DMFE02

    1. Apply seal packing to the transmission case, as shown in the illustration.

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

      Note

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

    2. A015C3K

      Install the transmission case by lightly tapping it into place with a plastic-faced hammer.

      Note

      Make sure that the oil receiver installed on the transmission side is above the oil application area of the intermediate plate side oil receiver.

    3. A015CDK

      Using a snap ring expander, install the 2 snap rings to the counter gear and input shaft.

  29. INSTALL REVERSE IDLER GEAR SHAFT WOODRUFF KEY

    A01589N

    1. Install the woodruff key to the reverse idler gear shaft.

  30. INSTALL REVERSE IDLER GEAR SHAFT


    1. Install the reverse idler gear shaft to the intermediate plate.

  31. INSTALL REVERSE IDLER THRUST WASHER


    1. Install the thrust washer to the reverse idler gear shaft.

      Note


      • Align the protrusion of the washer with the groove of the intermediate plate during installation.

      • Install the washer so that the dimpled surface of the washer contacts the reverse idler gear thrust surface.

  32. INSTALL REVERSE IDLER GEAR BUSH OR BEARING


    1. Install the bearing to the reverse idler gear shaft.

  33. INSTALL REVERSE IDLER GEAR


    1. Install the reverse idler gear to the reverse idler gear shaft.

  34. INSTALL NO. 2 REVERSE IDLER THRUST WASHER


    1. Install the thrust washer to the reverse idler gear shaft.

      Note

      Install the washer so that the dimpled surface of the washer contacts the reverse idler gear thrust surface.

  35. INSTALL TRANSMISSION MAGNET

    A0157FO

    1. Install the transmission magnet to the intermediate plate.

  36. INSTALL MANUAL TRANSMISSION OIL STRAINER SUB-ASSEMBLY

    A0159EFE01

    1. Install a new O-ring to the oil strainer.

    2. Apply a light coat of gear oil to the O-ring.

    3. Install the oil strainer to the transfer adapter with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  37. INSTALL TRANSFER ADAPTER STRAIGHT PIN AND RING PIN

    A015C25E02

    1. Using a plastic-faced hammer, tap in 4 new straight pins and 2 new ring pins to the transfer adapter.

      Standard Protrusion Height A (Straight Pin)
      4.0 to 6.0 mm (0.157 to 0.236 in.)
      Standard Protrusion Height B (Ring Pin)
      4.0 to 6.0 mm (0.157 to 0.236 in.)

  38. INSTALL TRANSFER ADAPTER SUB-ASSEMBLY

    A0158GYE02

    1. Apply seal packing to the transfer adapter, as shown in the illustration.

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

      Note

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

    2. A0158OZE01

      Install the transfer adapter and bracket to the transmission case with the 11 bolts.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 110 mm (4.33 in.)
      Bolt B 70 mm (2.75 in.)

  39. INSTALL TRANSFER ADAPTER PLUG

    A0157HG

    1. Using a T40 "TORX" socket wrench, install the transfer adapter plug to the transfer adapter.

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

  40. INSTALL SHIFT AND SELECT LEVER SHAFT

    A0157M5E02

    1. Install the shift and select lever, shift lever housing, and shift and select lever shaft to the transmission as shown in the illustration.

    2. Install the 2 bolts to the shift and select lever.

      Torque:
      38 N*m  { 390 kgf*cm, 28 ft.*lbf }

    3. Install the bolt to the shift lever housing.

      Torque:
      38 N*m  { 390 kgf*cm, 28 ft.*lbf }
    4. A0159PR

      Using a 14 mm hexagon wrench, install the interlock hole plug to the transfer adapter.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  41. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    A01558ZE01

    1. Using SST and a press, drive in a new oil seal.

      SST
      09950-60010   ( 09951-00460 )
      09950-70010   ( 09951-07150 )
      Standard Drive in Depth
      15.4 to 16.2 mm (0.607 to 0.637 in.)

    2. Apply gear oil to the lip of the oil seal.

  42. INSTALL FRONT BEARING RETAINER (MTM)

    A0156CZE02

    1. 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

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

    2. Apply adhesive to 2 or 3 threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A0156BM

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

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

  43. INSTALL TRANSMISSION OIL PUMP COVER OIL SEAL

    A0155MDE01

    1. Using SST and a hammer, tap a new oil seal into the oil pump cover in accordance with the dimension specified in the illustration.

      SST
      09950-70010   ( 09951-07150 )
      09950-60010   ( 09951-00640 )

  44. INSTALL TRANSMISSION OIL PUMP COVER

    A015CJO

    1. Apply MP grease to the straight pins.

    2. Install the 2 straight pins.

    3. Install a new O-ring to the oil pump cover.

    4. Align the oil pump drive rotor groove with the straight pin, and install the oil pump cover to the transfer adapter.

    5. Apply adhesive to 2 or 3 threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A015DX9

      Install the oil pump cover to the transfer adapter with the 5 bolts.

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

  45. INSTALL NO. 1 REVERSE RESTRICT PIN

    A015AE4

    1. Install the No. 1 reverse restrict pin and spring to the shift lever retainer.

    2. A01580O

      Using a 5 mm pin punch and hammer, tap a new slotted pin into the shift lever retainer.

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

    A015CH7E02

    1. Apply seal packing to the shift lever retainer, as shown in the illustration.

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

      Note

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

    2. Apply adhesive to 2 or 3 threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A0156NK

      Install the shift lever retainer to the transfer adapter with the 4 bolts.

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

  47. INSTALL REVERSE RESTRICT PIN ASSEMBLY

    A0157EC

    1. Apply adhesive to 2 or 3 threads of the reverse restrict pins.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the 2 reverse restrict pins to the shift lever retainer.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

  48. INSTALL CONTROL SHAFT COVER

    A015DE5E02

    1. Apply seal packing to the control shaft cover, as shown in the illustration.

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

      Note

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

    2. Apply adhesive to 2 or 3 threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A01582X

      Install the control shaft cover to the manual transmission with the 6 bolts.

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

  49. INSTALL SHIFT POSITION SWITCH (for 1VD-FTV)

    A01587LE01

    1. Using SST, install a new gasket and the shift position switch to the transmission.

      SST
      09817-16011
      Torque:
      44 N*m  { 450 kgf*cm, 33 ft.*lbf }

    2. Connect the wire harness clamp.

  50. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    A0156WXE01

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

      SST
      09817-16011
      Torque:
      44 N*m  { 450 kgf*cm, 33 ft.*lbf }

    2. Connect the wire harness clamp.

  51. INSTALL MANUAL TRANSMISSION CASE PLUG

    A0155A0

    1. Using a T55 "TORX" socket wrench, install a new gasket and the manual transmission case plug to the transmission.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

  52. INSTALL DRAIN PLUG

    A0156UO

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

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

  53. TEMPORARILY INSTALL FILLER PLUG

    A0158KM

    1. Temporarily install a new gasket and the filler plug to the manual transmission.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

      Tech Tips

      The filler plug will be tightened to a torque specification in the "Inspect Transmission Oil" procedure.

  54. INSTALL CLUTCH HOUSING

    A0155SUE04

    1. Apply adhesive to 2 or 3 threads of the bolts labeled A only.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the clutch housing with the 10 bolts.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 45 mm (1.77 in.)
      Bolt B 45 mm (1.77 in.)
      Bolt C 35 mm (1.38 in.)

  55. INSTALL TRANSMISSION BREATHER SUB-ASSEMBLY (for 1VD-FTV)

    A0159FO

    1. Connect the breather hose with the clamp.

    2. Install the wire harness clamp.

  56. INSTALL TRANSMISSION BREATHER SUB-ASSEMBLY (for 1GR-FE)

    A0158KD

    1. Connect the breather hose with the clamp.