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MANUAL TRANSAXLE UNIT REASSEMBLY

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  1. Click here

    INSTALL SHIFT FORK SHAFT BEARING


    1. A01IQK5E03

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

      09820-00031
      Standard depth
      0 to 0.5 mm (0 to 0.0197 in.)
  2. Click here

    INSTALL OUTPUT SHAFT COVER


    1. A01IQHIE03

      Install the output shaft cover as shown in the illustration.

      Table 1. Text in Illustration
      *1 Protrusion
      *2 Groove
  3. Click here

    INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING OUTER RACE


    1. A01IQW1E01

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

      09950-70010 09951-07100 09951-00710
  4. Click here

    INSTALL OUTPUT SHAFT COVER


    1. A01ION1E03

      Install the output shaft cover as shown in the illustration.

      Table 2. Text in Illustration
      *1 Protrusion
      *2 Groove
  5. Click here

    INSTALL OUTPUT SHAFT FRONT BEARING


    1. A01IU0KE01

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

      09223-15020
    2. A01IQ23

      Install the bearing lock plate bolt.

      11 N*m 112 kgf*cm 8 ft.*lbf
  6. Click here

    INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A01IN36E01

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

      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. Click here

    INSTALL INPUT SHAFT FRONT BEARING


    1. A01ITVME01

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

      09223-00010
    2. A01IR90

      Install the bearing lock plate bolt.

      11 N*m 112 kgf*cm 8 ft.*lbf
  8. Click here

    INSTALL INPUT AND OUTPUT SHAFT REAR BEARING SHAFT SNAP RING


    1. A01ITLC

      Using snap ring expander, install the 2 snap rings.

  9. Click here

    INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING


    1. A01IRK1E01

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

      09285-76010
      Standard clearance
      177.8 to 178.7 mm (7.00 to 7.03 in.)
  10. Click here

    INSTALL SHIFT FORK SHAFT BEARING


    1. A01IR9ME02

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

      09307-12010
      09820-00031
      Standard clearance A
      168.2 to 169.3 mm (6.63 to 6.66 in.)
      Standard clearance B
      162.2 to 163.3 mm (6.39 to 6.42 in.)
  11. Click here

    INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    1. A01IS3BE01

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

      09950-70010 09951-00910 09951-07150
  12. Click here

    INSTALL FRONT DIFFERENTIAL CASE REAR OUTER RACE BEARING


    1. A01ITK7

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

    2. A01IQ80E01

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

      09950-60010 09951-00910
      09950-70010 09951-07100
  13. Click here

    ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. A01IUIK

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

    2. A01IP8B

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

      29 N*m 300 kgf*cm 22 ft.*lbf
    3. A01IU6U

      Install the 6 bolts to the front transaxle case side.

      29 N*m 300 kgf*cm 22 ft.*lbf

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

    5. A01IPVKE07

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

      Table 3. Text in Illustration
      *1 Mark
      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. Click here

    INSTALL NO. 2 OUTPUT SHAFT REAR BEARING OUTER RACE


    1. A01IP43E05

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

      Table 4. Text in Illustration
      *1 Mark
      Tip:

      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. A01IPKBE01

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

      09950-60010 09951-00650
      09950-70010 09951-07200
  15. Click here

    ADJUST NO. 2 OUTPUT SHAFT REAR BEARING PRELOAD


    1. A01INVD

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

    2. A01IP8B

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

      29 N*m 300 kgf*cm 22 ft.*lbf
    3. A01IU6U

      Install the 6 bolts to the front transaxle case side.

      29 N*m 300 kgf*cm 22 ft.*lbf
    4. A01IPB8E03

      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.

      09564-33010
      New bearing preload
      4.1 to 5.9 N*m (42 to 60 kgf*cm, 36 to 52 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 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. Click here

    INSTALL TRANSMISSION MAGNET


    1. A01IRXL

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

  17. Click here

    INSTALL FRONT DIFFERENTIAL CASE ASSEMBLY


    1. A01IUIK

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

  18. Click here

    INSTALL TRANSMISSION OIL SEPARATOR


    1. A01IR2UE01

      for Front Transaxle Case Side:

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

      8.5 N*m 87 kgf*cm 75 in.*lbf
  19. Click here

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


    1. A01IQSF

      Install the 3 shafts at the same time.

  20. Click here

    INSTALL REVERSE IDLER GEAR


    1. A01IQTM

      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.

      Tip:

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

    2. A01IU61E02

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

    3. A01IPSHE03

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

      Table 5. Text in Illustration
      *1 Alignment Mark
  21. Click here

    INSTALL REVERSE SHIFT FORK


    1. A01ISIZ

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

  22. Click here

    INSTALL NO. 3 GEAR SHIFT FORK


    1. A01IO0Z

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

  23. Click here

    INSTALL 5TH AND 6TH SHIFT FORK SHAFT


    1. A01IP6X

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

    2. A01IPVX

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

      20 N*m 200 kgf*cm 14 ft.*lbf
  24. Click here

    INSTALL REVERSE SHIFT FORK SHAFT


    1. A01IQG1

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

    2. A01IQVZ

      Install the bolt to the reverse gear shift fork.

      20 N*m 200 kgf*cm 14 ft.*lbf
  25. Click here

    INSTALL SHIFT ARM


    1. A01IO2R

      Install the shaft arm to the front transaxle case.

  26. Click here

    INSTALL NO. 1 GEAR SHIFT FORK


    1. A01IOKF

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

  27. Click here

    INSTALL NO. 5 GEAR SHIFT FORK SHAFT


    1. A01IQ92

      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. A01ISI5

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

    4. A01IN84

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

    5. A01IQRF

      Install the shift arm pin to the shift arm.

    6. A01INMX

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

  28. Click here

    INSTALL NO. 2 GEAR SHIFT FORK


    1. A01IUOL

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

  29. Click here

    INSTALL 3RD AND 4TH SHIFT FORK SHAFT


    1. A01IP6M

      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. A01IPBY

      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. A01ITFT

      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. Click here

    INSTALL 1ST AND 2ND SHIFT FORK SHAFT


    1. A01IQIM

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

    2. A01ITVF

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

      20 N*m 200 kgf*cm 14 ft.*lbf
  31. Click here

    INSTALL TRANSMISSION OIL SEPARATOR


    1. A01IU9O

      for Manual Transmission Case Side:

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

      8.5 N*m 87 kgf*cm 75 in.*lbf
  32. Click here

    INSTALL NO. 1 OIL RECEIVER PIPE


    1. A01ISSA

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

      Note:

      Do not damage the No. 1 oil receiver pipe.

  33. Click here

    INSTALL MANUAL TRANSMISSION CASE


    1. A01IPO5

      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. A01ITRG

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

    3. A01INX9E05

      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.

      Table 6. Text in Illustration
      *1 8.5 mm (0.335 in.)
      *2 9.3 mm (0.366 in.)
    4. A01IP8B

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

      29 N*m 300 kgf*cm 22 ft.*lbf
    5. A01IU6U

      Install the 6 bolts to the front transaxle case.

      29 N*m 300 kgf*cm 22 ft.*lbf
  34. Click here

    INSTALL REVERSE IDLER GEAR SHAFT BOLT


    1. A01IO7U

      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
      80 N*m 816 kgf*cm 59 ft.*lbf
  35. Click here

    INSTALL BALL


    1. A01IT2E

      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 .

      22 N*m 228 kgf*cm 17 ft.*lbf
  36. Click here

    INSTALL MANUAL TRANSMISSION CASE PLUG


    1. A01IPSKE04

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

      Seal packing
      Toyota Genuine Seal Packing, Three Bond 1207B or equivalent
      Table 7. Text in Illustration
      *1 Seal Packing

    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.

      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. Click here

    INSTALL O-RING


    1. A01INFYE01

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

  38. Click here

    INSTALL SHIFT AND SELECT PIN


    1. A01IOXPE03

      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. Click here

    INSTALL MANUAL TRANSMISSION FILLER PLUG


    1. A01IOU0

      Install a new gasket and the manual transmission filler plug.

      39 N*m 400 kgf*cm 29 ft.*lbf
  40. Click here

    INSTALL DRAIN PLUG


    1. A01ING6

      Install a new gasket and the drain plug.

      39 N*m 400 kgf*cm 29 ft.*lbf
  41. Click here

    INSTALL TRANSAXLE CASE OIL SEAL LH


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

    2. A01IQ61E01

      Using SST and a hammer, tap in the transaxle case oil seal LH to the manual transaxle case.

      09950-70010 09951-07200
      09608-32010
      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
      Note:

      Do not damage the oil seal lip.

  42. Click here

    INSTALL TRANSAXLE CASE OIL SEAL RH


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

    2. A01ITDSE01

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

      09950-70010 09951-07200
      09649-17010
      Standard depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
      Note:

      Do not damage the oil seal lip.

  43. Click here

    INSTALL SHIFT AND SELECT LEVER ASSEMBLY


    1. A01ITU0E01

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

    2. A01IPPV

      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. A01INE6

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

      19 N*m 190 kgf*cm 14 ft.*lbf
  44. Click here

    INSTALL SHIFT GATE PIN


    1. A01IN8I

      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.

      30 N*m 306 kgf*cm 22 ft.*lbf
  45. Click here

    INSTALL NO. 2 LOCK BALL ASSEMBLY


    1. A01IUA7

      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.

      29 N*m 300 kgf*cm 22 ft.*lbf
  46. Click here

    INSTALL NO. 1 LOCK BALL ASSEMBLY


    1. A01IURB

      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.

      39 N*m 400 kgf*cm 29 ft.*lbf
  47. Click here

    INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    1. A01IQB8E02

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

      09816-30010
      40 N*m 410 kgf*cm 30 ft.*lbf
  48. Click here

    INSTALL SELECTING BELLCRANK ASSEMBLY


    1. A01ITF6

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

      20 N*m 204 kgf*cm 15 ft.*lbf
  49. Click here

    INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET


    1. A01IOP2E01

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

      17 N*m 173 kgf*cm 13 ft.*lbf
  50. Click here

    INSTALL RELEASE FORK SUPPORT


    1. A01IO0U

      w/ Precoated part


      1. Clean the release fork support installation hole.

      2. Install a new release fork support to the manual transaxle assembly.

        37 N*m 375 kgf*cm 27 ft.*lbf

    2. w/o Precoated part


      1. Install the release fork support to the manual transaxle assembly.

        47 N*m 479 kgf*cm 35 ft.*lbf
  51. Click here

    INSTALL CLUTCH RELEASE FORK BOOT


    1. A01ITAN

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

  52. Click here

    INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY


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

      Grease
      Toyota Genuine Release Hub Grease or equivalent
      Table 8. Text in Illustration
      *1 Release hub grease

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

  53. Click here

    INSTALL CLUTCH RELEASE BEARING ASSEMBLY


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

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Table 9. Text in Illustration
      *1 Clutch spline grease
    2. A01IPTIE01

      Apply release hub grease to the inside of the clutch release bearing.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
      Table 10. Text in Illustration
      *1 Release hub grease
    3. A01IONS

      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.