MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT


    1. A00XIO1E01

      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.

  2. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING (for Center Bearing Side)


    1. A00XKC8E02

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

  3. INSTALL INPUT SHAFT


    1. A00XGRGE02

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

      Note


      • Install the No. 2 synchronizer ring so that its groove fits onto the No. 2 synchromesh shifting key.

      • Check that the input shaft rotates smoothly.

  4. INSTALL COUNTER GEAR


    1. A00XF5XE02

      Install the counter gear to the intermediate plate.

  5. INSTALL COUNTER SHAFT CENTER BEARING


    1. A00XEIZE01

      Using SST and a hammer, tap in a new center bearing to the intermediate plate.

      SST
      09316-60011

      Tech Tips

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

  6. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A00XF70E02

      Apply gear oil to the sliding parts of the reverse idler gear and reverse idler gear shaft, and install the reverse idler gear and reverse idler shaft to the intermediate plate.

      Note

      Be sure to install the reverse idler gear shaft from the rear with the groove facing the rear side.

  7. INSTALL OUTPUT SHAFT REAR BEARING RETAINER


    1. A00XDBUE02

      Insert the protrusion of the bearing retainer into the groove of the reverse idler gear shaft. Then install the bearing retainer with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  8. INSTALL 5TH GEAR THRUST WASHER PIN


    1. A00XEMCE02

      Apply MP grease to the washer pin and install it to the counter gear.

  9. INSTALL 5TH GEAR THRUST WASHER


    1. A00XHNHE02

      Apply gear oil to the thrust washer and install it to the counter gear.

      Note

      Install the thrust washer so that its chamfered side faces the front side.

  10. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


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

      Note

      Make sure that the No. 3 transmission hub sleeve and counter 5th gear are facing the proper direction.

    2. A00XDFSE01
      Text in Illustration
      *a Cutout
      *b Protrusion

      Install the 2 No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring to the counter 5th gear as shown in the illustration.

      Tech Tips

      When installing the synchromesh shifting key spring, make sure the protrusion fits into the cutout.

    3. A00XFCJ

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

  11. INSTALL COUNTER 5TH GEAR BEARING


    1. A00XDW6E01

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

  12. INSTALL COUNTER 5TH GEAR


    1. A00XJ1CE01

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

  13. INSTALL OUTER NO. 3 SYNCHRONIZER RING


    1. A00XE0LE02

      Apply gear oil to the No. 3 synchronizer ring and install it to the counter gear.

      Note

      Install the No. 3 synchronizer ring so that its groove fits onto the No. 3 synchromesh shifting key.

  14. INSTALL NO. 5 GEAR SPLINE PIECE


    1. A00XHQHE01

      Using SST and a press, press in the gear spline piece to the counter gear.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Check that the gear rotates freely.

  15. INSTALL COUNTER GEAR REAR SHAFT SNAP RING


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

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Standard Snap Ring
      Mark Thickness
      A 2.80 to 2.85 mm (0.1102 to 0.1122 in.)
      B 2.85 to 2.90 mm (0.1122 to 0.1141 in.)
      C 2.90 to 2.95 mm (0.1141 to 0.1160 in.)
      D 2.95 to 3.00 mm (0.1160 to 0.1181 in.)
      E 3.00 to 3.05 mm (0.1181 to 0.1200 in.)
      F 3.05 to 3.10 mm (0.1200 to 0.1220 in.)
      G 3.10 to 3.15 mm (0.1220 to 0.1240 in.)

    2. Secure the intermediate plate in a vise between aluminum plates.

    3. A00XF04E01

      Using a brass bar and hammer, tap on the snap ring.

  16. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE


    1. A00XJXCE01

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00393 to 0.0137 in.)

      • If the clearance is not as specified, replace the counter 5th gear.

  17. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE


    1. A00XIUVE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000590 to 0.00267 in.)

      • If the clearance is not as specified, replace the counter 5th gear bearing with a new one.

  18. INSTALL OUTPUT SHAFT REAR BEARING


    1. A00XGS0E01

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

      SST
      09309-35010

  19. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING (for Rear Bearing Side)


    1. Select a shaft snap ring so that the thrust clearance between the output shaft bearing shaft and snap ring to be within the specification.

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Standard Snap Ring
      Mark Thickness Mark Thickness
      A 2.65 to 2.70 mm (0.1043 to 0.1063 in.) K 3.10 to 3.15 mm (0.1220 to 0.1240 in.)
      B 2.70 to 2.75 mm (0.1063 to 0.1083 in.) L 3.15 to 3.20 mm (0.1240 to 0.1260 in.)
      C 2.75 to 2.80 mm (0.1083 to 0.1102 in.) M 3.20 to 3.25 mm (0.1260 to 0.1280 in.)
      D 2.80 to 2.85 mm (0.1102 to 0.1122 in.) N 3.25 to 3.30 mm (0.1280 to 0.1299 in.)
      E 2.85 to 2.90 mm (0.1122 to 0.1141 in.) P 3.30 to 3.35 mm (0.1299 to 0.1319 in.)
      F 2.90 to 2.95 mm (0.1141 to 0.1160 in.) Q 3.35 to 3.40 mm (0.1319 to 0.1339 in.)
      G 2.95 to 3.00 mm (0.1160 to 0.1181 in.) R 3.40 to 3.45 mm (0.1339 to 0.1358 in.)
      H 3.00 to 3.05 mm (0.1181 to 0.1200 in.) S 3.45 to 3.50 mm (0.1358 to 0.1378 in.)
      J 3.05 to 3.10 mm (0.1200 to 0.1220 in.) - -
    2. A00XHF5E01

      Using a brass bar and hammer, tap on the snap ring.

  20. INSTALL REVERSE SHIFT ARM BRACKET


    1. A00XE62E01

      Install the arm bracket to the intermediate plate with the 2 bolts.

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

  21. INSTALL REVERSE SHIFT FORK


    1. A00XE5GE01

      Install the shift arm to the shift fork. Using a screwdriver and hammer, tap on a new E-ring.

    2. A00XFVLE01

      Install the reverse shift fork with the reverse shift arm to the intermediate plate.

  22. INSTALL NO. 4 GEAR SHIFT FORK SHAFT


    1. A00XFCOE01

      Install the compression spring and reverse shift fork ball to the reverse shift fork.

    2. A00XDC3E01

      Apply gear oil to the sliding part of the No. 4 shift fork shaft.

    3. While pushing the reverse shift fork ball lightly with a screwdriver, install the No. 4 shift fork shaft.

    4. A00XHY3E01

      Using a brass bar and hammer, tap on the snap ring to the No. 4 shift fork shaft.

  23. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. A00XG9BE02

      Install the reverse shift fork ball to the reverse shift fork.

    2. A00XF8VE03

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

    3. A00XFCLE02

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

    4. A00XHH6E01

      Using a brass bar and hammer, tap on the snap ring to the shift fork shaft.

    5. A00XFFGE02

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

  24. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. A00XF8VE04

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

    2. A00XGRPE02

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

    3. A00XG2DE02

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

    4. A00XE2RE02

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

    5. Using a brass bar and hammer, tap in the shift fork shaft snap ring to the No. 1 shift fork shaft.

  25. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A00XIHWE02

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

    2. A00XIHME02

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

    3. A00XKBOE02

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

    4. A00XDF5E01

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

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    5. A00XJ5SE01

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

  26. INSTALL NO. 1 SHIFT DETENT BALL SPRING SEAT


    1. A00XHZFE02

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

    2. Apply adhesive to 2 or 3 threads of the 2 spring seats.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A00XDG1E02

      Using a T40 "TORX" socket wrench, install the 2 spring seats to the intermediate plate.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
    4. A00XH8JE02

      Install the detent ball and low side compression spring to the intermediate plate.

    5. Apply adhesive to 2 or 3 threads of the spring seat.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    6. A00XFANE02

      Using a T40 "TORX" socket wrench, install the spring seat to the intermediate plate.

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

  27. INSTALL TRANSMISSION MAGNET


    1. A00XIWXE02

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

  28. INSTALL MANUAL TRANSMISSION CASE


    1. A00XEFWE11
      Text in Illustration
      *1 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. A00XCYLE01

      Place the transmission case on wooden blocks.

    3. Using a plastic-faced hammer, tap the intermediate plate to install the transmission case.

  29. INSTALL NO. 1 COUNTER GEAR FRONT BEARING SNAP RING


    1. A00XDYCE02

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

  30. INSTALL FRONT BEARING SHAFT SNAP RING


    1. A00XI9VE02

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

  31. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A00XGYHE01

      Using SST and a hammer, tap in a new oil seal to the front bearing retainer.

      SST
      09950-60010   ( 09951-00300, 09951-00520, 09952-06010 )
      09950-70010   ( 09951-07100 )
      Standard oil seal depth
      11.20 to 12.20 mm (0.441 to 0.480 in.)

    2. Apply a light coat of MP grease to the lip of the oil seal.

  32. INSTALL FRONT BEARING RETAINER


    1. A00XEOWE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the bearing retainer as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A00XGJ8E02

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

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

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

  33. INSTALL TRANSFER ADAPTER OIL SEAL


    1. A00XDZKE02

      Using SST and a hammer, tap in a new oil seal to the transfer adapter.

      SST
      09710-30050
      09950-70010   ( 09951-07100 )
      Standard oil seal depth
      45.4 to 46.4 mm (1.79 to 1.82 in.)

    2. Apply a light coat of MP grease to the lip of the oil seal.

  34. INSTALL REVERSE RESTRICT PIN ASSEMBLY


    1. A00XG7GE02

      Install the restrict pin to the transfer adapter.

    2. A00XJKEE02

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

    3. A00XIV0E02

      Using a T40 "TORX" socket wrench, install the reverse restrict pin plug to the transfer adapter.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

  35. INSTALL TRANSFER OIL RECEIVER PIPE


    1. A00XHATE02

      Install the oil receiver pipe to the transfer adapter.

  36. INSTALL TRANSFER ADAPTER


    1. A00XEFWE12
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A00XH6WE01

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

    3. A00XGI4E05

      Install the transfer adapter to the manual transmission case with the 10 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      80 mm (3.15 in.) for bolt A

      92 mm (3.62 in.) for bolt B

      130 mm (5.12 in.) for bolt C

  37. INSTALL SHIFT AND SELECT LEVER


    1. Install the shift and select lever with the shift lever housing to the transfer adapter.

    2. Install the bolt to the shift lever housing.

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

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


    1. A00XEOJ

      Install the control shift lever retainer and a new gasket with the 4 bolts.

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

  39. INSTALL RESTRICT PIN


    1. Install the 2 restrict pins.

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

  40. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


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

      SST
      09817-16011
      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  41. INSTALL CLUTCH HOUSING

    A00XIP3E01

    1. Temporarily install the clutch housing with the 7 bolts labeled A.

    2. Apply adhesive to the 2 bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Temporarily install the 2 bolts labeled B.

    4. Tighten the 9 bolts.

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

  42. INSTALL RELEASE FORK SUPPORT


    1. Install the release fork support to the manual transmission unit.

      Torque:
      47 N*m  { 479 kgf*cm, 34 ft.*lbf }

  43. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A00JZJTE02
    Text in Illustration
    *1 Release hub grease

    1. Apply release hub grease to the clutch release bearing, and then install it to the clutch release fork with the clip.

      Grease
      Toyota Genuine Release Hub Grease or equivalent

  44. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. Install the clutch release fork.

      Note

      After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

    2. A00JX6QE01
      Text in Illustration
      *1 Clutch spline grease

      Apply clutch spline grease to the spline of the input shaft.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  45. INSTALL CLUTCH RELEASE FORK BOOT


    1. Install the release fork boot to the clutch housing.

  46. INSTALL DRAIN PLUG


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

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

  47. INSTALL MANUAL TRANSMISSION FILLER PLUG


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

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