MANUAL TRANSAXLE UNIT REASSEMBLY

PROCEDURE

1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

   1. 

      Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the differential case assembly.

      09309-37010

      09506-35010

   2. 

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

      09950-60020

      09951-00680

      09950-70010

      09951-07200

2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

   1. 

      Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the differential case assembly.

      09636-20010

      09726-40010

   2. 

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

      09309-36010

      09950-60020

      09951-00730

      09950-70010

      09951-07100

      Tip:

      Use a front differential case rear plate washer of the same thickness as the removed one.

3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

   1. Remove any remaining seal packing from the contact surfaces of the front transaxle case and manual transmission case.

   2. 

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

   3. 

      Install the manual transmission case to the front transaxle case with the 16 bolts.

      29.4 N*m

      300 kgf*cm

      22 ft.*lbf

   4. 

      *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.

      09564-32011

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

      09564-32011

      Preload (at Starting)

      New Bearing

      1.0 to 1.6 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf)

      Used Bearing

      0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 12 in.*lbf)

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

      Front Differential Case Rear 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 (0.100)
      13	2.175 (0.0856)	29	2.575 (0.101)
      14	2.200 (0.0866)	30	2.600 (0.102)
      15	2.225 (0.0876)	31	2.625 (0.103)
      16	2.250 (0.0886)	32	2.650 (0.104)
      17	2.275 (0.0896)	33	2.675 (0.105)
      18	2.300 (0.0906)	34	2.700 (0.106)
      19	2.325 (0.0915)	35	2.725 (0.107)
      20	2.350 (0.0925)	36	2.750 (0.108)
      21	2.375 (0.0935)	37	2.775 (0.109)
      22	2.400 (0.0945)	38	2.800 (0.110)
      23	2.425 (0.0955)	39	2.825 (0.111)
      24	2.450 (0.0965)	40	2.850 (0.112)
      25	2.475 (0.0974)	-	-

      Tip:

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

      • Make a memo as the torque values will be needed to adjust output shaft bearing preload.

   6. Remove the 16 bolts and manual transmission case from the front transaxle case.

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

4. INSTALL FRONT OUTPUT SHAFT BEARING (OUTER RACE)

   1. 

      *a

      Key

      Install the output shaft cover to the front transaxle case.

      Note:

      Insert the key of the output shaft cover into the front transaxle case groove.

   2. 

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

      09950-60010

      09951-00630

      09950-70010

5. INSTALL REAR OUTPUT SHAFT BEARING (OUTER RACE)

   1. 

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

      09950-60010

      09951-00590

      09950-70010

      09951-07200

      Tip:

      Use a rear output shaft bearing shim of the same thickness as the removed one.

6. ADJUST OUTPUT SHAFT BEARING PRELOAD

   1. Remove any remaining seal packing from the contact surfaces of the front transaxle case and manual transmission case.

   2. 

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

   3. 

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

   4. 

      Install the manual transmission case to the front transaxle case with the 16 bolts.

      29.4 N*m

      300 kgf*cm

      22 ft.*lbf

   5. 

      *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.

      09564-32011

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

      09564-32011

      Formula

      Measured preload - Differential side bearing preload = Output shaft bearing preload

      Bearing	Differential gear ratio	Preload (at starting)
      New bearing	3.944	4.0 to 6.9 N*m (41 to 70 kgf*cm, 35 to 61 in.*lbf)
      Used bearing		2.6 to 4.4 N*m (27 to 45 kgf*cm, 23 to 39 in.*lbf)
      New bearing	3.736	3.8 to 6.5 N*m (39 to 66 kgf*cm, 34 to 58 in.*lbf)
      Used bearing		2.5 to 4.2 N*m (25 to 43 kgf*cm, 22 to 37 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.

      Rear Output Shaft Bearing Shim 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 (0.100)
      61	2.025 (0.0797)	83	2.575 (0.101)
      62	2.050 (0.0807)	84	2.600 (0.102)
      63	2.075 (0.0817)	85	2.625 (0.103)
      64	2.100 (0.0827)	86	2.650 (0.104)
      65	2.125 (0.0837)	87	2.675 (0.105)
      66	2.150 (0.0846)	88	2.700 (0.106)
      67	2.175 (0.0856)	89	2.725 (0.107)
      68	2.200 (0.0866)	90	2.750 (0.108)
      69	2.225 (0.0876)	91	2.775 (0.109)
      70	2.250 (0.0886)	92	2.800 (0.110)
      71	2.275 (0.0896)	-	-

      Tip:

      Select a thicker rear output shaft bearing shim to increase the preload or a thinner rear output shaft bearing shim to decrease the preload.

   7. Remove the 16 bolts and manual transmission case from the front transaxle case.

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

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

7. INSTALL OUTER SHIFT LEVER OIL SEAL

   1. 

      *a

      Depth

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

      09950-60010

      09951-00260

      09950-70010

      09951-07100

      Standard Depth

      0.5 to 1.0 mm (0.0197 to 0.0394 in.)

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

8. INSTALL OUTER NO. 1 SHIFT LEVER

   1. 

      *a	Mark
      *b	Depth

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

      Tip:

      Install the inner No. 1 shift lever with its mark facing the outside of the manual transmission case.

   2. Using a 5 mm pin punch and a hammer, install 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 MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY

   1. 

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

      17 N*m

      173 kgf*cm

      13 ft.*lbf

      Tip:

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

10. INSTALL TRANSMISSION OIL SEPARATOR

    1. 

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

       17 N*m

       173 kgf*cm

       13 ft.*lbf

       Tip:

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

11. INSTALL NO. 1 OIL RECEIVER PIPE

    1. 

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

       Tip:

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

12. INSTALL STRAIGHT PIN

    1. 

       *a	Protrusion Height

       Using a plastic hammer, install 5 new straight pins to the front transaxle case 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. 

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

14. INSTALL BREATHER PLUG

    1. 

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

       09350-30020

       09350-07110

15. INSTALL TRANSMISSION OIL SEPARATOR

    1. 

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

       17 N*m

       173 kgf*cm

       13 ft.*lbf

16. INSTALL FRONT TRANSAXLE CASE OIL SEAL

    1. 

       *a

       Depth

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

       09950-60010

       09951-00350

       09950-70010

       09951-07100

       Standard Depth

       0.9 to 1.9 mm (0.0354 to 0.0748 in.)

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

17. INSTALL TRANSMISSION MAGNET

    1. 

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

18. INSTALL INPUT SHAFT COVER

    1. 

       *a

       Key

       Install the input shaft cover to the manual transmission case.

       Note:

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

19. INSTALL REAR INPUT SHAFT BEARING SHIM

    1. 

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

       Note:

       The rear input shaft bearing shim should be cleaned before assembly.

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

       

       *1	Manual Transmission Case	*2	Input Shaft Assembly
       *3	Front Transaxle Case	-	-
       *a	Dimension (A)	*b	Dimension (B)
       *c	Dimension (C)	-	-

    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 value using the following formula.

       Formula

       (Dimension (A) + Dimension (B)) - Dimension (C) - Rear input shaft bearing shim thickness = 0.02 mm (0.000787 in.) to 0.14 mm (0.00551 in.)

       If the preload 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 preload is within the specification.

       Rear Input Shaft Bearing Shim Thickness

       Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
       08	1.30 (0.0512)	14	1.60 (0.0630)
       09	1.35 (0.0531)	15	1.65 (0.0650)
       10	1.40 (0.0551)	16	1.70 (0.0669)
       11	1.45 (0.0571)	17	1.75 (0.0689)
       12	1.50 (0.0591)	18	1.80 (0.0709)
       13	1.55 (0.0610)	19	1.85 (0.0728)

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

       Note:

       Do not apply MP grease to the oil grooves.

20. INSTALL DIFFERENTIAL CASE ASSEMBLY

    1. 

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

21. INSTALL NO. 3 REVERSE PRE-BALK HEAD

    1. Secure the No. 3 gear shift fork assembly in a vise between aluminum plates.

       Note:

       Do not overtighten the vise.

    2. 

       Install the No. 3 reverse pre-balk head to the No. 3 gear shift fork assembly.

    3. 

       *a

       Depth

       Using a 5 mm pin punch and a hammer, install the slotted spring pin to the No. 3 reverse pre-balk head.

       Standard Depth

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

22. INSTALL NO. 3 GEAR SHIFT HEAD

    1. 

       Install the No. 3 gear shift head to the No. 3 gear shift fork assembly.

    2. 

       *a

       Height

       Using a 5 mm pin punch and a hammer, install the slotted spring pin to the No. 3 gear shift head.

       Standard Height

       1.0 mm (0.0394 in.) or less

23. INSTALL SHIFT LEVER STOPPER

    1. 

       Install the shift lever stopper to the No. 2 gear shift fork assembly as shown in the illustration.

    2. 

       *a

       Depth

       Using a 5 mm pin punch and a hammer, install the slotted spring pin to the shift lever stopper.

       Standard Depth

       -0.1 to 0.9 mm (-0.00394 to 0.0354 in.)

    3. 

       Install the torsion spring to the No. 2 gear shift fork assembly.

24. INSTALL NO. 2 REVERSE PRE-BALK HEAD

    1. 

       *1	Bimetal Formed Bushing
       *a	Depth

       Using SST and a hammer, install 2 new bimetal formed bushings to the No. 2 reverse pre-balk head.

       09950-60010

       09951-00210

       09950-70010

       09951-07100

       Standard Depth

       0 to 1.0 mm (0 to 0.0394 in.)

    2. Secure the No. 2 reverse pre-balk head in a vise between aluminum plates.

       Note:

       Do not overtighten the vise.

    3. 

       *a

       Height

       Using a 3 mm pin punch and a hammer, install the straight pin to the No. 2 reverse pre-balk head.

       Standard Height

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

    4. Secure the No. 2 gear shift fork assembly in a vise between aluminum plates.

       Note:

       Do not overtighten the vise.

    5. Install the No. 2 reverse pre-balk head to the No. 2 gear shift fork assembly as shown in the illustration.

       

       *1	No. 2 Reverse Pre-balk Head	*2	Torsion Spring
       *3	Shift Lever Stopper	*4	Straight Pin
       *a	Turn	*b	Push

    6. 

       Install the spacer to the No. 2 gear shift fork assembly.

    7. 

       *1	Snap Ring
       *a	Protective Tape

       Using a screwdriver with its tip wrapped with protective tape and a hammer, install the snap ring to the No. 2 gear shift fork assembly.

       Tip:

       Use a piece of cloth to keep the snap ring from flying off.

25. INSTALL NO. 2 GEAR SHIFT HEAD

    1. 

       Install the No. 2 gear shift head to the No. 2 gear shift fork assembly.

    2. 

       *a

       Height

       Using a 5 mm pin punch and a hammer, install the slotted spring pin to the No. 2 gear shift head.

       Standard Height

       1.0 mm (0.0394 in.) or less

26. INSTALL NO. 1 GEAR SHIFT HEAD

    1. Secure the No. 1 gear shift fork assembly in a vise between aluminum plates.

       Note:

       Do not overtighten the vise.

    2. 

       Install the No. 1 gear shift head to the No. 1 gear shift fork assembly.

    3. 

       *a

       Height

       Using a 5 mm pin punch and a hammer, install the slotted spring pin to the No. 1 gear shift head.

       Standard Height

       1.0 mm (0.0394 in.) or less

27. INSTALL INPUT SHAFT ASSEMBLY

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

    2. 

       *1	No. 1 Gear Shift Fork Shaft Assembly
       *2	Output Shaft Assembly

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

    3. 

       *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 gear oil and install them to the input shaft assembly.

    4. Temporarily install the output shaft assembly, input shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly, and tie them with a rope or string.

    5. 

       Install the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly to the front transaxle case.

28. INSTALL OUTER SELECT LEVER OIL SEAL

    1. 

       *a

       Depth

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

       09950-60010

       09951-00240

       09950-70010

       09951-07100

       Standard 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.

29. INSTALL OUTER SELECT LEVER

    1. Clean the bolt hole of the outer select lever.

    2. 

       *a

       Mark

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

       Tip:

       Install the inner select lever with its mark facing the outside of the front transaxle case.

30. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    1. 

       *1	Shift and Select Lever Shaft Assembly
       *2	Inner Select Lever
       *3	Shift Inter Lock Plate

       Turn the shift and select lever shaft assembly and shift inter lock plate counterclockwise, and install them to the front transaxle case.

       Tip:

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

    2. Clean the inner select lever set bolt.

    3. 

       *a

       Adhesive

       Apply adhesive to 2 or 3 threads on the end of the inner select lever set bolt.

       Adhesive

       Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

       Note:

       In order to ensure proper installation of the inner select lever set bolt, apply adhesive to the inner select lever set bolt and install it within 10 minutes of adhesive application.

    4. 

       Using a 6 mm hexagon socket wrench, install the inner select lever set bolt.

       28 N*m

       286 kgf*cm

       21 ft.*lbf

31. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. 

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

       17 N*m

       173 kgf*cm

       13 ft.*lbf

32. INSTALL REVERSE SHIFT FORK

    1. Secure the No. 4 gear shift fork shaft in a vise between aluminum plates.

       Note:

       Do not overtighten the vise.

    2. 

       Install the reverse shift fork to the No. 4 gear shift fork shaft.

    3. 

       *a

       Depth

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

       Standard Depth

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

33. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY

    1. 

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

34. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

    1. Clean the reverse idler gear shaft bolt hole.

    2. 

       *a	Parallel
       *b	Reverse Idler Gear Shaft Bolt Hole
       *c	Screw Hole

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

       Note:

       Make sure that the reverse idler gear shaft bolt hole is parallel to the screw hole on the front transaxle case.

       Tip:

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

35. INSTALL MANUAL TRANSMISSION CASE

    1. Remove any remaining seal packing from the contact surfaces of the front transaxle case and manual transmission case.

    2. 

       *a	FIPG (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.

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

    3. 

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

       Tip:

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

    4. 

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

    5. 

       Install the manual transmission case to the front transaxle case with the 16 bolts.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

36. INSTALL OUTER SHIFT LEVER E-RING

    1. 

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

37. INSTALL TRANSMISSION CASE OIL SEAL

    1. 

       *a

       Depth

       Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.

       09316-60011

       09316-00011

       Standard Depth

       10.6 to 11.6 mm (0.417 to 0.457 in.)

       Note:

       Do not damage the transmission case oil seal lip.

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

38. INSTALL TRANSAXLE CASE OIL SEAL

    1. 

       *a

       Depth

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

       09630-24014

       09620-24051

       09950-60010

       09951-00410

       09951-00530

       09952-06010

       09950-70010

       09951-07100

       Standard Depth

       1.2 to 2.2 mm (0.0472 to 0.0866 in.)

       Note:

       Do not damage the transaxle case oil seal lip.

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

39. INSTALL SHIFT DETENT BALL

    1. Clean the shift detent ball plugs and installation holes in the manual transmission case.

    2. 

       *a

       Adhesive

       Apply adhesive to 2 or 3 threads on the ends of the 2 shift detent ball plugs.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

       Note:

       In order to ensure proper installation of the 2 shift detent ball plugs, apply adhesive to the 2 shift detent ball plugs and install them within 10 minutes of adhesive application.

    3. 

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

    4. Using a 6 mm hexagon socket wrench, install the 2 shift detent ball plugs to the manual transmission case.

       22 N*m

       224 kgf*cm

       16 ft.*lbf

       Note:

       Be careful not to drop the shift detent balls into the manual transmission case.

    5. Clean the shift detent ball plug and installation hole in the manual transmission case.

    6. 

       *a

       Adhesive

       Apply adhesive to 2 or 3 threads on the end of the shift detent ball plug.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

       Note:

       In order to ensure proper installation of the shift detent ball plug, apply adhesive to the shift detent ball plug and install it within 10 minutes of adhesive application.

    7. 

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

    8. Using a 6 mm hexagon socket wrench, install the shift detent ball plug to the manual transmission case.

       22 N*m

       224 kgf*cm

       16 ft.*lbf

       Note:

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

40. INSTALL LOCK BALL PIN

    1. Clean the shift and select lever shaft straight screw with head plug and installation holes in the manual transmission case.

    2. 

       *a

       Adhesive

       Apply adhesive to 2 or 3 threads on the end of the shift and select lever shaft straight screw with head plug.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

       Note:

       In order to ensure proper installation of the shift and select lever shaft straight screw with head plug, apply adhesive to the shift and select lever shaft straight screw with head plug and install it within 10 minutes of adhesive application.

    3. 

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

    4. Using a 10 mm hexagon socket wrench, install the shift and select lever shaft straight screw with head plug to the manual transmission case.

       24.5 N*m

       250 kgf*cm

       18 ft.*lbf

41. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    1. Clean the reverse idler gear shaft bolt.

    2. 

       *a

       Adhesive

       Apply adhesive to 2 or 3 threads on the end of the reverse idler gear shaft bolt.

       Adhesive

       Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

       Note:

       In order to ensure proper installation of the reverse idler gear shaft bolt, apply adhesive to the reverse idler gear shaft bolt and install it within 10 minutes of adhesive application.

    3. 

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

       30 N*m

       306 kgf*cm

       22 ft.*lbf

42. INSTALL NO. 1 LOCK BALL ASSEMBLY

    1. Clean the No. 1 lock ball assembly and installation hole in the manual transmission case.

    2. 

       *a

       Adhesive

       Apply adhesive to 2 or 3 threads on the end of the No. 1 lock ball assembly.

       Adhesive

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

       Note:

       In order to ensure proper installation of the No. 1 lock ball assembly, apply adhesive to the No. 1 lock ball assembly and install it within 10 minutes of adhesive application.

    3. 

       Install the No. 1 lock ball assembly to the manual transmission case.

       29.4 N*m

       300 kgf*cm

       22 ft.*lbf

43. INSTALL TRANSMISSION CASE PLUG

    1. 

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

       28 N*m

       286 kgf*cm

       21 ft.*lbf

44. INSTALL NO. 1 CLUTCH HOUSING COVER

    1. 

       Install the No. 1 clutch housing cover to the front transaxle case.

45. INSTALL RELEASE CYLINDER BLEEDER PLUG

    1. Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.

       8.4 N*m

       86 kgf*cm

       74 in.*lbf

46. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP

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

47. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

48. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

49. INSPECT CLUTCH PIPE LINE

    Click here

50. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

51. INSTALL WIRE HARNESS CLAMP BRACKET (w/ Stop And Start System)

    1. 

       Install the wire harness clamp bracket to the manual transmission case with the bolt.

       12.5 N*m

       127 kgf*cm

       9 ft.*lbf

52. INSTALL CONTROL CABLE BRACKET ASSEMBLY

    1. 

       Hook the outer select lever to the reverse restrict pin assembly to secure it.

    2. 

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

       17 N*m

       173 kgf*cm

       13 ft.*lbf

53. INSTALL NEUTRAL POSITION SWITCH (w/ Stop And Start System)

    1. 

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

       40.2 N*m

       410 kgf*cm

       30 ft.*lbf

54. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    1. 

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

       40.2 N*m

       410 kgf*cm

       30 ft.*lbf

55. INSTALL MANUAL TRANSMISSION FILLER PLUG

    1. 

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

       39.2 N*m

       400 kgf*cm

       29 ft.*lbf

       Tip:

       Face the tapered side of the gasket toward the manual transmission case.

56. INSTALL MANUAL TRANSMISSION DRAIN PLUG

    1. 

       Using a 10 mm hexagon socket wrench, install the manual transmission drain plug and a new gasket to the front transaxle case.

       45 N*m

       459 kgf*cm

       33 ft.*lbf

       Tip:

       Face the tapered side of the gasket toward the front transaxle case.