MULTI-MODE 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 assembly.

      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. A005INDE03
      Text in Illustration
      *1 Front Differential Case 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 15 in.*lbf)
      Used bearing
      0.8 to 1.3 N*m (9 to 14 kgf*cm, 7 to 12 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) 26 2.500 (0.0984)
      11 2.125 (0.0837) 27 2.525 (0.0994)
      12 2.150 (0.0846) 28 2.550 (0.1004)
      13 2.175 (0.0856) 29 2.575 (0.1014)
      14 2.200 (0.0866) 30 2.600 (0.1024)
      15 2.225 (0.0876) 31 2.625 (0.1033)
      16 2.250 (0.0886) 32 2.650 (0.1043)
      17 2.275 (0.0896) 33 2.675 (0.1053)
      18 2.300 (0.0906) 34 2.700 (0.1063)
      19 2.325 (0.0915) 35 2.725 (0.1073)
      20 2.350 (0.0925) 36 2.750 (0.1083)
      21 2.375 (0.0935) 37 2.775 (0.1093)
      22 2.400 (0.0945) 38 2.800 (0.1102)
      23 2.425 (0.0955) 39 2.825 (0.1112)
      24 2.450 (0.0965) 40 2.850 (0.1122)
      25 2.475 (0.0974) - -

      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 Adjust 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. A005J63E02

      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. A005KCJ

      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. A005H78E03
      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
      3.6 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, 21 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) 72 2.300 (0.0906)
      51 1.775 (0.0699) 73 2.325 (0.0915)
      52 1.800 (0.0709) 74 2.350 (0.0925)
      53 1.825 (0.0719) 75 2.375 (0.0935)
      54 1.850 (0.0728) 76 2.400 (0.0945)
      55 1.875 (0.0738) 77 2.425 (0.0955)
      56 1.900 (0.0748) 78 2.450 (0.0965)
      57 1.925 (0.0758) 79 2.475 (0.0974)
      58 1.950 (0.0768) 80 2.500 (0.0984)
      59 1.975 (0.0778) 81 2.525 (0.0994)
      60 2.000 (0.0787) 82 2.550 (0.1004)
      61 2.025 (0.0797) 83 2.575 (0.1014)
      62 2.050 (0.0807) 84 2.600 (0.1024)
      63 2.075 (0.0817) 85 2.625 (0.1033)
      64 2.100 (0.0827) 86 2.650 (0.1043)
      65 2.125 (0.0837) 87 2.675 (0.1053)
      66 2.150 (0.0846) 88 2.700 (0.1063)
      67 2.175 (0.0856) 89 2.725 (0.1073)
      68 2.200 (0.0866) 90 2.750 (0.1083)
      69 2.225 (0.0876) 91 2.775 (0.1093)
      70 2.250 (0.0886) 92 2.800 (0.1102)
      71 2.275 (0.0896) - -

      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 TRANSMISSION CASE GASKET


    1. A005J4ME03
      Text in Illustration
      *a Depth

      Using SST and a hammer, install the new transmission case gasket onto the manual transmission case.

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )
      Drive in depth
      0 to 1.0 mm (0 to 0.0394 in.)

  8. 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.

  9. 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.

  10. INSTALL NO. 1 OIL RECEIVER PIPE


    1. A005HNY

      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.

  11. 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.)

  12. INSTALL BREATHER PLUG


    1. A005I9CE02

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

      SST
      09350-30020   ( 09350-07110 )

  13. 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 }

  14. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A005KUME09
      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.

  15. INSTALL TRANSMISSION MAGNET


    1. A005GOT

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

  16. INSTALL INPUT SHAFT COVER


    1. A005GS8

      Install the output shaft cover onto the manual transmission case.

      Note

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

  17. INSTALL REAR INPUT SHAFT BEARING SHIM

    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. The 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).

      A005M80E02

    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.)
      10 1.40 (0.0551) 17 1.75 (0.0689)
      11 1.45 (0.0571) 18 1.80 (0.0709)
      12 1.50 (0.0591) 19 1.85 (0.0728)
      13 1.55 (0.0610) 20 1.90 (0.0748)
      14 1.60 (0.0630) 21 1.95 (0.0768)
      15 1.65 (0.0650) 22 2.00 (0.0787)
      16 1.70 (0.0669) 23 2.05 (0.0807)

    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.

  18. 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.

  19. INSTALL INPUT SHAFT ASSEMBLY


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

    2. A005IN5E02
      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. A005I0GE02
      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.

  20. INSTALL SHIFT INTER LOCK PLATE


    1. A005HF5

      Install the shift inter lock plate onto the front transaxle case.

  21. INSTALL SHIFT AND SELECT LEVER SHAFT


    1. A005JXH

      Make sure that the shift and select lever shaft is installed as shown in the illustration.

    2. A005L8FE01
      Text in Illustration
      *a Depth

      Using a pin punch (5 mm) and a hammer, install the slotted spring pin and the shift and select lever shaft head onto the shift and select lever shaft.

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

  22. INSTALL INNER SELECT LEVER


    1. A005I26E02
      Text in Illustration
      *a Depth

      Using a pin punch (5 mm) and a hammer, install the slotted spring pin and onto the inner select lever.

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

  23. INSTALL INNER NO. 1 SHIFT LEVER


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

      A005HX1E01
      Text in Illustration
      *a Depth
      *b Plane
      Driven in depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Tech Tips

      The inner No. 1 shaft lever can be installed in either direction.

  24. INSTALL FRONT INNER SHIFT LEVER


    1. A005JGUE02
      Text in Illustration
      *a Depth

      Using a pin punch (5 mm) and a hammer, install the slotted spring pin and onto the front inner shift lever.

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

      Note

      Check the installation direction.

  25. INSTALL INNER NO. 2 SHIFT LEVER


    1. A005K5IE02
      Text in Illustration
      *a Depth

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

      Driven in depth
      0 to 0.6 mm (0 to 0.0236 in.)

      Note

      Check the installation direction.

  26. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    1. A005H6P

      Turn the shift and select lever shaft assembly and the 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.

  27. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    1. A005JO3

      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 }

  28. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY


    1. A005J20

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

  29. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A005JJ1E02
      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.

  30. INSTALL MANUAL TRANSMISSION CASE


    1. A005JGZE02
      Text in Illustration
      *1 Seal Packing

      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. A005IRA

      Install the 16 bolts onto the manual transmission case.

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

  31. INSTALL TRANSMISSION CASE OIL SEAL

    Click here

  32. INSTALL TRANSAXLE CASE OIL SEAL

    Click here

  33. INSTALL SHIFT DETENT BALL


    1. A005MB6

      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 wrench 6 mm.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    3. A005KKG

      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 wrench 6 mm.

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

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A005IGQ

      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 TRANSMISSION CASE PLUG


    1. A005K0D

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

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

  36. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  37. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  38. INSPECT CLUTCH PIPE LINE

    Click here

  39. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  40. INSTALL NO. 1 CLUTCH HOUSING COVER

    Click here

  41. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY


    1. A005IPIE02
      Text in Illustration
      *1 Seal Packing

      Apply FIPG to the shift and select actuator assembly 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. Install the wire harness clamp bracket with the 6 bolts.

      A005H9CE03
      Text in Illustration
      *1 Shift Sensor Shaft *2 Reverse Shift Head
      *3 Select Lever Gear *4 Inner Select Lever
      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note


      • Securely engage the shift sensor shaft in the shift reverse shift head.

      • Securely engage the select lever gear engagement in the inner select lever.

  42. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A005MG9

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

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

  43. INSTALL TRANSMISSION REVOLUTION SENSOR


    1. Install a new O-ring onto the transmission revolution sensor.

    2. A005MIG

      Install the transmission revolution sensor with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  44. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A005LZB

      Using a deep socket wrench 27 mm, install the back-up light switch 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. A005IEM

      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. A005KXV

      Using a socket hexagon wrench 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 }