MULTI-MODE 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 to the differential case.

      09309-37010

      09506-35010

   2. 

      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 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 to the differential case.

      09636-20010

      09726-40010

   2. 

      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 to the manual transmission case.

      09309-36010

      09950-60020

      09951-00730

      09950-70010

      09951-07100

      Tip:

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

3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

   1. 

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

   2. 

      Install the manual transmission case with the 16 bolts.

      29.4 N*m

      300 kgf*cm

      22 ft.*lbf

   3. 

      *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

   4. 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 out of specification, select a proper front differential case rear plate washer.

      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 (0.1004)
      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)	-	-

      Tip:

      • Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

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

   5. Remove the 16 bolts and manual transmission case.

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

4. INSTALL FRONT OUTPUT SHAFT BEARING

   1. 

      Install the output shaft cover to the front transaxle case.

      Note:

      Insert the output shaft cover key into the case groove.

   2. 

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

      09950-60010

      09951-00630

      09950-70010

      09950-70010

5. INSTALL REAR OUTPUT SHAFT BEARING

   1. 

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

      09950-60010

      09951-00590

      09950-70010

      09951-07200

      Tip:

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

6. ADJUST OUTPUT SHAFT BEARING PRELOAD

   1. 

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

   2. 

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

   3. 

      Install the manual transmission case with the 16 bolts.

      29.4 N*m

      300 kgf*cm

      22 ft.*lbf

   4. 

      *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

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

      09564-32011

      Formula

      (Differential side bearing preload + Output shaft bearing preload) - Differential side bearing preload = Output shaft bearing preload

      Preload (at starting)

      New Bearing

      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)

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

      Rear Output Shaft Bearing Shim

      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)	-	-

      Tip:

      Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

   6. Remove the 16 bolts and 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. 

      *a

      Depth

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

      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. 

      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.

9. 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 transmission case.

10. 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.

11. INSTALL STRAIGHT PIN

    1. 

       *a

       Depth

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

       Protrusion Height (A)

       8.5 to 9.5 mm (0.335 to 0.374 in.)

       Protrusion Height (B)

       8.5 to 9.5 mm (0.335 to 0.374 in.)

12. INSTALL BREATHER PLUG

    1. 

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

       09350-30020

       09350-07110

13. 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

14. 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

       Driven in 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.

15. INSTALL TRANSMISSION MAGNET

    1. 

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

16. INSTALL INPUT SHAFT COVER

    1. 

       Install the input shaft cover to the manual transmission case.

       Note:

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

17. INSTALL REAR INPUT SHAFT BEARING SHIM

    1. The rear input shaft bearing shim should be washed before assembly.

       Note:

       Apply grease to the shim to prevent it from falling off from the case during reassembly.

    2. Measure the area between the end of the manual transmission case and the 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 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 and 0.14 mm (0.00551 in.)

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

       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.

18. INSTALL DIFFERENTIAL CASE ASSEMBLY

    1. 

       Coat the differential case tapered roller bearing with gear oil and install the differential case assembly to the front transaxle case.

19. INSTALL INPUT SHAFT ASSEMBLY

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

    2. 

       *1	No. 1 Gear Shift Fork Shaft Assembly

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

    3. 

       *1	No. 2 Gear Shift Fork Shaft Assembly
       *2	No. 3 Gear Shift Fork 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.

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

    5. 

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

20. INSTALL SHIFT INTER LOCK PLATE

    1. 

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

21. INSTALL SHIFT AND SELECT LEVER SHAFT

    1. 

       *a	5 mm Pin Punch
       *b	Depth

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

       *a	5 mm Pin Punch
       *b	Depth

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

       

       *a	5 mm Pin Punch	*b	Depth
       *c	Plane	-	-

       Driven in Depth

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

       Tip:

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

24. INSTALL FRONT INNER SHIFT LEVER

    1. 

       *a	5 mm Pin Punch
       *b	Depth

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

       *a	5 mm Pin Punch
       *b	Depth

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

       Turn the shift and select lever shaft assembly and the inner select lever 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.

27. 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

28. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY

    1. 

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

29. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

    1. 

       *a

       Parallel

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

       Note:

       Make sure that the reverse idler gear shaft bolt installation surface 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.

30. INSTALL MANUAL TRANSMISSION CASE

    1. 

       *a	FIPG
       *b	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 packing (FIPG) material must be removed and reapplied.

    2. 

       Install the 16 bolts to the manual transmission case.

       29.4 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. 

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

    2. Coat the threads of the 2 shift detent ball plugs with sealant.

       Sealant

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a 6 mm hexagon socket wrench, install the 2 shift detent ball plugs.

       22 N*m

       224 kgf*cm

       16 ft.*lbf

    4. 

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

    5. Coat the threads of the shift detent ball plug with sealant.

       Sealant

       Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Using a 6 mm hexagon socket wrench, install the shift detent ball plugs.

       22 N*m

       224 kgf*cm

       16 ft.*lbf

34. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    1. 

       Coat the threads of the reverse idler gear shaft bolt with sealant.

       Sealant

       Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

       30 N*m

       306 kgf*cm

       22 ft.*lbf

35. INSTALL TRANSMISSION CASE PLUG

    1. 

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

       28 N*m

       286 kgf*cm

       21 ft.*lbf

36. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP

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

37. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

38. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

39. INSPECT CLUTCH PIPE LINE

    Click here

40. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

41. INSTALL NO. 1 CLUTCH HOUSING COVER

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

42. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY

    1. 

       Install the breather plug cap to the shift and select actuator assembly.

    2. 

       Install the breather protector to the shift and select actuator assembly with the bolt.

       18 N*m

       184 kgf*cm

       13 ft.*lbf

    3. 

       Using a plastic hammer, tap in 2 new ring pins to the specified protrusion height.

       Protrusion Height

       5.2 to 5.8 mm (0.205 to 0.228 in.)

    4. 

       *a	FIPG
       *b	Seal Diameter 1.2 mm (0.0472 in.)

       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.

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

    5. When replacing the shift and select actuator with a new one:

       1. 

          Move the select inner lever as shown in the illustration.

       2. 

          *a	Shift and Select Lever Shaft Head
          *b	Shift Actuator Plate
          *c	Select Actuator Plate
          *d	Inner Select Lever

          Install the shift and select actuator and wire harness clamp bracket to the transaxle case with the 6 bolts.

          18 N*m

          184 kgf*cm

          13 ft.*lbf

          Note:

          • Securely engage the shift actuator plate to the shift and select lever shaft head.

          • Securely engage the select actuator plate to the inner select lever.

    6. When reusing the shift and select actuator:

       1. 

          *a	Shift and Select Lever Shaft Head
          *b	Shift Actuator Plate
          *c	Select Actuator Plate
          *d	Inner Select Lever

          Install the shift and select actuator to the transaxle case with the 6 bolts.

          18 N*m

          184 kgf*cm

          13 ft.*lbf

          Note:

          • Securely engage the shift actuator plate to the shift and select lever shaft head.

          • Securely engage the select actuator plate to the inner select lever.

43. INSTALL NEUTRAL POSITION SWITCH

    1. 

       *a	27 mm Deep Socket Wrench

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

       40.2 N*m

       410 kgf*cm

       30 ft.*lbf

44. INSTALL TRANSMISSION REVOLUTION SENSOR

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

    2. 

       Install the transmission revolution sensor with the bolt.

       7.8 N*m

       80 kgf*cm

       69 in.*lbf

45. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    1. 

       *a	27 mm Deep Socket Wrench

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

       40.2 N*m

       410 kgf*cm

       30 ft.*lbf

46. INSTALL MANUAL TRANSMISSION FILLER PLUG

    1. 

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

       39.2 N*m

       400 kgf*cm

       29 ft.*lbf

47. INSTALL MANUAL TRANSMISSION DRAIN PLUG

    1. 

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

       45 N*m

       459 kgf*cm

       33 ft.*lbf