MANUAL TRANSAXLE UNIT REASSEMBLY


  1. INSTALL SHIFT FORK SHAFT BEARING


    1. A00E7SAE03

      Using SST and a press, press in 4 new shift fork shaft bearings.

      SST
      09820-00031
      Standard depth
      0 to 0.5 mm (0 to 0.0197 in.)

  2. INSTALL OUTPUT SHAFT COVER


    1. A00E8JIE03
      Text in Illustration
      *1 Protrusion
      *2 Groove

      Install the output shaft cover as shown in the illustration.

  3. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING OUTER RACE


    1. A00E7UDE01

      Using SST and a hammer, tap in the No. 2 output shaft front bearing outer race.

      SST
      09950-70010   ( 09951-07100, 09951-00710 )

  4. INSTALL OUTPUT SHAFT COVER


    1. A00E7CRE03
      Text in Illustration
      *1 Protrusion
      *2 Groove

      Install the output shaft cover as shown in the illustration.

  5. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A00E72FE01

      Coat a new front bearing with gear oil. Then, using SST and a press, install the bearing to the front transaxle case.

      SST
      09223-15020
    2. A00E9UT

      Install the bearing lock plate bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  6. INSTALL TRANSAXLE CASE OIL SEAL


    1. A00EAFBE01

      Using SST and a hammer, install a new oil seal to the front transaxle case.

      SST
      09950-60010   ( 09951-00580 )
      Standard depth
      4.4 to 5.0 mm (0.174 to 0.196 in.)

    2. Coat the lip of the oil seal with MP grease.

  7. INSTALL INPUT SHAFT FRONT BEARING


    1. A00E7FME01

      Coat a new input shaft front bearing with gear oil. Then, using SST and a press, install the bearing to the front transaxle case.

      SST
      09223-00010
    2. A00EA4Y

      Install the bearing lock plate bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  8. INSTALL INPUT AND OUTPUT SHAFT REAR BEARING SHAFT SNAP RING


    1. A00E8EP

      Using snap ring expander, install the 2 snap rings.

  9. INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A00E9OME01

      Using SST and a press, press in a new shift and select lever shaft needle roller bearing.

      SST
      09285-76010
      Clearance
      177.8 to 178.7 mm (7.00 to 7.03 in.)

  10. INSTALL SHIFT FORK SHAFT BEARING


    1. A00E7DJE02

      Using SST and a press, press in 4 new shift fork shaft bearings.

      SST
      09307-12010
      09820-00031
      Clearance A
      168.2 to 169.3 mm (6.63 to 6.66 in.)
      Clearance B
      162.2 to 163.3 mm (6.39 to 6.42 in.)

  11. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A00E7QJE01

      Using SST and a hammer, tap in the front differential case front tapered roller bearing.

      SST
      09950-70010   ( 09951-00910, 09951-07150 )

  12. INSTALL FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING


    1. A00EB38

      Install the front differential case rear shim into the manual transmission case.

    2. A00E7X5E01

      Using SST and a hammer, install the front differential case rear outer race bearing.

      SST
      09950-60010   ( 09951-00910 )
      09950-70010   ( 09951-07100 )

  13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A00E6LT

      Coat the differential case assembly with gear oil and install it to the front transaxle case.

    2. A00EAFR

      Install the manual transmission case to the front transaxle case with the 12 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A00E7YQ

      Install the 6 bolts to the front transaxle case side.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

    4. Turn the differential case in both directions and make sure it turns smoothly.

    5. A00EA4FE07
      Text in Illustration
      *1 Mark

      Using SST and a torque wrench, measure the starting preload.

      SST
      09564-33010
      New bearing preload
      1.00 to 2.49 N*m (10.2 to 25.4 kgf*cm, 8.85 to 22.04 in.*lbf)

      • If the preload is not as specified, replace the shim with one of a different thickness. Use the table below to select a shim which will ensure that the preload is within the specification.

      Standard Shim Thickness
      Mark Specified Condition Mark Specified Condition Mark Specified Condition
      0 1.99 to 2.01 mm (0.0783 to 0.0791 in.) 6 2.29 to 2.31 mm (0.0902 to 0.0909 in.) C 2.59 to 2.61 mm (0.1020 to 0.1027 in.)
      1 2.04 to 2.06 mm (0.0803 to 0.0811 in.) 7 2.34 to 2.36 mm (0.0921 to 0.0929 in.) D 2.64 to 2.66 mm (0.1040 to 0.1047 in.)
      2 2.09 to 2.11 mm (0.0823 to 0.0831 in.) 8 2.39 to 2.41 mm (0.0941 to 0.0949 in.) E 2.69 to 2.71 mm (0.1060 to 0.1066 in.)
      3 2.14 to 2.16 mm (0.0843 to 0.0850 in.) 9 2.44 to 2.46 mm (0.0961 to 0.0969 in.) F 2.74 to 2.76 mm (0.1079 to 0.1086 in.)
      4 2.19 to 2.21 mm (0.0862 to 0.0870 in.) A 2.49 to 2.51 mm (0.0981 to 0.0988 in.) G 2.79 to 2.81 mm (0.1099 to 0.1106 in.)
      5 2.24 to 2.26 mm (0.0882 to 0.0890 in.) B 2.54 to 2.56 mm (0.1000 to 0.1007 in.) H 2.84 to 2.86 mm (0.1119 to 0.1125 in.)

    6. Remove the 18 bolts and manual transmission case.

  14. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING OUTER RACE


    1. A00E9CAE05
      Text in Illustration
      *1 Mark

      Install the output shaft rear bearing shim to the manual transmission case.

      Tech Tips

      When reusing the output shaft rear tapered roller bearing, first install a shim of the same thickness as the original. When installing a new output shaft front bearing, first select and install a shim which is thinner than the original.

    2. A00E7C3E01

      Using SST and a press, press in the No. 2 output shaft rear bearing outer race.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07200 )

  15. ADJUST NO. 2 OUTPUT SHAFT REAR BEARING PRELOAD


    1. A00E6TU

      Install the No. 2 output shaft and differential case to the front transaxle case.

    2. A00EAFR

      Install the manual transmission case to the front transaxle case with the 12 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A00E7YQ

      Install the 6 bolts to the front transaxle case side.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A00EA0GE03

      Using SST and a torque wrench, measure the No. 2 output shaft rear bearing preload. Subtract the value of the differential side bearing preload from the measured No. 2 output shaft rear bearing preload.

      SST
      09564-33010
      New bearing preload
      3.9 to 5.5 N*m (40 to 56 kgf*cm, 35 to 49 in.*lbf)

      If the preload is not as specified, replace the shim with one of a different thickness. Use the table below to select a shim which will ensure that the preload is within the specification.

      Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition Mark Specified Condition
      A 1.79 to 1.81 mm (0.0705 to 0.0713 in.) G 2.09 to 2.11 mm (0.0823 to 0.0831 in.) N 2.39 to 2.41 mm (0.0941 to 0.0949 in.)
      B 1.84 to 1.86 mm (0.0724 to 0.0732 in.) H 2.14 to 2.16 mm (0.0843 to 0.0850 in.) P 2.44 to 2.46 mm (0.0961 to 0.0969 in.)
      C 1.89 to 1.91 mm (0.0744 to 0.0752 in.) J 2.19 to 2.21 mm (0.0862 to 0.0870 in.) Q 2.49 to 2.51 mm (0.0980 to 0.0988 in.)
      D 1.94 to 1.96 mm (0.0764 to 0.0772 in.) K 2.24 to 2.26 mm (0.0882 to 0.0890 in.) R 2.54 to 2.56 mm (0.1000 to 0.1007 in.)
      E 1.99 to 2.01 mm (0.0783 to 0.0791 in.) L 2.29 to 2.31 mm (0.0902 to 0.0909 in.) S 2.59 to 2.61 mm (0.1020 to 0.1027 in.)
      F 2.04 to 2.06 mm (0.0803 to 0.0811 in.) M 2.34 to 2.36 mm (0.0921 to 0.0929 in.) T 2.64 to 2.66 mm (0.1040 to 0.1047 in.)

    5. Remove the 18 bolts and manual transmission case.

    6. Remove the output shaft assembly from the front transaxle case.

    7. Remove the differential case from the front transaxle case.

  16. INSTALL TRANSMISSION MAGNET


    1. A00EAL3

      Clean and install the transmission magnet to the front transaxle case.

  17. INSTALL FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A00E6LT

      Coat the differential case with gear oil, and install it to the front transaxle case.

  18. INSTALL TRANSMISSION OIL SEPARATOR


    1. A00E7ZAE01

      for Front Transaxle Case Side:

      Install the transmission oil separator to the front transaxle case with the 2 bolts.

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

  19. INSTALL INPUT SHAFT, NO. 1 OUTPUT SHAFT AND NO. 2 OUTPUT SHAFT


    1. A00E8RO

      Install the 3 shafts at the same time.

  20. INSTALL REVERSE IDLER GEAR


    1. A00E9H1

      Coat the reverse idler gear, needle roller bearing and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.

      Tech Tips

      Make sure that the protruding part of the reverse idler thrust washer fits into the groove of the reverse idler shaft.

    2. A00E9OZE02

      Install the reverse idler gear shaft by sliding and lifting it.

    3. A00E6PSE03
      Text in Illustration
      *1 Alignment Mark

      Align the mark of the reverse idler gear shaft with the hole of the bolt.

  21. INSTALL REVERSE SHIFT FORK


    1. A00EA8R

      Install the reverse shift fork to the No. 4 hub sleeve.

  22. INSTALL NO. 3 GEAR SHIFT FORK


    1. A00E7UZ

      Install the No. 3 gear shift fork to the No. 3 hub sleeve.

  23. INSTALL 5TH AND 6TH SHIFT FORK SHAFT


    1. A00E8SL

      Install the 5th and 6th shift fork shaft to the front transaxle case.

    2. A00E943

      Install the bolt to the No. 3 gear shift fork.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  24. INSTALL REVERSE SHIFT FORK SHAFT


    1. A00E7M1

      Install the reverse shift fork shaft to the front transaxle case.

    2. A00E86O

      Install the bolt to the reverse gear shift fork.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  25. INSTALL SHIFT ARM


    1. A00E6QO

      Install the shaft arm to the front transaxle case.

  26. INSTALL NO. 1 GEAR SHIFT FORK


    1. A00E8LI

      Install the No. 1 gear shift fork to the No. 1 hub sleeve.

  27. INSTALL NO. 5 GEAR SHIFT FORK SHAFT


    1. A00E7NM

      Install the No. 3 gear shift head to the No. 5 gear shift fork shaft.

    2. Using a 5 mm pin punch and hammer, tap a new pin into the No. 3 gear shift head.

      Standard depth
      -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
    3. A00E96G

      Install the No. 5 gear shift fork shaft to the front transaxle case.

    4. A00E7LA

      Connect the shift arm to the No. 5 gear shift fork shaft.

    5. A00E8Y4

      Install the shift arm pin to the shift arm.

    6. A00E6OV

      Using a brass bar and hammer, tap a new E-ring to the shift arm pin.

  28. INSTALL NO. 2 GEAR SHIFT FORK


    1. A00E7CI

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

  29. INSTALL 3RD AND 4TH SHIFT FORK SHAFT


    1. A00E76D

      Install the No. 3 gear shift head to the 3rd and 4th shift fork shaft.

    2. Install the 3rd and 4th shift fork shaft to the transmission case.

    3. A00E7YU

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

      Standard depth
      -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
    4. A00EAU7

      Using a 5 mm pin punch and hammer, tap the pin into the No. 2 gear shift head.

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

  30. INSTALL 1ST AND 2ND SHIFT FORK SHAFT


    1. A00EAPY

      Install the 1st and 2nd shift fork shaft to the front transaxle case.

    2. A00E8QP

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

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  31. INSTALL TRANSMISSION OIL SEPARATOR


    1. A00EAIG

      for Manual Transmission Case Side:

      Install the transmission oil separator to the manual transmission case with the 2 bolts.

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

  32. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A00EAVW

      Install the No. 1 oil receiver pipe to the manual transmission case.

      Note

      Do not damage the No. 1 oil receiver pipe.

  33. INSTALL MANUAL TRANSMISSION CASE


    1. A00E76V

      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
      Seal diameter
      1.2 mm (0.0472 in.)

      Note

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

    2. A00EAR6

      Using 2 pairs of snap ring pliers to keep the snap ring stretched, install the manual transmission case.

    3. A00E8NZE05
      Text in Illustration
      *1 8.5 mm (0.335 in.)
      *2 9.3 mm (0.366 in.)

      Install a bolt to the No. 1 output shaft and lift the No. 1 output shaft from the service hole. Make sure that the snap rings are positioned correctly in the bearing grooves by checking that the distances between the centers of snap ring holes are as shown in the illustration.

    4. A00EAFR

      Install the manual transmission case to the front transaxle case with the 12 bolts .

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    5. A00E7YQ

      Install the 6 bolts to the front transaxle case.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A00EARV

      Coat the reverse idler gear shaft bolt with adhesive, and install a new gasket and the shaft bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

  35. INSTALL BALL


    1. A00EAL8

      Coat the 4 detent ball plugs with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Using a 6 mm hexagon wrench, install the 4 balls, 4 springs, 4 spring seats and 4 detent ball plugs .

      Torque:
      22 N*m  { 228 kgf*cm, 17 ft.*lbf }

  36. INSTALL MANUAL TRANSMISSION CASE PLUG


    1. A00E7ULE04
      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, Three Bond 1207B or equivalent

    2. Coat the transmission case plug with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the manual transmission case plug to the manual transmission case.

      Torque:
      for case plug*1
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      for case plug*2
      22 N*m  { 228 kgf*cm, 17 ft.*lbf }

  37. INSTALL O-RING


    1. A00E719E01

      Coat a new O-ring with the grease, and install it to the shift and select pin.

  38. INSTALL SHIFT AND SELECT PIN


    1. A00EAAHE03

      Install the spring.

    2. While pressing in the shift and select pin *1 in as far as it will go, push in the shift and select pin *2 to install it.

  39. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A00E90S

      Install a new gasket and the manual transmission filler plug.

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

  40. INSTALL DRAIN PLUG


    1. A00E74K

      Install a new gasket and the drain plug.

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

  41. INSTALL TRANSMISSION CASE OIL SEAL


    1. Coat the lip of a new oil seal with MP grease.

    2. A00EB2XE05

      Using SST and a hammer, install the transmission case oil seal.

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

      Note

      Do not damage the lip of the oil seal.

  42. INSTALL TRANSAXLE CASE OIL SEAL


    1. Coat the lip of a new oil seal with MP grease.

    2. A00EB3VE02

      Using SST and a hammer, install the transaxle case oil seal.

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

      Note

      Do not damage the lip of the oil seal.

  43. INSTALL SHIFT AND SELECT LEVER ASSEMBLY


    1. A00EA1NE01

      Align the 4 shift fork shafts as shown in the illustration.

    2. A00E7AW

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

      Seal packing
      Toyota Genuine Seal Packing, Three Bond 1207B or equivalent

    3. Coat the 4 bolts with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A00E894

      Install the shift and select lever shaft to the manual transmission case with the 4 bolts.

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

  44. INSTALL SHIFT GATE PIN


    1. A00EAZO

      Coat the shift gate pin with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the shift gate pin to the manual transmission case.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  45. INSTALL NO. 2 LOCK BALL ASSEMBLY


    1. A00E77J

      Coat the No. 2 lock ball with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the No. 2 lock ball to the manual transmission case.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  46. INSTALL NO. 1 LOCK BALL ASSEMBLY


    1. A00E9K6

      Coat the No. 1 lock ball with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the No. 1 lock ball onto the manual transmission case.

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

  47. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A00E9N9E01

    1. Using SST, install a new gasket and the park/neutral position switch to the manual transmission case.

      SST
      09816-30010
      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }

  48. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00E90WE02

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

      SST
      09816-30010
      Torque:
      40 N*m  { 410 kgf*cm, 30 ft.*lbf }

  49. INSTALL SELECTING BELLCRANK ASSEMBLY


    1. A00E7IG

      Install the selecting bellcrank to the manual transmission case with the 2 bolts.

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

  50. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET


    1. A00E6ZNE01

      Install the floor shift control lever housing support bracket to the manual transaxle with the 3 bolts.

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

  51. INSTALL RELEASE FORK SUPPORT


    1. A00E9HU

      Install the release fork support to the manual transaxle assembly.

      Torque:
      37 N*m  { 375 kgf*cm, 27 ft.*lbf }

  52. INSTALL CLUTCH RELEASE FORK BOOT


    1. A00E927

      Install the clutch release fork boot to the front transaxle case.

  53. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    A00E87NE01
    Text in Illustration
    *1 Multemp 8158 Grease or equivalent

    1. Apply release hub grease to the release fork where it contacts the release bearing, push rod and release fork support.

      Grease
      Multemp 8158 Grease or equivalent
      Grease
      Toyota Genuine Release Hub Grease or equivalent

    2. Install the release fork to the release bearing with the clip.

  54. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A00E9V4E01

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

      Text in Illustration
      *1 Clutch spline grease
      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
    2. A00E8U7

      Install the clutch release bearing together with the release fork to the manual transaxle assembly.

      Note

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