MANUAL TRANSMISSION UNIT INSTALLATION


  1. INSTALL OUTPUT SHAFT ASSEMBLY

    A01J30G

    1. 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

    A01J4TUE02

    1. Using a snap ring expander, install the shaft snap ring to the output shaft.

  3. INSTALL INPUT SHAFT ASSEMBLY

    A01J4G7E02

    1. 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 into the No. 2 synchromesh shifting key.

      • Check that the input shaft rotates slightly.

  4. INSTALL COUNTER GEAR

    A01J77UE02

    1. Temporarily install the counter gear to the intermediate plate.

  5. INSTALL COUNTER SHAFT CENTER BEARING

    A01J6OJE01

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

      SST
      09316-60011

      Tech Tips

      Install the bearing while tapping the tip of the counter gear with a plastic-faced hammer so that the counter gear will not hit the side wall of the output shaft gear by being pushed forward.

  6. INSTALL REVERSE IDLER GEAR

    A01J7ONE02

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

      Note

      Face the groove side of the reverse idler shaft to the rear side, and install it from the rear side.

  7. INSTALL REAR BEARING RETAINER

    A01J3UDE02

    1. 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:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  8. INSTALL 5TH GEAR THRUST WASHER PIN

    A01J5HQE02

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

  9. INSTALL 5TH GEAR THRUST WASHER

    A01J7L5E02

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

      Note

      Install the thrust washer so that its chamfer side faces to the front side.

  10. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY SPRING


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

      Note

      Be sure of the direction of the No. 3 transmission hub sleeve and the counter 5th gear.

    2. A01J6UAE02

      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 No. 3 synchromesh shifting key spring, make sure the protrusion fits into the cutout.

    3. A01J4KP

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

  11. INSTALL COUNTER 5TH GEAR BEARING

    A01J5H6E01

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

  12. INSTALL COUNTER 5TH GEAR

    A01J6IKE01

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

  13. INSTALL NO. 3 SYNCHRONIZER RING

    A01J6PFE02

    1. 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 into the No. 3 synchromesh shifting key.

  14. INSTALL NO. 5 GEAR SPLINE PIECE

    A01J755E01

    1. 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 rotate freely.

  15. INSTALL COUNTER GEAR REAR SHAFT SNAP RING


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

      Standard clearance
      0.10 mm (0.0039 in.) or less
      Standard snap ring thickness
      Thickness
      2.80 to 2.85 mm (0.1102 to 0.1122 in.)
      2.85 to 2.90 mm (0.1122 to 0.1141 in.)
      2.90 to 2.95 mm (0.1141 to 0.1160 in.)
      2.95 to 3.00 mm (0.1160 to 0.1181 in.)
      3.00 to 3.05 mm (0.1181 to 0.1200 in.)
      3.05 to 3.10 mm (0.1200 to 0.1220 in.)
      3.10 to 3.15 mm (0.1220 to 0.1240 in.)
    2. A01J5CSE01

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

  16. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE

    A01J7LFE02

    1. Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)

      If the clearance is not as specified, replace the counter shaft 5th gear and No. 3 synchronizer ring.

  17. INSPECT COUNTER 5TH GEAR RADIAL CLEARANCE

    A01J43PE02

    1. Using a dial indicator, check the gear radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.0006 to 0.0027 in.)

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

  18. INSTALL OUTPUT SHAFT REAR BEARING

    A01J6G7E03

    1. 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


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

      Standard clearance
      0.10 mm (0.0039 in.) or less
      Standard snap ring thickness
      Thickness Thickness
      2.65 to 2.70 mm (0.1043 to 0.1063 in.) 3.10 to 3.15 mm (0.1220 to 0.1240 in.)
      2.70 to 2.75 mm (0.1063 to 0.1083 in.) 3.15 to 3.20 mm (0.1240 to 0.1260 in.)
      2.75 to 2.80 mm (0.1083 to 0.1102 in.) 3.20 to 3.25 mm (0.1260 to 0.1280 in.)
      2.80 to 2.85 mm (0.1102 to 0.1122 in.) 3.25 to 3.30 mm (0.1280 to 0.1299 in.)
      2.85 to 2.90 mm (0.1122 to 0.1141 in.) 3.30 to 3.35 mm (0.1299 to 0.1319 in.)
      2.90 to 2.95 mm (0.1141 to 0.1160 in.) 3.35 to 3.40 mm (0.1319 to 0.1339 in.)
      2.95 to 3.00 mm (0.1160 to 0.1181 in.) 3.40 to 3.45 mm (0.1339 to 0.1358 in.)
      3.00 to 3.05 mm (0.1181 to 0.1200 in.) 3.45 to 3.50 mm (0.1358 to 0.1378 in.)
      3.05 to 3.10 mm (0.1200 to 0.1220 in.) -
    2. A01J72QE01

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

  20. INSTALL REVERSE SHIFT ARM BRACKET

    A01J76NE01

    1. Install the arm bracket on the intermediate plate with the 2 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  21. INSTALL REVERSE SHIFT FORK

    A01J378E01

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

    2. A01J4MHE01

      Install the tip of the reverse shift arm to the reverse idler gear. Align the cut end of the reverse shift arm with the reverse shift arm bracket pin, and install them.

  22. INSTALL NO. 4 SHIFT FORK SHAFT

    A01J4DUE01

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

    2. A01J7MSE01

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

    3. Using a screwdriver, install the No. 3 shift fork shaft by pushing the reverse shift fork ball lightly.

    4. A01J3M4E01

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

  23. INSTALL NO. 3 SHIFT FORK SHAFT

    A01J406E02

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

    2. A01J33JE03

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

    3. A01J5XME02

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

    4. A01J3MRE01

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

    5. A01J3UIE02

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

  24. INSTALL NO. 1 SHIFT FORK SHAFT


    1. A01J33JE04

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

    2. A01J4RYE02

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

    3. A01J5ZYE02

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

    4. A01J5M3E02

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

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }
    5. A01J775E01

      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 SHIFT SHAFT

    A01J4QBE02

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

    2. A01J2YKE02

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

    3. A01J70VE02

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

    4. A01J65RE02

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

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }
    5. A01J774E01

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

  26. INSTALL NO. 1 SHIFT DETENT BALL SPRING SEAT

    A01J6GTE02

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

    2. A01J63OE02

      Using a T40 ''torx'' socket wrench, install the 3 spring seats to the intermediate plate.

      Torque:
      18.5 N*m  { 190 kgf*cm, 14 ft.*lbf }
    3. A01J6YME02

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

    4. A01J6WWE02

      Using a T40 ''torx'' socket wrench, install the spring seat to the intermediate plate.

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

  27. INSTALL TRANSMISSION MAGNET

    A01J5QTE02

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

  28. INSTALL MANUAL TRANSMISSION CASE

    A01J5QTE03

    1. 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. A01J5RUE01

      Using a plastic-faced hammer, tap the transmission case to attach it to the intermediate plate.

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

    A01J5NRE02

    1. Using a snap ring expander, install the snap ring to the transmission case.

  30. INSTALL FRONT BEARING SHAFT SNAP RING

    A01J6PME02

    1. Using a snap ring expander, install the snap ring to the transmission case.

  31. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    A01J3B1E03

    1. 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 (0.4409 to 0.4803 in.)

    2. Lightly apply MP grease to the tip of the oil seal.

  32. INSTALL FRONT BEARING RETAINER

    A01J4Q7E01

    1. 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. A01J6TGE02

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

      Torque:
      16.5 N*m  { 170 kgf*cm, 12 ft.*lbf }

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

  33. INSTALL TRANSFER ADAPTER OIL SEAL

    A01J46SE02

    1. 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 (1.787 to 1.827 in.)

    2. Lightly apply MP grease to the tip of the oil seal.

  34. INSTALL REVERSE RESTRICT PIN

    A01J38UE02

    1. Install the restrict pin to the transfer adapter.

    2. A01J7EKE02

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

    3. A01J6JGE02

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

  35. INSTALL OIL RECEIVER PIPE

    A01J5V5E02

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

  36. INSTALL TRANSFER ADAPTER

    A01J71PE01

    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
    2. A01J6TLE01

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

    3. A01J3W0E04

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

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

  37. INSTALL SHIFT AND SELECT LEVER SHAFT

    A01J6ZSE02

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

    2. A01J5P7E02

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

  38. INSTALL TRANSFER CONTROL SHIFT LEVER RETAINER

    A01J5Y3E04

    1. Install the select return spring on the shift lever retainer.

    2. A01J663E04

      Install the shift lever retainer to the transfer adapter with the 4 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  39. INSTALL CONTROL SHIFT LEVER RETAINER

    A01J77LE06

    1. Install the control shift lever retainer and oil deflector.

    2. Install the 4 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  40. INSTALL RESTRICT PIN

    A01J6F3E07

    1. Install the 2 restrict pins.

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

  41. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    A01J54UE05

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

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

  42. INSTALL CLUTCH HOUSING

    A01J356E02

    1. Install the clutch housing to the transmission case with the 9 bolts.

      Torque:
      36 N*m  { 370 kgf*cm, 27 ft.*lbf }

  43. INSTALL CLUTCH RELEASE FORK BOOT

    A01J4UXE02

    1. Install the fork boot to the clutch housing.

  44. INSTALL RELEASE FORK SUPPORT

    A01J6WGE02

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

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

  45. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A01J4SZE01

    1. Apply Multemp 8158 Grease or equivalent to the clutch release bearing, and install it to the clutch release fork.

      Grease
      Multemp 8158 Grease or equivalent

  46. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    A01J4QYE02

    1. Install the clutch release fork.

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

  47. INSTALL DRAIN PLUG

    A01J468E02

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

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

  48. INSTALL FILLER PLUG

    A01J5LYE02

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

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