MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A005LBXE01

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

      SST
      09309-37010
      09506-35010
    2. A005LKZE05

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

      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07200 )

  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    1. A005MK2E01

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

      SST
      09636-20010
      09726-40010
    2. A005K3YE05

      Using SST and a press, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer onto the manual transmission case.

      SST
      09309-36010
      09950-60020   ( 09951-00730 )
      09950-70010   ( 09951-07100 )

      Tech Tips

      Use a plate washer of the same thickness as the removed one.

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A005GMH

      Coat the differential case assembly with manual transaxle oil and install it onto the front transaxle case.

    2. A005IRA

      Install the manual transmission case with the 16 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. A005KTYE04
      Text in Illustration
      *1 Front Differential Case Rear Plate Washer

      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
      09564-32011

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

      SST
      09564-32011
      Preload (at starting)
      New bearing
      1.0 to 1.6 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)
      Used bearing
      0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 11 in.*lbf)

      If the preload is out of specification, select a front differential case rear plate washer.

      Plate Washer Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      10 2.100 (0.0827) 11 2.125 (0.0837)
      12 2.150 (0.0846) 13 2.175 (0.0856)
      14 2.200 (0.0866) 15 2.225 (0.0876)
      16 2.250 (0.0886) 17 2.275 (0.0896)
      18 2.300 (0.0906) 19 2.325 (0.0915)
      20 2.350 (0.0925) 21 2.375 (0.0935)
      22 2.400 (0.0945) 23 2.425 (0.0955)
      24 2.450 (0.0965) 25 2.475 (0.0974)
      26 2.500 (0.0984) 27 2.525 (0.0994)
      28 2.550 (0.1004) 29 2.575 (0.1014)
      30 2.600 (0.1024) 31 2.625 (0.1033)
      32 2.650 (0.1043) 33 2.675 (0.1053)
      34 2.700 (0.1063) 35 2.725 (0.1073)
      36 2.750 (0.1083) 37 2.775 (0.1093)
      38 2.800 (0.1102) 39 2.825 (0.1112)
      40 2.850 (0.1122) - -

      Tech Tips


      • Select a thicker front differential case rear plate washer to increase the preload; a thinner front differential case rear plate washer to decrease the preload.

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

    5. Remove the 16 bolts and the manual transmission case.

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

  4. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A005HCY

      Install the output shaft cover onto the front transaxle case.

      Note

      Insert the output shaft cover key into the case groove.

    2. A005II1E01

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

      SST
      09950-60010   ( 09951-00630 )
      09950-70010
      09950-70010

  5. INSTALL REAR OUTPUT SHAFT BEARING


    1. A005H7PE05

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

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07200 )

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD


    1. A005GMH

      Coat the differential case assembly with manual transaxle oil and install it onto the front transaxle case.

    2. A005LEM

      Coat the output shaft assembly with manual transaxle oil and install it onto the front transaxle case.

    3. A005IRA

      Install the manual transmission case with the 16 bolts.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. A005JA1E03
      Text in Illustration
      *1 Rear Output Shaft 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
      09564-32011

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

      SST
      09564-32011
      Formula
      (Differential side bearing preload + Output shaft bearing preload) - Differential side bearing preload = Output shaft bearing preload.
      Preload (at starting)
      New bearing
      3.2 to 6.2 N*m (37 to 63 kgf*cm, 32 to 55 in.*lbf)
      Used bearing
      2.3 to 4.0 N*m (24 to 41 kgf*cm, 20 to 35 in.*lbf)

      If the preload is out of specification, select a rear output shaft bearing shim.

      Plate Washer Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      50 1.750 (0.0689) 51 1.775 (0.0699)
      52 1.800 (0.0709) 53 1.825 (0.0719)
      54 1.850 (0.0728) 55 1.875 (0.0738)
      56 1.900 (0.0748) 57 1.925 (0.0758)
      58 1.950 (0.0768) 59 1.975 (0.0778)
      60 2.000 (0.0787) 61 2.025 (0.0797)
      62 2.050 (0.0807) 63 2.075 (0.0817)
      64 2.100 (0.0827) 65 2.125 (0.0837)
      66 2.150 (0.0846) 67 2.175 (0.0856)
      68 2.200 (0.0866) 69 2.225 (0.0876)
      70 2.250 (0.0886) 71 2.275 (0.0896)
      72 2.300 (0.0906) 73 2.325 (0.0915)
      74 2.350 (0.0925) 75 2.375 (0.0935)
      76 2.400 (0.0945) 77 2.425 (0.0955)
      78 2.450 (0.0965) 79 2.475 (0.0974)
      80 2.500 (0.0984) 81 2.525 (0.0994)
      82 2.550 (0.1004) 83 2.575 (0.1014)
      84 2.600 (0.1024) 85 2.625 (0.1033)
      86 2.650 (0.1043) 87 2.675 (0.1053)
      88 2.700 (0.1063) 89 2.725 (0.1073)
      90 2.750 (0.1083) 91 2.775 (0.1093)
      92 2.800 (0.1102) - -

      Tech Tips

      Select a thicker plate washer to increase the preload; a thinner plate washer to decrease the preload

    6. Remove the 16 bolts and the manual transmission case.

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

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

  7. INSTALL OUTER SHIFT LEVER OIL SEAL


    1. A005I1HE07
      Text in Illustration
      *a Depth

      Using SST and a hammer, install a new outer shaft lever oil seal onto the manual transmission case.

      SST
      09950-60010   ( 09951-00260 )
      09950-70010   ( 09951-07100 )
      Driven in depth
      0.5 to 1.0 mm (0.0197 to 0.0394 in.)

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

  8. INSTALL OUTER NO. 1 SHIFT LEVER


    1. A005LXIE04
      Text in Illustration
      *1 Slotted Spring Pin
      *2 Inner No. 1 Shift Lever
      *3 Outer No. 1 Shift Lever
      *a Depth
      *b Mark

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

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

      Tech Tips

      Install the lever with its mark facing outside of the manual transmission case.

    2. Using a pin punch 5 mm and a hammer, install the inner shift lever slotted spring pin onto the inner No. 1 shift lever.

  9. INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    1. A005LUS

      Install the manual transmission oil separator sub-assembly onto the manual transmission case with the 4 bolts.

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

      Tech Tips

      Make sure that the end tabs of the manual transmission oil separator sub-assembly are inserted in the grooves of the manual transmission case.

  10. INSTALL TRANSMISSION OIL SEPARATOR


    1. A005KV8

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

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

      Tech Tips

      Make sure that the tip of the transmission oil separator is inserted in the groove of the transmission case.

  11. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A005GU5

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

      Tech Tips

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

  12. INSTALL STRAIGHT PIN


    1. A005GRXE03
      Text in Illustration
      *a Protrusion Height

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

      Protrusion height
      8.5 to 9.5 mm (0.335 to 0.374 in.)

  13. INSTALL REVERSE RESTRICT PIN ASSEMBLY


    1. A005MA4

      Install the reverse restrict pin assembly onto the front transaxle case.

  14. INSTALL BREATHER PLUG


    1. A005JNGE03

      Using SST and a hammer, install the breather plug onto the front transaxle case.

      SST
      09350-30020   ( 09350-07110 )

  15. INSTALL TRANSMISSION OIL SEPARATOR


    1. A005JK8

      Install the transmission oil separator onto the front transaxle case with the 4 bolts.

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

  16. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A005KUME08
      Text in Illustration
      *a Depth

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

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )
      Driven in depth
      0.9 to 1.9 mm (0.0354 to 0.0748 in.)

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

  17. INSTALL TRANSMISSION MAGNET


    1. A005GOT

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

  18. INSTALL INPUT SHAFT COVER


    1. A005GS8

      Install the input shaft cover onto the manual transmission case.

      Note

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

  19. INSTALL REAR INPUT SHAFT BEARING SHIM

    A005M80E01
    Text in Illustration
    *1 Manual Transmission Case
    *2 Input Shaft Assembly
    *3 Front Transaxle Case
    *a Dimension A
    *b Dimension B
    *c Dimension C

    1. Rear input shaft bearing shim should be washed before assembly.

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

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

    4. Measure the area 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 value using the following formula.

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

      If the thickness is out of specification, select a rear output shaft bearing shim.

      Rear Input Shaft Bearing Shim Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      8 1.30 (0.0512) 9 1.35 (0.0531)
      10 1.40 (0.0551) 11 1.45 (0.0571)
      12 1.50 (0.0591) 13 1.55 (0.0610)
      14 1.60 (0.0630) 15 1.65 (0.0650)
      16 1.70 (0.0669) 17 1.75 (0.0689)
      18 1.80 (0.0709) 19 1.85 (0.0728)

    6. Coat the rear input shaft bearing shim with MP grease and install it onto the manual transmission case.

      Note

      Do not apply MP grease to the oil grooves.

  20. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. A005GMH

      Coat the differential case tapered roller bearing with manual transaxle oil and install the differential case assembly onto the front transaxle case.

  21. INSTALL INPUT SHAFT ASSEMBLY


    1. Apply manual transaxle oil to all sliding and rotating parts.

    2. A005JBGE06
      Text in Illustration
      *1 No. 1 Gear Shift Fork Shaft Assembly
      *2 Output Shaft Assembly

      Coat the No. 1 gear shift fork shaft assembly with manual transaxle oil and install it.

    3. A005M94E05
      Text in Illustration
      *1 No. 2 Gear Shift Fork Shaft Assembly
      *2 No. 3 Gear Shift Fork Shaft Assembly
      *3 Input Shaft Assembly

      Coat the No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly with manual transaxle oil and install them.

    4. Provisionally install the output shaft, input shaft and 3 gear shift fork shafts, and tie them with a rope or string.

    5. A005JYY

      Install the input shaft assembly, output shaft assembly, and 3 gear shift fork shaft assemblies from the front transaxle case.

  22. INSTALL OUTER SELECT LEVER OIL SEAL


    1. A005I7NE06
      Text in Illustration
      *a Depth

      Using SST and a hammer, install a new outer select lever oil seal onto the front transaxle case.

      SST
      09950-60010   ( 09951-00240 )
      09950-70010   ( 09951-07100 )
      Driven in depth
      0.5 to 1.0 mm (0.0197 to 0.0394 in.)

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

  23. INSTALL OUTER SELECT LEVER


    1. A005H3YE12
      Text in Illustration
      *1 Inner Select Lever
      *2 Outer Select Lever
      *a Position Mark

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

      Tech Tips

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

  24. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A005HU2

      Turn the shift and select lever shaft assembly and inner select lever counterclockwise and install them to the front transaxle case.

      Tech Tips

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

    2. A005KIZ

      Coat the threads of the inner select lever set bolt with sealant and install them using a socket hexagon 6 mm.

      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  25. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A005GX3

      Install the reverse shift arm bracket assembly onto the front transaxle case with the 2 bolts.

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

  26. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A005JCK

      Coat the reverse shift fork shaft assembly with manual transaxle oil and install it.

  27. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A005JYNE04
      Text in Illustration
      *a Parallel

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

      Note

      Make sure that the reverse idler gear shaft bolt installation surface of the reverse idler gear is parallel to the output shaft assembly.

      Tech Tips

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

  28. INSTALL MANUAL TRANSMISSION CASE


    1. A005IOCE08
      Text in Illustration
      *1 FIPG
      *a Seal Diameter 1.2 mm (0.0472 in.)

      Apply FIPG to the manual transmission case as shown in the illustration.

      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      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. A005L34

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

      Tech Tips

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

    3. A005HIK

      Pull the outer No. 1 shift lever counterclockwise and turn the outer No. 1 shift lever.

    4. A005IRA

      Install the 16 bolts onto the manual transmission case.

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

  29. INSTALL OUTER SHIFT LEVER E RING


    1. A005KJR

      Install the outer shift lever E ring onto the outer No. 1 shift lever.

  30. INSTALL TRANSMISSION CASE OIL SEAL

    Click here

  31. INSTALL TRANSAXLE CASE OIL SEAL

    Click here

  32. INSTALL SHIFT DETENT BALL


    1. A005LLN

      Install the 2 shift detent balls and 2 shift detent ball compression springs onto the manual transmission case.

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

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    3. A005JHN

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

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

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

  33. INSTALL LOCK BALL PIN


    1. A005GE6

      Install the lock ball pin and shift and select lever shaft compression spring onto the manual transmission case.

    2. Coat the threads of the shift and select lever shaft straight screw with head with sealant and install them using a socket hexagon 10 mm.

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

      Note

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

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A005LOZ

      Coat the threads of the reverse idler gear shaft bolt with sealant and install it with a new gasket.

      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  35. INSTALL NO. 1 LOCK BALL ASSEMBLY


    1. A005LDP

      Coat the threads of the No. 1 lock ball assembly with sealant and install it onto the manual transmission case using a deep socket wrench 24 mm.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  36. INSTALL TRANSMISSION CASE PLUG


    1. A005IFK

      Install the transmission case plug onto the manual transmission case with a new gasket.

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

  37. INSTALL TRANSMISSION CASE PLUG


    1. A005J17

      Install the transmission case plug onto the manual transmission case with a new gasket.

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

  38. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  39. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  40. INSPECT CLUTCH PIPE LINE

    Click here

  41. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  42. INSTALL NO. 1 CLUTCH HOUSING COVER

    Click here

  43. INSTALL CONTROL CABLE BRACKET ASSEMBLY


    1. A005M1C

      Hook the outer lever to the low fixture lever of the reverse restrict pin to secure it.

    2. A005GVV

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

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

  44. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A005LZB

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

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

  45. INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A005J5T

      Install the manual transmission filler plug onto the manual transmission case with a new gasket.

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

  46. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    1. A005M66

      Using a socket hexagon 10 mm, install the manual transmission drain plug onto the front transaxle case with a new gasket.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }