MANUAL TRANSMISSION UNIT INSTALLATION


  1. INSTALL OUTPUT SHAFT ASSEMBLY

    A01E05FE01

    1. Install the output shaft into the intermediate plate by pushing on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.

    2. A01E2POE01

      Using a snap ring expander, install the snap ring to the enter bearing.

      Tech Tips

      Be sure the shaft snap ring is flush with the intermediate plate surface.

  2. INSTALL COUNTER GEAR ASSEMBLY

    A01E2XTE01

    1. Coat the input shaft and the No. 2 synchronizer ring with gear oil.

    2. Temporarily install the counter gear, input shaft and a new center bearing to the intermediate plate.

      Note

      Install the bearing (with snap ring) to the counter gear's rear side.

    3. A01E0CFE01

      Using a plastic-faced hammer, install the center bearing to the intermediate plate by tapping the outer race to the counter gear center bearing.

      Tech Tips

      Hold the front side of the counter gear by hand.

    4. A01E2FIE01

      Using a snap ring expander, install the snap ring to the counter shaft center bearing.

  3. INSTALL OUTPUT SHAFT REAR BEARING RETAINER

    A01E0ITE01

    1. Using a T40 "torx" socket wrench, install the rear bearing retainer to the intermediate palate with the 4 screws.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  4. INSTALL REVERSE IDLER GEAR

    A01E0C7E01

    1. Install the idler gear shaft and idler gear to the intermediate plate.

    2. A01DXODE01

      Install the idler gear shaft stopper to the intermediate plate with the colt.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  5. INSTALL REVERSE SHIFT ARM

    A01DWMFE01

    1. Install a new E-ring and the shift fork to the shift arm.

  6. INSTALL REVERSE SHIFT ARM BRACKET

    A01E09YE01

    1. Install the arm bracket with the shift arm to the intermediate plate.

    2. Install the 2 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  7. INSTALL 5TH GEAR THRUST WASHER LOCK BALL

    A01E07LE01

    1. Install the lock ball.

  8. INSTALL 5TH GEAR THRUST WASHER

    A01E15ME01

  9. INSTALL COUNTER SHAFT 5TH GEAR ASSEMBLY

    A01E2QEE01

    1. Install the 5th gear to the counter gear.

    2. A01DW73E01

      Temporarily install the No. 3 synchronizer ring on the No. 5 gear spline piece.

    3. A01E2DZE01

      Dismount the intermediate plate from the vise.

    4. Stand the transmission as shown in the illustration.

    5. A01DW77E01

      Using a press and 22 mm socket wrench, press in the No. 5 gear spline piece with the No. 3 synchronizer ring slots aligned with the shifting keys.

    6. Mount the intermediate plate to the vise.

    7. A01E1CEE01

      Select a snap ring that will allow minimal axial play.

      Standard clearance
      0.10 mm (0.0039 in.) or less
      Counter gear rear shaft snap ring thickness
      Mark Thickness
      A 2.80 to 2.85 mm (0.110 to 0.112 in.)
      B 2.85 to 2.90 mm (0.112 to 0.114 in.)
      C 2.90 to 2.95 mm (0.114 to 0.116 in.)
      D 2.95 to 3.00 mm (0.116 to 0.118 in.)
      E 3.00 to 3.05 mm (0.118 to 0.120 in.)
      F 3.05 to 3.10 mm (0.120 to 0.122 in.)
      G 3.10 to 3.15 mm (0.122 to 0.124 in.)
    8. A01DX3WE01

      Using a brass bar and hammer, tap in the snap ring to the counter gear.

  10. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE

    A01E16HE01

    1. Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.100 to 0.300 mm (0.0039 to 0.0117 in.)
      Maximum clearance
      0.300 mm (0.0117 in.)

  11. INSTALL NO. 2 SHIFT FORK SHAFT

    A01E2FRE01

    1. Install the No. 2 shift fork shaft through the No. 2 gear shift fork, No. 1 gear shift fork and intermediate plate.

    2. A01DWI6E01

      Using a brass bar and hammer, tap in the shaft snap ring to the No. 2 shift fork shaft.

    3. A01DYN5E01

      Install the bolt to the No. 2 gear shift fork.

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }

  12. INSTALL NO. 2 SHIFT INTERLOCK PIN

    A01E0IPE01

    1. Coat the No. 2 shift interlock pin with MP grease, and install it into the No. 1 gear shift fork shaft.

  13. INSTALL NO. 1 SHIFT FORK SHAFT

    A01DXP0E01

    1. Coat the No. 1 interlock pin with MP grease.

    2. Using a magnetic finger, install the No. 1 interlock pin to the intermediate plate.

    3. Install the No. 1 gear shift fork shaft through the No. 2 gear shift fork and intermediate plate.

    4. A01DYLUE01

      Install the bolt to the No. 1 shift fork.

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }
    5. A01E0BWE01

      Using pliers, install the snap ring to the No. 1 gear shift fork shaft.

  14. INSTALL NO. 3 HEAD GEAR SHIFT

    A01E0EEE01

    1. Install the No. 3 head gear shift to the No. 3 shift fork shaft.

    2. Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the No. 3 shift fork shaft.

  15. INSTALL NO. 2 SHIFT INTERLOCK PIN

    A01DWNRE01

    1. Coat the No. 2 interlock pin with MP grease, and install it into the No. 3 shift fork shaft.

  16. INSTALL NO. 3 SHIFT FORK SHAFT

    A01E0UOE01

    1. Coat the ball pin shift interlock with MP grease.

    2. Using a magnetic finger, install the No. 3 shift interlock pin to the intermediate plate.

    3. Install the No. 3 shift fork shaft through the reverse shift fork and the intermediate plate.

    4. Coat the shift detent ball with MP grease.

    5. Install the shift detent ball and the shift detent ball low side compression spring to the reverse shift fork.

    6. Install the No. 3 shift fork shaft through the reverse shift arm.

  17. INSTALL NO. 5 SHIFT FORK SHAFT

    A01E1XSE03

    1. Install the reverse shift head and No. 5 shift fork shaft.

    2. A01DWDVE01

      Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the reverse shift head.

  18. INSTALL NO. 4 SHIFT FORK SHAFT

    A01DVIQE01

    1. Coat the ball pin shift interlock with MP grease.

    2. Using a magnetic finger, install the ball pin shift interlock to the intermediate plate.

    3. Install the No. 4 shift fork shaft through the reverse shift fork, intermediate plate and reverse shift head.

    4. A01DYTRE01

      Using a brass bar and hammer, tap in the shift fork shaft snap ring and 2 reverse shift head rings.

    5. A01DV61E01

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

      Torque:
      20 N*m  { 204 kgf*cm, 14 ft.*lbf }

  19. INSTALL NO. 2 SHIFT DETENT BALL

    A01E14ZE01

    1. Coat the No. 2 detent ball with MP grease.

    2. Install the No. 2 detent ball and compression spring to the intermediate plate.

    3. A01DUY1E01

      Coat the spring seat with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. Using a T40 "torx" socket wrench, install the spring seat to the intermediate plate.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  20. INSTALL SHIFT DETENT BALL

    A01E1QWE01

    1. Coat the 3 shift detent balls with MP grease, and install them and the 3 compression springs to the intermediate plate.

    2. A01DZATE01

      Coat the 3 spring seats with adhesive.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a T40 "torx" socket wrench, install the 3 spring seats to the intermediate plate.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  21. INSTALL MANUAL TRANSMISSION CASE

    A01DZFJE01

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

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A01E1L7

      Stand the intermediate plate as shown in the illustration.

    3. Using a plastic-faced hammer, install the transmission case to the intermediate plate as shown in the illustration.

  22. INSTALL NO. 1 COUNTER GEAR FRONT BEARING SNAP RING

    A01E1K5E01

    1. Using a snap ring expander, install the snap ring to the front bearing.

  23. INSTALL FRONT BEARING SHAFT SNAP RING

    A01DVM9E01

    1. Using a snap ring expander, install the snap ring to the input shaft front bearing.

  24. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL

    A01DZCEE01

    1. Using SST, press in a new oil seat to the front bearing retainer.

      SST
      09950-60010   ( 09952-06010, 09951-00440 )
      Oil seal depth
      12.5 to 13.5 m (0.492 to 0.531 in.)

  25. CHECK BEARING RETAINER FRONT

    A01E0JVE01

    1. Check that "FIPG" is imprinted on the bearing retainer front.

  26. INSTALL BEARING RETAINER FRONT

    A01DZ3XE02

    1. w/o Gasket:

      Apply seal packing to the bearing retainer front as shown in the illustration.

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

    2. w/ Gasket:

      Install the bearing retainer front with gasket to the transmission case.

    3. A01E14KE01

      w/o Gasket:

      Install the bearing retainer front with gasket to the transmission case.

    4. Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Install the 8 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 12 ft.*lbf }

  27. INSTALL EXTENSION HOUSING OIL SEAL

    A01DZ8NE01

    1. Using SST, tap in a new oil seal to the extension housing.

      SST
      09223-00010

    2. Lightly apply MP grease to the tip of the oil seal.

      Oil seal depth
      0 +- 0.5 mm (0 +- 0.0196 in.)

      Note

      Be careful no to damage the oil seal lip.

  28. INSTALL REVERSE RESTRICT PIN

    A01E1BTE01

    1. Install the restrict pin to the extension housing.

    2. A01DWCWE01

      Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the extension housing.

    3. A01E0M2E01

      Using a T40 "torx" socket wrench, install the plug to the extension housing.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  29. INSTALL OIL RECEIVER


    1. Install the oil receiver with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  30. INSTALL OIL RECEIVER PIPE

    A01DZMVE01

    1. Install the oil receiver pipe to the extension housing.

  31. INSTALL TRANSMISSION MAGNET

    A01E0N1E01

    1. Install the magnet to the extension housing.

  32. INSTALL EXTENSION HOUSING

    A01DZHEE01

    1. Apply seal packing to the extension housing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A01DWEPE01

      Install the shift and select lever to the extension housing.

    3. Connect the shift and select lever to the shift fork shaft and put in the shift lever housing.

    4. Align No. 5 shift fork shaft to the extension housing installation hole and push in the extension housing.

    5. A01DWXOE01

      Install the extension housing to the manual transmission case with the 8 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    6. A01E0HAE01

      Install the bolt to the shift lever housing.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  33. INSTALL SHAFT DETENT BALL

    A01E19YE01

    1. Coat the shift detent ball with MP grease, and install it and the compression spring to the extension housing.

    2. A01E02JE01

      Using a T40 "torx" socket wrench, install the spring seat to the extension housing.

      Torque:
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  34. INSTALL SPEEDOMETER DRIVEN GEAR


    1. Install a new O-ring to the driven gear.

    2. Install the driven gear with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  35. INSTALL CONTROL SHIFT LEVER RETAINER

    A01DYG6E01

    1. Install the oil deflector and shift lever retainer to the extension housing with the 4 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  36. INSTALL RESTRICT PIN

    A01DZC7E01

    1. Install the 2 restrict pins to the extension housing.

      Torque:
      28 N*m  { 290 kgf*cm, 21 ft.*lbf }

  37. INSTALL CLUTCH HOUSING

    A01DXQQE01

    1. Install the clutch housing.

    2. Apply adhesive to the bolt threads.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the 9 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  38. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    A01DZ5HE01

    1. Using SST, install the back-up light switch to the transmission case.

      SST
      09817-16011
      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  39. INSTALL CLUTCH RELEASE FORK BOOT

    A01DWHQE01

    1. Install the release fork boot to the clutch housing.

  40. INSTALL RELEASE FORK SUPPORT

    A01DZHAE01

    1. Install the release fork support to the clutch housing.

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

  41. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A01DZVRE01

    1. Coat the release bearing with Multemp 8158 Grease or equivalent, and install it to the release fork.

      Grease
      Multemp 8158 Grease or equivalent

  42. INSTALL CLUTCH RELEASE FORK

    A01E2MNE01

    1. Install the release fork to the input shaft.

    2. Apply molybdenum disulphide lithium base grease to the input shaft spline.

  43. INSTALL DRAIN PLUG

    A01DX3FE01

    1. Install a new gasket and the drain plug to the transmission case.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  44. INSTALL FILLER PLUG

    A01DWFVE01

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

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }