MANUAL TRANSMISSION UNIT (for 1GR-FE) REASSEMBLY


  1. INSTALL NO. 1 RELEASE ARM


    1. Install the shift arm and shift arm pivot to the interlock bracket.

    2. Install a new E-ring to the shift arm pivot.

  2. INSTALL NO. 4 GEAR SHIFT FORK SHAFT

    A00JVR9

    1. Install the compression spring and shift detent ball to the interlock bracket.

    2. Install the No. 4 shift fork shaft.

  3. INSTALL NO. 4 GEAR SHIFT FORK

    A00JXM0

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

    2. Using a 5 mm pin punch and hammer, tap a new slotted pin into the No. 4 shift fork and No. 4 shift fork shaft.

      Standard depth
      0 to 0.5 mm (0 to 0.0196 in.)

  4. INSTALL NO. 1 GEAR SHIFT FORK

    A00K16T

    1. Install the No. 1 shift fork and No. 2 shift head to the No. 4 shift fork shaft.

    2. Using a 5 mm pin punch and hammer, tap a new slotted pin into the No. 2 shift head and No. 4 shift fork shaft.

      Standard depth
      0 to 0.5 mm (0 to 0.0196 in.)

  5. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

    A00JTVO

    1. Install the compression spring and shift detent ball to the interlock bracket.

    2. Install the No. 1 shift fork shaft to the interlock bracket.

  6. INSTALL NO. 1 GEAR SHIFT HEAD

    A00JTY1

    1. Install the No. 1 shift head to the No. 1 shift fork shaft.

    2. Using a 5 mm pin punch and hammer, tap a new slotted pin into the No. 1 shaft head and No. 1 shift fork shaft.

      Standard depth
      0 to 0.5 mm (0 to 0.0196 in.)

  7. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

    A00JUXK

    1. Install the compression spring and shift detent +ball to the interlock bracket.

    2. Install the No. 2 shift fork shaft to the interlock bracket.

  8. INSTALL NO. 2 GEAR SHIFT FORK

    A00K0EX

    1. Install the No. 2 shift fork with a new bolt.

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

  9. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

    A00JZRN

    1. Install the compression spring and shift detent ball to the interlock bracket.

    2. Install the No. 3 shift fork shaft to the interlock bracket.

  10. INSTALL NO. 3 GEAR SHIFT FORK

    A00JWQQ

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

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

  11. INSTALL TRANSMISSION CASE NEEDLE BEARING


    1. A00JZEHE01
      Text in Illustration
      *a Front

      Using SST, install the bearing to the front transmission case.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )

  12. INSTALL TRANSMISSION CASE OIL SEAL

    A00JVNDE05

    1. Using SST and a hammer, tap a new oil seal into the front transmission case so that dimension A in the illustration is as specified.

      SST
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00470 )
      Dimension A
      60.0 to 60.8 mm (2.362 to 2.394 in.)

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

  13. INSTALL FRONT BEARING SHAFT SNAP RING

    A00JY1V

    1. Using snap ring pliers, install the 2 snap rings.

  14. INSTALL NO. 3 OIL RECEIVER PIPE

    A00JUHU

    1. Install the No. 3 oil receiver pipe to the front transmission case.

      Tech Tips

      Align the protrusion of the oil receiver pipe with the cutout of the front transmission case and install the oil receiver pipe to the clutch housing.

  15. INSTALL FRONT TRANSMISSION CASE

    A00K09V

    1. Apply gear oil to all sliding and rotating parts.

    2. Temporarily install the output shaft, input shaft, counter gear shaft and control assembly, and tie them with a piece of rope or string.

    3. A00K1JW

      Using a snap ring expander, expand the 2 snap rings and install the output shaft, input shaft, counter gear shaft and control assembly.

      Tech Tips

      Make sure that the snap ring fits into the grooves of the input shaft and front bearing of the counter gear shaft.

    4. Untie the output shaft, input shaft, counter gear shaft and control assembly.

    5. A00JYJ3

      Using a 27 mm hexagon wrench, install the case plug to the front transmission case.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
    6. A00JUOQ

      Install the interlock bracket with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  16. INSTALL REVERSE IDLER GEAR

    A00JWPNE02
    Text in Illustration
    *a 15°

    1. Install the reverse idler gear, reverse idler gear bearing and reverse idler gear shaft.

      Tech Tips

      Make sure that the reverse idler gear faces the correct direction as shown in the illustration.

      Note

      Make sure that the hole in the reverse idler shaft is in the position shown in the illustration.

  17. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    A00JZ5NE01

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

      SST
      09817-16011
      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  18. INSTALL SHIFT AND SELECT LEVER


    1. Install the spring and lock ball pin to the shift and select lever.

    2. Install the select lever, select cam and interlock plate to the lever shaft.

    3. A00K0QW

      Using a 5 mm pin punch and hammer, tap in the straight pin to the lever shaft.

      Standard depth
      1.0 to 2.0 mm (0.0394 to 0.0787 in.)

    4. Install the bolt to the shift and select lever.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    5. Install a new E-ring to the lever shaft.

  19. INSTALL SHIFT AND SELECT LEVER SHAFT

    A00JYBS

    1. Align the groove of the shift and select cam with the reverse idler shaft and the claw with the groove of the control assembly, and then install the shift and select lever shaft.

  20. INSTALL NO. 2 OIL RECEIVER PIPE


    1. Install the No. 2 oil receiver pipe to the transmission middle case.

  21. INSTALL DRAIN PLUG SUB-ASSEMBLY


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

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

  22. INSTALL TRANSMISSION MIDDLE CASE

    A00JZ23E04

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

      Seal Packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Text in Illustration
      *1 Seal Packing

      Note

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

    2. A00JUO5E01

      Install the transmission middle case to the front transmission case with the 11 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      Bolt length
      Bolt A: 40 mm (1.57 in.)
      Bolt B: 80 mm (3.15 in.)

  23. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. Install a new gasket and the reverse idler gear shaft bolt to the reverse idler gear shaft.

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

  24. INSTALL TRANSMISSION OIL SEPARATOR


    1. Install the transmission oil separator with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  25. INSTALL TRANSFER ADAPTER NEEDLE ROLLER BEARING


    1. A00JWE3E01
      Text in Illustration
      *a Front

      Using SST, install the bearing to the transfer adapter.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07150 )

  26. INSTALL COUNTER GEAR REAR RADIAL BALL BEARING

    A00JUY9E01

    1. Coat a new counter gear rear radial ball bearing with gear oil, and then using SST and a press, install it to the transfer adapter.

      SST
      09950-70010   ( 09951-07360 )
      09950-60010   ( 09951-00650 )
    2. A00K0ZI

      Install the bearing lock plate with the bolt.

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

  27. INSTALL REAR OUTPUT SHAFT BEARING

    A00K15TE01

    1. Using SST and a press, press in 2 new rear output shaft bearings (outer race) to the transfer adapter.

      SST
      09950-70010   ( 09951-07100, 09951-07360 )
      09950-60020   ( 09951-00790 )

  28. INSTALL OIL SEPARATOR PACKING SEAL

    A00JVQP

    1. Install the oil separator packing seal to the transfer adapter.

      Tech Tips

      Insert the protruding part of the oil separator packing seal into the groove of the transfer adapter.

  29. INSTALL NO. 1 OIL RECEIVER PIPE


    1. Install the No. 1 oil receiver pipe to the transfer adapter.

  30. INSTALL TRANSFER ADAPTER CASE PLUG


    1. Using a 14 mm hexagon socket wrench, install the case plug to the transfer adapter.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  31. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. Install 2 new gaskets and the 2 transmission filler plugs to the transfer adapter.

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

  32. INSTALL TRANSFER ADAPTER

    A00K0A4E04
    Text in Illustration
    *1 Seal Packing

    1. Apply seal packing to the transmission rear 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 seal packing (FIPG material) must be removed and reapplied.

    2. Install the transfer adapter and 4 brackets to the transmission case with the 10 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  33. INSTALL SHIFT DETENT BALL PLUG


    1. Install the ball and compression spring to the transfer adapter.

    2. Install a new shift detent ball plug to the transfer adapter.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  34. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. Using a belt and wooden block, securely fasten the transmission to the workbench.

    2. Install a new output shaft spacer and a new rear output shaft bearing.

    3. A00JXYSE01
      Text in Illustration
      *1 Output Shaft Spacer
      *2 Rear Output Shaft Bearing
      *3 Manual Transmission Output Shaft Rear Set Nut

      Temporarily install a new nut by hand.

      Tech Tips

      Fit the spacer and rear output shaft bearing securely.

    4. Move the shift and select lever shaft to N.

    5. Using SST, rotate the output shaft 15 times at a speed of 100 rpm or less in order to settle the bearing.

    6. A00JY03E01

      Using SST and a torque wrench, measure the output shaft preload.*1

      SST
      09326-35010   ( 09326-03010, 09326-03020 )
    7. A00JY44E03
      Text in Illustration
      *1 Input Shaft

      Engage 5th gear, and then secure the input shaft using SST.

      SST
      09322-35010   ( 09322-03010, 09322-03020, 09322-03030, 90105-12087, 90170-12030, 94622-51200 )

      Tech Tips


      • Install SST securely so that (A) is in-line with the input shaft.

      • Make sure that (A) moves back and forth by hand after installing SST.

    8. A00JVSD

      Using SST and a torque wrench, tighten the nut.

      Torque:
      580 N*m  { 5914 kgf*cm, 428 ft.*lbf }

    9. Move the shift and select lever shaft to N.

    10. Using SST, rotate the output shaft 15 times at a speed of 100 rpm or less in order to settle the bearing.

    11. A00JY03E01

      Using SST and a torque wrench, measure the output shaft preload.*2

      SST
      09326-35010   ( 09326-03010, 09326-03020 )

    12. Adjust the preload so that the difference between *1 and *2 is within the specified range.

      Standard Preload (at starting)
      *2 - *1 = 0.45 to 1.05 N*m (4.59 to 10.7 kgf*cm, 3.98 to 9.29 in.*lbf)

      • If the preload is more than the standard, replace the output shaft spacer.

    13. A00JTUW

      Using a chisel and hammer, caulk the rear set nut.

  35. INSTALL MANUAL TRANSMISSION CASE COVER

    A00JU6KE01
    Text in Illustration
    *1 Seal Packing

    1. Apply seal packing to the transmission case 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 seal packing (FIPG material) must be removed and reapplied.

    2. Install the transmission case cover with the 4 bolts.

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

  36. INSTALL SHIFT LEVER HOUSING


    1. Install the shift lever housing with the bolt.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

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

    A00JUUTE01
    Text in Illustration
    *1 Seal Packing

    1. Apply seal packing to the floor shift control 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 seal packing (FIPG material) must be removed and reapplied.

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

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

  38. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


    1. A00JUTYE03
      Text in Illustration
      *1 Release hub grease

      Apply release hub grease to the release fork, release bearing, push rod contact point and pivot points shown in the illustration.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
    2. A00K13YE01
      Text in Illustration
      *1 Clutch spline grease

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

    3. Install the clutch release bearing to the clutch release fork with the clip.

    4. Install the release fork support to the transmission unit.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

    5. Install the clutch release fork with the clutch release bearing to the transmission unit.

      Tech Tips

      After installation, move the fork back and forth to check that the release bearing slides smoothly.