MANUAL TRANSMISSION UNIT (for 1KD-FTV) REASSEMBLY


  1. INSTALL NO. 1 RELEASE ARM


    1. Install the release 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


    1. A00XDZI

      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

    A00XD0J

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

    2. Using 5 mm a 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

    A00XKCW

    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

    A00XJ3V

    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

    A00XDYK

    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

    A00XIDB

    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

    A00XCLG

    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

    A00XE9X

    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

    A00XHUB

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

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

  11. INSTALL TRANSMISSION CASE NEEDLE BEARING


    1. A00XFF1E01
      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

    A00XG8UE05

    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

    A00XIVX

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

  14. INSTALL NO. 3 OIL RECEIVER PIPE

    A00XHKT

    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 transmission case and install the oil receiver pipe to the front transmission case.

  15. INSTALL FRONT TRANSMISSION CASE

    A00XK7O

    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. A00XGQ5

      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. A00XGFS

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

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
    6. A00XJCK

      Install the interlock bracket with the 4 bolts.

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

  16. INSTALL REVERSE IDLER GEAR

    A00XCWLE02
    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

    A00XCZVE01

    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, 32 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. A00XHCB

      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 a new 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

    A00XK1O

    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

    A00XJROE04

    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. A00XK80E01

      Install the transmission middle case with the 11 bolts.

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

  23. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    A00XIH2

    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

    A00XIPG

    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. A00XH7UE01
      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


    1. A00XEMDE01

      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. A00XKCR

      Install the bearing lock plate with the bolt.

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

  27. INSTALL REAR OUTPUT SHAFT BEARING


    1. A00XCR0E01

      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 TRANSFER ADAPTER CASE PLUG


    1. Install the case plug to the transfer adapter.

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

  29. INSTALL OIL SEPARATOR PACKING SEAL

    A00XDVD

    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.

  30. INSTALL NO. 1 OIL RECEIVER PIPE


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

  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

    A00XK8FE04
    Text in Illustration
    *1 Seal Packing

    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 seal packing (FIPG material) must be removed and reapplied.

    2. Install the transfer adapter and 2 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. A00XGS5E01
      Text in Illustration
      *1 Output Shaft Spacer
      *2 Rear Output Shaft Bearing
      *3 Manual Transmission Output Shaft Rear Set Nut

      Temporarily install a new rear set 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. A00XI2YE01

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

      SST
      09326-35010   ( 09326-03010, 09326-03020 )
    7. A00XD9JE03
      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. A00XD6IE01

      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. A00XI2YE01

      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. A00XCHW

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

  35. INSTALL MANUAL TRANSMISSION CASE COVER

    A00XI5IE01
    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

    A00XFPHE01
    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 SUPPORT BOOT


    1. Install the support boot to the front transmission case.

  39. INSTALL RELEASE FORK SUPPORT


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

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

  40. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A00JY9HE02
    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

  41. 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. A00JXKVE01
      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