MANUAL TRANSMISSION UNIT REASSEMBLY


  1. INSTALL OUTPUT SHAFT ASSEMBLY


    1. A00JW22E01

      Install the output shaft to the intermediate plate by pushing on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.

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

      Tech Tips

      Make sure the shaft snap ring is flush with the intermediate plate surface.

  2. INSTALL INPUT SHAFT ASSEMBLY


    1. A00JZHT

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

  3. INSTALL COUNTER GEAR ASSEMBLY


    1. A00JXSNE01

      Coat the input shaft and No. 2 synchronizer ring with gear oil.

    2. Temporarily install the counter gear, input shaft and a new center bearing to the intermediate plate.

      Note

      Install the bearing (with snap ring) to the rear side of the counter gear.

    3. A00JW8JE01

      Using a plastic-faced hammer, install the center bearing to the intermediate plate by tapping the outer race to the counter gear center bearing.

      Tech Tips

      Hold the front side of the counter gear by hand.

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

  4. INSTALL OUTPUT SHAFT REAR BEARING RETAINER


    1. Using a T40 "TORX" socket, install the output shaft rear bearing retainer to the intermediate plate with the 4 screws.

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

  5. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


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

    2. Install the reverse idler gear shaft stopper to the intermediate plate with the bolt.

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

  6. INSTALL REVERSE SHIFT ARM BRACKET


    1. Install the reverse shift arm bracket to the intermediate plate with the 2 bolts.

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

  7. INSTALL 5TH GEAR BEARING INNER RACE LOCK BALL


    1. Install the lock ball.

  8. INSTALL 5TH GEAR THRUST WASHER


    1. Install the 5th gear thrust washer.

  9. INSTALL NO. 3 TRANSMISSION HUB SLEEVE


    1. Coat the counter shaft 5th gear with gear oil.

    2. A00JZ1PE01
      A00JZMB

      Install the counter 5th gear, counter shaft 5th gear bearing, 3 synchromesh shifting keys, 2 synchromesh shifting key springs and No. 3 transmission hub sleeve.

      Text in Illustration
      *1 No. 3 Transmission Hub Sleeve
      *2 No. 3 Synchromesh Shifting Key Spring
      *3 Counter Shaft 5th Gear Bearing
      *4 No. 3 Synchromesh Shifting Key
      *5 Counter Shaft 5th Gear

      Tech Tips

      Be sure to set the No. 3 transmission hub sleeve and 3 synchromesh shifting keys to the counter shaft 5th gear incorrect direction.

      Text in Illustration
      A00JWY4 Front

  10. INSTALL COUNTER SHAFT 5TH GEAR


    1. A00JVO1E01

      Install the counter 5th gear bearing to the 5th gear.

    2. Install the counter shaft 5th gear to the counter gear.

    3. A00K268E01

      Temporarily install the No. 1 synchronizer ring on the No. 5 gear spline piece.

    4. A00JZ3NE01

      Remove the intermediate plate from the vise.

    5. Stand the transmission as shown in the illustration.

    6. A00JZV3E01

      Using a press and 22 mm socket wrench, install the No. 5 gear spline piece with the No. 1 synchronizer ring slots aligned with the shifting keys.

    7. Fix the intermediate plate in a vise between aluminum plates.

    8. A00JU1JE01

      Select a snap ring that will allow minimal axial play.

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Standard Counter Gear Rear Shaft Snap Ring
      Mark Thickness
      A 2.80 to 2.85 mm (0.110 to 0.112 in.)
      B 2.85 to 2.90 mm (0.112 to 0.114 in.)
      C 2.90 to 2.95 mm (0.114 to 0.116 in.)
      D 2.95 to 3.00 mm (0.116 to 0.118 in.)
      E 3.00 to 3.05 mm (0.118 to 0.120 in.)
      F 3.05 to 3.10 mm (0.120 to 0.122 in.)
      G 3.10 to 3.15 mm (0.122 to 0.124 in.)
    9. A00K245E01

      Using a brass bar and hammer, tap the snap ring to the counter gear.

  11. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A00JVGHE01

      Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.30 mm (0.00394 to 0.0118 in.)

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

  12. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    1. A00K0HKE02

      Install the No. 2 gear shift fork and No. 1 gear shift fork.

    2. Pass the No. 2 gear shift fork shaft through the intermediate plate, No. 2 gear shift fork and No. 1 gear shift fork to install it.

    3. A00JX1QE01

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

    4. Install the bolt to the No. 2 gear shift fork.

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

  13. INSTALL NO. 2 SHIFT INTERLOCK PIN


    1. A00K1MBE01

      Coat the No. 2 shift interlock pin with MP grease and install it to the No. 1 gear shift fork shaft.

  14. INSTALL NO. 1 GEAR SHIFT FORK SHAFT


    1. Coat the No. 1 shift interlock pin with MP grease.

    2. A00JVQGE01

      Using a magnet hand, install the No. 1 shift interlock pin to the intermediate plate.

    3. Pass the No. 1 gear shift fork shaft through the intermediate plate and No. 2 gear shift fork to install it.

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    5. A00JUPFE01

      Using pliers, install the shaft snap ring to the No. 1 gear shift fork shaft.

  15. INSTALL REVERSE SHIFT ARM


    1. A00K1A8

      Install the shift arm shoe E-ring and the shift arm shoe to the reverse shift arm.

    2. A00JWIO

      Install the reverse shift arm E-ring and reverse shift fork to the reverse shift arm.

    3. Install the reverse shift arm to the reverse shift arm bracket.

  16. INSTALL NO. 2 SHIFT INTERLOCK PIN


    1. A00JTXVE01

      Coat the No. 2 shift interlock pin with MP grease, and install it to the No. 3 gear shift fork shaft.

  17. INSTALL NO. 3 SHIFT INTERLOCK PIN


    1. A00JYUN

      Coat the No. 3 shift interlock pin with MP grease.

    2. Using a magnet hand, install the No. 3 shift interlock pin to the intermediate plate.

  18. INSTALL NO. 3 GEAR SHIFT FORK SHAFT


    1. Install the No. 3 gear shift fork shaft through the reverse shift fork and intermediate plate.

    2. A00JV0P

      Install the reverse shift head ring to the reverse shift fork shaft.

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

  19. INSTALL NO. 5 GEAR SHIFT FORK SHAFT


    1. A00K00PE03

      Install the No. 5 gear shift fork shaft and reverse shift head.

    2. Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the No. 3 shift fork shaft.

  20. INSTALL NO. 4 GEAR SHIFT FORK SHAFT


    1. A00K17A

      Coat the 2 shift detent balls with MP grease.

    2. Using a magnet hand, install the 2 shift detent balls to the intermediate plate.

    3. A00K1R6

      Pass the No. 4 gear shift fork shaft through the reverse shift fork, intermediate plate and reverse shift head to install it.

    4. Install a new No. 3 gear shift fork with the bolt.

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

  21. INSTALL NO. 2 SHIFT DETENT BALL


    1. A00K02ZE01

      Coat the No. 2 detent ball with MP grease.

    2. Install the No. 2 detent ball and compression spring to the intermediate plate.

    3. Coat the spring seat with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  22. INSTALL SHIFT DETENT BALL


    1. Coat the 3 shift detent balls with MP grease, and then install them and the 3 compression springs to the intermediate plate.

    2. Coat the spring seat and 2 ball plugs with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a T40 "TORX" socket, install the spring seat and 2 ball plugs to the intermediate plate.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  23. INSTALL MANUAL TRANSMISSION CASE


    1. A00JTWSE02
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A00JZJR

      Stand the intermediate plate as shown in the illustration.

    3. Using a plastic-faced hammer, install the transmission case to the intermediate plate as shown in the illustration.

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


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

  25. INSTALL FRONT BEARING SHAFT SNAP RING


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

  26. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    1. A00JZ50E03
      Text in Illustration
      *a Oil Seal Depth

      Using SST, press in a new oil seal to the front bearing retainer.

      SST
      09950-60010   ( 09951-00440, 09952-06010 )
      Standard depth
      12.2 to 13.2 m (0.480 to 0.519 in.)

      Note

      Do not damage the oil seal lip.

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

  27. INSTALL FRONT BEARING RETAINER


    1. Install a new gasket and the front bearing retainer to the transmission case.

    2. Install the 8 bolts.

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

  28. INSTALL TRANSFER ADAPTER OIL SEAL


    1. A00K0JIE01

      Using SST, tap in a new oil seal to the transfer adaptor.

      SST
      09223-00010
      Standard depth
      45 to 46 mm (1.78 to 1.81 in.)

      Note

      Be careful not to damage the lip of the oil seal.

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

  29. INSTALL NO. 1 REVERSE RESTRICT PIN ASSEMBLY


    1. Install the restrict pin to the transfer adaptor.

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

    3. Using a T40 "TORX" socket, install the plug to the transfer adaptor.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  30. INSTALL SHIFT AND SELECT LEVER


    1. A00JZSXE03
      Text in Illustration
      *1 Shift Lever Housing
      *2 Shift and Select Lever

      Install the shift and select lever and shift lever housing to the transfer adaptor.

  31. INSTALL TRANSFER OIL RECEIVER PIPE


    1. Install the oil receiver pipe to the transfer adaptor.

  32. INSTALL TRANSMISSION MAGNET


    1. Install the magnet to the transfer adaptor.

  33. INSTALL TRANSFER ADAPTER


    1. A00JU88E02
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A00K0L6E01

      Install the transfer adaptor to the manual transmission case with the 8 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

      130 mm (5.12 in.) for bolt B

    3. Install the bolt to the shift lever housing.

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

  34. INSTALL SHIFT DETENT BALL


    1. A00K284E02

      Coat the shift detent ball with MP grease, and then install it and the compression spring to the transfer adapter.

    2. Using a T40 "TORX" socket, install the spring seat to the transfer adapter.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

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


    1. Install a new gasket to the transfer adapter.

    2. Install the shift lever retainer with the 4 bolts.

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

  36. INSTALL RESTRICT PIN


    1. Install the 2 restrict pins to the transfer adaptor.

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

  37. INSTALL FRONT TRANSMISSION CASE


    1. A00JZ8DE01

      Install the front transmission case.

    2. Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the 9 bolts.

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

  38. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00JYGGE01

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

      SST
      09817-16011
      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  39. INSTALL CLUTCH RELEASE FORK BOOT


    1. Install the release fork boot to the front transmission case.

  40. INSTALL RELEASE FORK SUPPORT


    1. Install the release fork support to the front transmission case.

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

  41. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A00JZJTE01
    Text in Illustration
    *a 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

  42. 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. A00K167E01
      Text in Illustration
      *a Clutch spline grease

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

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  43. INSTALL DRAIN PLUG SUB-ASSEMBLY


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

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

  44. INSTALL MANUAL TRANSMISSION FILLER PLUG


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

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