MANUAL TRANSAXLE UNIT REASSEMBLY


  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A00DTIXE01

      Using SST and a press, press a new front differential case front tapered roller bearing onto the differential case.

      SST
      09316-20011
      09950-60010   ( 09951-00580, 09952-06010 )
      09950-60020   ( 09951-00910 )
      09950-40011   ( 09957-04010 )
      09950-70010   ( 09951-07100 )
    2. A00DUUOE01

      Using SST and a press, press the front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer into the front transaxle case.

      SST
      09950-60010   ( 09952-06010 )
      09950-60020   ( 09951-00780, 09951-00890 )
      09950-70010   ( 09951-07100 )

  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A00DTVEE01

      Using SST and a press, press a new front differential case rear tapered roller bearing onto the differential case.

      SST
      09316-20011
      09950-60010   ( 09951-00580, 09952-06010 )
      09950-60020   ( 09951-00910 )
      09950-40011   ( 09957-04010 )
      09950-70010   ( 09951-07100 )
    2. A00DTK6E01

      Using SST, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer as shown in the illustration.

      SST
      09950-60020   ( 09951-00770, 09951-00890 )

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A00DQMY

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

    2. A00DQU4

      Install the manual transmission case with the 17 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A00DSMTE01

      Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      SST
      09564-50010

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

      SST
      09564-50010
      Standard preload (at starting)
      New bearing
      1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)
      Used bearing
      0.24 to 0.37 N*m (2.44 to 3.77 kgf*cm, 2.12 to 3.27 in.*lbf)

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

      Standard Shim Thickness
      Mark Specified Condition Mark Specified Condition
      A 2.05 mm (0.0807 in.) K 2.50 mm (0.0984 in.)
      B 2.10 mm (0.0827 in.) L 2.55 mm (0.100 in.)
      C 2.15 mm (0.0846 in.) M 2.60 mm (0.102 in.)
      D 2.20 mm (0.0866 in.) N 2.65 mm (0.104 in.)
      E 2.25 mm (0.0886 in.) P 2.70 mm (0.106 in.)
      F 2.30 mm (0.0906 in.) Q 2.75 mm (0.108 in.)
      G 2.35 mm (0.0925 in.) R 2.80 mm (0.110 in.)
      H 2.40 mm (0.0945 in.) S 2.85 mm (0.112 in.)
      J 2.45 mm (0.0965 in.) T 2.90 mm (0.114 in.)

      Tech Tips


      • Select a thicker plate washer to increase the preload, or a thinner plate washer to decrease the preload.

      • Make a memo as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.

    5. Remove the 17 bolts and manual transmission case.

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

    7. Replace the installed front differential case rear plate washer with the one selected above.

  4. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A00DU01

      Install the output shaft cover to the front transaxle case.

      Note

      Insert the output shaft cover key into the case groove.

    2. A00DSL7E01

      Using SST and a press, press the front output shaft bearing (outer race) into the front transaxle case.

      SST
      09950-60010   ( 09951-00620, 09952-06010 )
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

  5. INSTALL REAR OUTPUT SHAFT BEARING


    1. A00DUQ6E01

      Using SST and a press, press the rear output shaft bearing (outer race) together with the rear output shaft bearing shim into the manual transmission case.

      SST
      09950-60010   ( 09951-00490, 09951-00620, 09952-06010 )
      09950-70010   ( 09951-07150 )

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A00DQMY

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

    2. A00DUFH

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

    3. A00DQU4

      Install the manual transmission case with the 17 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A00DSKRE01
      Text in Illustration
      *1 Bearing Shim

      Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      SST
      09564-50010

    5. Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing preload using the following formula.

      SST
      09564-50010
      Formula
      Value A - Differential side bearing preload = Output shaft bearing preload
      Preload (at starting)
      New bearing
      2.80 to 5.60 N*m (29 to 57 kgf*cm, 25 to 50 in.*lbf)
      Used bearing
      2.31 to 4.62 N*m (24 to 47 kgf*cm, 20 to 41 in.*lbf)

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

      Standard Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition
      A 1.30 mm (0.511 in.) P 1.95 mm (0.768 in.)
      B 1.35 mm (0.531 in.) Q 2.00 mm (0.787 in.)
      C 1.40 mm (0.551 in.) R 2.05 mm (0.807 in.)
      D 1.45 mm (0.571 in.) S 2.10 mm (0.827 in.)
      E 1.50 mm (0.591 in.) T 2.15 mm (0.846 in.)
      F 1.55 mm (0.610 in.) U 2.20 mm (0.866 in.)
      G 1.60 mm (0.630 in.) V 2.25 mm (0.886 in.)
      H 1.65 mm (0.650 in.) W 2.30 mm (0.906 in.)
      J 1.70 mm (0.669 in.) X 2.35 mm (0.925 in.)
      K 1.75 mm (0.689 in.) Y 2.40 mm (0.945 in.)
      L 1.80 mm (0.709 in.) Z 2.45 mm (0.965 in.)
      M 1.85 mm (0.728 in.) 1 2.50 mm (0.984 in.)
      N 1.90 mm (0.748 in.) - -

      Tech Tips

      Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

    6. Remove the 17 bolts and manual transmission case.

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

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

    9. Replace the installed rear output shaft bearing shim with the one selected above.

  7. INSTALL OUTER SHIFT LEVER OIL SEAL


    1. A00DT74E01

      Using SST and a hammer, tap in a new outer shift lever oil seal to the manual transmission case.

      SST
      09950-60010   ( 09951-00280 )
      09950-70010   ( 09951-07100 )
      Standard depth
      0.5 to 1.0 mm (0.0197 to 0.0393 in.)

    2. Coat the lip of the outer shaft lever oil seal with MP grease.

  8. INSTALL OUTER NO. 1 SHIFT LEVER


    1. A00DQGZE01

      Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.

    2. Using a 5 mm pin punch and hammer, tap in the inner shift lever slotted spring pin to the inner No. 1 shift lever.

      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  9. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A00DRJJ

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

      Tech Tips

      Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

  10. INSTALL STRAIGHT PIN


    1. A00DRERE01

      Using a plastic-faced hammer, tap in 5 new straight pins to the specified protrusion height.

      Protrusion height
      10.5 to 11.5 mm (0.413 to 0.452 in.)
      Text in Illustration
      *1 10.5 to 11.5 mm

  11. INSTALL BREATHER PLUG


    1. A00DRS6E01

      Using SST and a hammer, tap in the breather plug to the front transaxle case.

      SST
      09350-30020   ( 09350-07110 )

  12. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A00DTQWE01

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

      SST
      09612-22011
      Standard depth
      1.0 to 2.0 mm (0.0393 to 0.0787 in.)

    2. Coat the lip of the front transaxle case oil seal with MP grease.

  13. INSTALL TRANSMISSION MAGNET


    1. A00DU9W

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

  14. INSTALL INPUT SHAFT COVER


    1. A00DQAC

      Install the input shaft cover to the manual transmission case.

      Note

      Insert the input shaft cover key into the manual transmission case groove.

  15. INSTALL REAR INPUT SHAFT BEARING SHIM


    1. Install the rear input shaft bearing shim onto the manual transmission case.

      Note

      Apply grease allowed on shim, (to avoid) falling shim off, from case during assembly.

    2. A00DV0GE01
      Text in Illustration
      *1 Manual Transmission Case
      *2 Input Shaft Assembly
      *3 Front Transaxle Case
      *4 Dimension A
      *5 Dimension C
      *6 Dimension B

      Measure the distance between the end of the manual transmission case and rear input shaft bearing shim (Dimension A).

    3. Measure the distance between the end of the front transaxle case and installation surface of the front input shaft bearing (Dimension B).

    4. Measure the distance between both input shaft bearing outer races (Dimension C).

      Note

      Measure Dimension C with each bearing having no axial clearance.

    5. Calculate the rear input shaft bearing shim clearance using the following formula.

      Formula
      (Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

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

      Standard Rear Input Shaft Bearing Shim Thickness
      Mark Specified Condition Mark Specified Condition
      A 1.15 mm (0.0453 in.) H 1.50 mm (0.0591 in.)
      B 1.20 mm (0.0472 in.) J 1.55 mm (0.0610 in.)
      C 1.25 mm (0.0492 in.) K 1.60 mm (0.0630 in.)
      D 1.30 mm (0.0512 in.) L 1.65 mm (0.0650 in.)
      E 1.35 mm (0.0531 in.) M 1.70 mm (0.0669 in.)
      F 1.40 mm (0.0551 in.) N 1.75 mm (0.0689 in.)
      G 1.45 mm (0.0571 in.) P 1.80 mm (0.0709 in.)

    6. Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the one selected above.

      Note

      Apply grease to the shim to prevent it from falling off the case during assembly.

  16. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A00DQMY

      Coat the differential case tapered roller bearing with gear oil and install it to the front transaxle case.

  17. INSTALL INPUT SHAFT ASSEMBLY


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

    2. A00DSF9E01
      Text in Illustration
      *1 No. 1 Gear Shift Fork Shaft
      *2 Output Shaft

      Coat the No. 1 gear shift fork shaft with gear oil and install it onto the output shaft assembly.

    3. A00DSCUE01
      Text in Illustration
      *1 No. 2 Gear Shift Fork Shaft
      *2 Input Shaft

      Coat the No. 2 gear shift fork shaft with gear oil and install it onto the input shaft assembly.

    4. Temporarily install the output shaft with No. 1 gear shift fork shaft to the input shaft assembly, and tie them with a rope or string.

    5. A00DPY7

      Install the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.

  18. INSTALL OUTER SELECT LEVER OIL SEAL


    1. A00DS6CE01

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

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )
      Standard depth
      0.5 to 1.0 mm (0.0197 to 0.0393 in.)

    2. Coat the lip of the outer select lever oil seal with MP grease.

  19. INSTALL OUTER SELECT LEVER


    1. A00DQEWE01
      Text in Illustration
      *1 Mark

      Install the outer select lever and inner select lever to the front transaxle case.

      Tech Tips

      Install the lever with its mark positioned outside of the front transaxle case.

    2. A00DTOD

      Coat the threads of the inner select lever bolt with adhesive and install it.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  20. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A00DQTR

      Install the shift interlock plate and shift and select lever shaft assembly to the front transaxle case, and then turn them counterclockwise.

      Tech Tips

      When installing the shift interlock plate, make sure to engage it with the inner select lever.

  21. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A00DSGB

      Coat the threads of the 2 bolts with adhesive, and then install the reverse shift arm bracket with the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  22. INSTALL REVERSE SHIFT FORK


    1. A00DQ2P

      Using a pin punch 5 mm and a hammer, install the reverse shift fork slotted pin onto the reverse shift fork shaft.

      Standard depth
      -0.5 to 1.0 mm (-0.0197 to 0.03934 in.)

      Note

      Confirm the installation direction.

  23. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A00DT9D

      Coat the reverse shift fork shaft assembly with gear oil and install it onto the front transaxle case.

  24. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A00DQX1E01
      Text in Illustration
      *1 Case Hole
      *2 I-groove mark of the reverse idler gear shaft

      Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

      Note

      Using the bolt hole of the case for reference, align the I-groove mark of the reverse idler gear shaft within the range shown (approximately 20°).

      Tech Tips

      Raise the edge of the reverse shift arm bracket assembly and connect the reverse shift arm bracket assembly to the reverse shift fork shaft assembly.

  25. INSTALL MANUAL TRANSMISSION CASE


    1. A00DRQX

      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 packing diameter
      1.2 mm (0.0472 in.)

      Note


      • Remove any oil from the contact surfaces.

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

    2. A00DS8N

      Push the outer No. 1 shift lever and install the manual transmission case.

      Tech Tips

      Pushing the outer No. 1 shift lever allows the manual transmission case to be installed.

    3. A00DRO5

      Turn the outer No. 1 shift lever counterclockwise and then pull it.

    4. A00DQU4

      Install the manual transmission case with the 17 bolts.

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

  26. INSTALL OUTER SHIFT LEVER E-RING


    1. A00DRFF

      Install the outer shift lever E-ring to the outer No. 1 shift lever.

  27. INSTALL TRANSMISSION CASE OIL SEAL


    1. A00DTBLE01

      for LH side:


      1. Using SST and a hammer, tap in a new transmission case oil seal to the manual transmission case.

        SST
        09608-32010
        09950-70010   ( 09951-07100 )
        Standard depth
        -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

        Note

        Do not damage the oil seal lip.

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

    2. A00DTBHE01

      for RH side:


      1. Using SST and a hammer, tap in a new transmission case oil seal to the front transaxle case.

        SST
        09710-30050
        09950-70010   ( 09951-07100 )
        Standard depth
        -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

        Note

        Do not damage the oil seal lip.

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

  28. INSTALL SHIFT DETENT BALL


    1. Install the 2 shift detent balls and 2 compression springs to the manual transmission case.

      Note

      Be careful not to drop the ball into the manual transmission case.

    2. A00DUC1

      Coat the threads of the 2 shift detent ball plugs with adhesive and install them using a 6 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    3. A00DR1R

      Install the shift detent ball and compression spring to the manual transmission case.

      Note

      Be careful not to drop the lock ball pin into the manual transmission case.

    4. Coat the threads of the shift detent ball plug with adhesive and install it using a 6 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  29. INSTALL LOCK BALL PIN


    1. Install the lock ball pin and compression spring to the manual transmission case.

      Note

      Be careful not to drop the lock ball pin into the manual transmission case.

    2. A00DQMM

      Coat the threads of the plug with adhesive and install it using a 10 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Install the lock ball pin and compression spring to the manual transmission case.

      Note

      Be careful not to drop the lock ball pin into the manual transmission case.

    4. A00DUV6

      Coat the threads of the plug with adhesive and install it using a 10 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  30. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A00DT80

      Install a new gasket and the reverse idler gear shaft bolt to the manual transmission case.

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

  31. INSTALL RELEASE CYLINDER BLEEDER PLUG


    1. Install the release cylinder bleeder plug to the clutch release bleeder.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  32. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP


    1. Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.

  33. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. A00OMAZ

      Temporarily install the clutch release cylinder to bleeder tube to a new clutch release with bearing cylinder assembly.

    2. Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.

    3. A00OKOL

      Install the clutch release with bearing cylinder assembly with 3 new bolts.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

      Note


      • The clutch release with bearing cylinder and installation bolts cannot be reused and must be replaced with new ones.

      • Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder fits securely with the transaxle during installation. The first bolt should be tightened by hand while holding the clutch release with bearing cylinder.

      • Make sure that none of the clutch spline grease adheres to the clutch release with bearing cylinder.

      • The clutch release with bearing cylinder cannot be disassembled.

    4. A00OM0N

      Install the clutch tube boot to the manual transaxle assembly.

    5. A00OIV5

      Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

    6. Temporarily install the clutch release bleeder sub-assembly with the 2 bolts.

    7. A00ONIM

      Using a union nut wrench, install the clutch release cylinder to bleeder tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    8. A00OLWFE01
      Text in Illustration
      *1 Clutch spline grease

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  34. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A00OIV5

      Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

    2. Install the clutch release bleeder sub-assembly with the 2 bolts.

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

    3. Using a union nut wrench, install the clutch release cylinder to bleeder tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  35. INSTALL CLUTCH RELEASE CYLINDER TO BLEEDER TUBE

    A00ONP7

    1. Using a union nut wrench, install the clutch release bleeder tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  36. INSPECT CLUTCH PIPE LINE

    A00OJUZE01

    1. Using SST, apply a pressure of 100 kPa (1.0 kgf/cm2, 15 psi) to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

      SST
      09992-00242

      If the pressure drops, replace the clutch release cylinder to bleeder tube.

  37. INSTALL CONTROL CABLE BRACKET ASSEMBLY


    1. A00DQZ4

      Install the control cable bracket to the manual transmission case with the 3 bolts.

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

  38. INSTALL NEUTRAL POSITION SWITCH


    1. A00DQTL

      Using a 27 mm deep socket wrench, install a new gasket and the neutral position switch to the manual transmission case.

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

  39. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A00DS90

      Using a 27 mm deep socket wrench, install a new gasket and the back-up light switch to the manual transmission case.

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

  40. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A00DPR7

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

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

  41. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    1. A00DUCU

      Install a new gasket and the manual transmission drain plug to the front transaxle case.

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