MANUAL TRANSAXLE UNIT REASSEMBLY
PROCEDURE
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
-
Using SST and a press, press a new front differential case front tapered roller bearing onto the differential case assembly.
09316-20011
09950-40011
09957-04010
09950-60010
09951-00580
09952-06010
09950-60020
09951-00910
09950-70010
09951-07100
Install the front differential oil baffle into the front transaxle case.
-
Using SST and a press, press the front differential case front tapered roller bearing (outer race) into the front transaxle case.
09950-60010
09952-06010
09950-60020
09951-00770
09951-00910
09950-70010
09951-07100
-
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
-
Using SST and a press, press a new front differential case rear tapered roller bearing onto the differential case assembly.
09316-20011
09950-40011
09957-04010
09950-60010
09951-00580
09952-06010
09950-60020
09951-00910
09950-70010
09951-07100
-
Using SST, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear shim as shown in the illustration.
09950-60020
09951-00770
09951-00890
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INSTALL FRONT OUTPUT SHAFT BEARING
-
Install the output shaft cover to the front transaxle case.
Note:Insert the output shaft cover key into the case groove.
-
Using SST and a press, press the front output shaft bearing (outer race) into the front transaxle case.
09950-60010
09951-00620
09952-06010
09950-60020
09951-00710
09950-70010
09951-07100
-
INSTALL REAR OUTPUT SHAFT BEARING
-
Using SST and a press, press the rear output shaft bearing (outer race) together with the rear output shaft bearing shim into the manual transmission case.
09950-60010
09951-00490
09951-00620
09952-06010
09950-70010
09951-07150
-
INSTALL STRAIGHT PIN
-
*a
Protrusion
Using a plastic-faced hammer, tap in 5 new straight pins to the specified protrusion height.
Protrusion height
10.5 to 11.5 mm (0.414 to 0.452 in.)
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ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
-
Coat the differential case assembly with gear oil and install it to the front transaxle case.
-
Install the manual transmission case with the 17 bolts.
29.4 N*m
300 kgf*cm
22 ft.*lbf
-
Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
09564-50010
Using SST and a torque wrench, measure the preload.
09564-50010
Standard preload (at starting)
New bearing
1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)
Used bearing
0.24 to 0.37 N*m (2.44 to 3.77 kgf*cm, 2.12 to 3.27 in.*lbf)
If the preload is not as specified, replace the front differential case rear shim with another one of a different thickness. Use the table below to select a front differential case rear shim which will ensure that the preload is within the specification.
Standard Shim Thickness
Mark
Specified Condition
Mark
Specified Condition
A
2.05 mm (0.0807 in.)
K
2.50 mm (0.0984 in.)
B
2.10 mm (0.0827 in.)
L
2.55 mm (0.100 in.)
C
2.15 mm (0.0846 in.)
M
2.60 mm (0.102 in.)
D
2.20 mm (0.0866 in.)
N
2.65 mm (0.104 in.)
E
2.25 mm (0.0886 in.)
P
2.70 mm (0.106 in.)
F
2.30 mm (0.0906 in.)
Q
2.75 mm (0.108 in.)
G
2.35 mm (0.0925 in.)
R
2.80 mm (0.110 in.)
H
2.40 mm (0.0945 in.)
S
2.85 mm (0.112 in.)
J
2.45 mm (0.0965 in.)
T
2.90 mm (0.114 in.)
Tip:Select a thicker front differential case rear shim to increase the preload, or a thinner front differential case rear shim to decrease the preload.
Make a memo as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.
Remove the 17 bolts and manual transmission case.
Remove the differential case assembly from the front transaxle case.
Replace the installed front differential case rear shim with the one selected above.
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ADJUST OUTPUT SHAFT BEARING PRELOAD
-
Coat the differential case assembly with gear oil and install it to the front transaxle case.
-
Coat the output shaft assembly with gear oil and install it to the front transaxle case.
-
Install the manual transmission case with the 17 bolts.
29.4 N*m
300 kgf*cm
22 ft.*lbf
-
*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.
09564-50010
Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing preload using the following formula.
09564-50010
Formula
Value A - Differential side bearing preload = Output shaft bearing preload
Preload (at starting)
New bearing
3.17 to 6.35 N*m (32 to 65 kgf*cm, 28 to 56 in.*lbf)
Used bearing
2.61 to 5.24 N*m (27 to 53 kgf*cm, 23 to 46 in.*lbf)
If the preload is not as specified, replace the rear output shaft bearing shim with another 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.
Standard Bearing Shim Thickness
Mark
Specified Condition
Mark
Specified Condition
A
1.30 mm (0.511 in.)
P
1.95 mm (0.768 in.)
B
1.35 mm (0.531 in.)
Q
2.00 mm (0.787 in.)
C
1.40 mm (0.551 in.)
R
2.05 mm (0.807 in.)
D
1.45 mm (0.571 in.)
S
2.10 mm (0.827 in.)
E
1.50 mm (0.591 in.)
T
2.15 mm (0.846 in.)
F
1.55 mm (0.610 in.)
U
2.20 mm (0.866 in.)
G
1.60 mm (0.630 in.)
V
2.25 mm (0.886 in.)
H
1.65 mm (0.650 in.)
W
2.30 mm (0.906 in.)
J
1.70 mm (0.669 in.)
X
2.35 mm (0.925 in.)
K
1.75 mm (0.689 in.)
Y
2.40 mm (0.945 in.)
L
1.80 mm (0.709 in.)
Z
2.45 mm (0.965 in.)
M
1.85 mm (0.728 in.)
1
2.50 mm (0.984 in.)
N
1.90 mm (0.748 in.)
-
-
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.
Remove the 17 bolts and manual transmission case.
Remove the output shaft assembly from the front transaxle case.
Remove the differential case assembly from the front transaxle case.
Replace the installed rear output shaft bearing shim with the one selected above.
-
INSTALL OUTER SHIFT LEVER OIL SEAL
-
*a
Depth
Using SST and a hammer, tap in a new outer shift lever oil seal to the manual transmission case.
09950-60010
09951-00280
09950-70010
09951-07100
Standard depth
0.5 to 1.0 mm (0.0197 to 0.0393 in.)
Coat the lip of the outer shift lever oil seal with MP grease.
-
INSTALL OUTER NO. 1 SHIFT LEVER
-
*a
Depth
Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.
Using a 5 mm pin punch and hammer, tap in 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.)
-
INSTALL NO. 1 OIL RECEIVER PIPE
-
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.
-
INSTALL BREATHER PLUG
-
Using SST and a hammer, tap in the breather plug to the front transaxle case.
09350-30020
09350-07110
-
INSTALL FRONT TRANSAXLE CASE OIL SEAL
-
*a
Depth
Using SST and a hammer, tap in a new front transaxle case oil seal to the front transaxle case.
09612-22011
Standard depth
1.0 to 2.0 mm (0.0394 to 0.0787 in.)
Coat the lip of the front transaxle case oil seal with MP grease.
-
INSTALL TRANSMISSION MAGNET
-
Clean the transmission magnet and install it to the front transaxle case.
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INSTALL INPUT SHAFT COVER
-
Install the input shaft cover to the manual transmission case.
Note:Insert the input shaft cover key into the manual transmission case groove.
-
INSTALL REAR INPUT SHAFT BEARING SHIM
Install the rear input shaft bearing shim onto the manual transmission case.
Note:Apply grease to the rear input shaft bearing shim to prevent it from falling off the case during assembly.
-
*1
Manual Transmission Case
*2
Input Shaft Assembly
*3
Front Transaxle Case
*a
Dimension A
*b
Dimension C
*c
Dimension B
Measure the distance between the end of the manual transmission case and installation surface of the rear input shaft bearing shim (Dimension A).
Measure the distance between the end of the front transaxle case and installation surface of the front input shaft bearing (Dimension B).
Measure the distance between both input shaft bearing outer races (Dimension C).
Note:Measure Dimension C with each bearing having no axial clearance.
Calculate the rear input shaft bearing shim clearance using the following formula.
Formula
(Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)
If the clearance is not as specified, replace the rear input shaft bearing shim with another one of a different thickness. Use the table below to select a rear input shaft bearing shim which will ensure that the clearance is within the specification.
Standard Rear Input Shaft Bearing Shim Thickness
Mark
Specified Condition
Mark
Specified Condition
A
1.15 mm (0.0453 in.)
H
1.50 mm (0.0591 in.)
B
1.20 mm (0.0472 in.)
J
1.55 mm (0.0610 in.)
C
1.25 mm (0.0492 in.)
K
1.60 mm (0.0630 in.)
D
1.30 mm (0.0512 in.)
L
1.65 mm (0.0650 in.)
E
1.35 mm (0.0531 in.)
M
1.70 mm (0.0669 in.)
F
1.40 mm (0.0551 in.)
N
1.75 mm (0.0689 in.)
G
1.45 mm (0.0571 in.)
P
1.80 mm (0.0709 in.)
Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the one selected above.
Note:Do not apply MP grease to the oil grooves.
INSTALL DIFFERENTIAL CASE ASSEMBLY
-
Coat the differential case tapered roller bearing with gear oil and install it to the front transaxle case.
-
INSTALL INPUT SHAFT ASSEMBLY
Apply gear oil to all sliding and rotating parts.
-
*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 onto the output shaft assembly.
-
*1
No. 2 Gear Shift Fork Shaft Assembly
*2
Input Shaft Assembly
Coat the No. 2 gear shift fork shaft assembly with gear oil and install it onto the input shaft assembly.
Temporarily install the output shaft assembly together with the No. 1 gear shift fork shaft assembly to the input shaft assembly, and tie them with a rope or string.
-
Install the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.
INSTALL OUTER SELECT LEVER OIL SEAL
-
*a
Depth
Using SST and a hammer, tap in a new outer select lever oil seal to the front transaxle case.
09950-60010
09951-00250
09950-70010
09951-07100
Standard depth
0.5 to 1.0 mm (0.0197 to 0.0393 in.)
Coat the lip of the outer select lever oil seal with MP grease.
-
INSTALL OUTER SELECT LEVER
-
*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 positioned outside of the front transaxle case.
-
Coat the threads of the inner select lever bolt with adhesive and install it.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
38 N*m
387 kgf*cm
28 ft.*lbf
-
INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
-
Install the shift interlock plate and shift and select lever shaft assembly to the front transaxle case, and then turn them counterclockwise.
Tip:When installing the shift interlock plate, make sure to engage it with the inner select lever.
-
INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
-
Coat the threads of the 2 bolts with adhesive, and then, using a 6 mm hexagon wrench, install the reverse shift arm bracket assembly with the 2 bolts.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
17.2 N*m
175 kgf*cm
13 ft.*lbf
-
INSTALL REVERSE SHIFT FORK
-
Using a 5 mm pin punch and hammer, install the reverse shift fork slotted spring pin onto the reverse shift fork shaft.
Standard driven in depth
-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
Note:Confirm the installation direction.
-
INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY
-
Coat the reverse shift fork shaft assembly with gear oil and install it onto the front transaxle case.
-
INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
-
Coat the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.
Note:
*a
Case Hole
*b
I-groove mark of the Reverse Idler Gear Shaft
Using the bolt hole of the case for reference, align the I-groove mark of the reverse idler gear shaft within the range shown (approximately 20°).
Tip:Raise the edge of the reverse shift arm bracket assembly and connect the reverse shift arm bracket assembly to the reverse shift fork shaft assembly.
-
INSTALL MANUAL TRANSMISSION CASE
-
*a
Seal Packing
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 packing diameter
1.2 mm (0.0472 in.)
Note:Remove any oil from the contact surfaces.
Assemble the parts within 10 minutes of application. Otherwise, the seal packing must be removed and reapplied.
-
Push the outer No. 1 shift lever and install the manual transmission case.
Tip:Pushing the outer No. 1 shift lever allows the manual transmission case to be installed.
-
Turn the outer No. 1 shift lever counterclockwise and then pull it.
-
Install the manual transmission case with the 17 bolts.
29.4 N*m
300 kgf*cm
22 ft.*lbf
-
INSTALL OUTER SHIFT LEVER E-RING
-
Install the outer shift lever E-ring to the outer No. 1 shift lever.
-
INSTALL TRANSMISSION CASE OIL SEAL (for LH Side)
INSTALL TRANSAXLE CASE OIL SEAL (for RH Side)
INSTALL SHIFT DETENT BALL
Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.
Note:Be careful not to drop the shift detent ball into the manual transmission case.
-
Coat the threads of the 2 shift detent ball plugs with adhesive and install them using a 6 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
22 N*m
224 kgf*cm
16 ft.*lbf
-
Install the shift detent ball and shift detent ball compression spring to the manual transmission case.
Note:Be careful not to drop the lock ball pin into the manual transmission case.
Coat the threads of the shift detent ball plug with adhesive and install it using a 6 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
22 N*m
224 kgf*cm
16 ft.*lbf
INSTALL LOCK BALL PIN
Install the lock ball pin and shift and select lever shaft compression spring to the manual transmission case.
Note:Be careful not to drop the lock ball pin into the manual transmission case.
-
Coat the threads of the shift and select lever shaft straight screw with head plug with adhesive and install it using a 10 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
24.5 N*m
250 kgf*cm
18 ft.*lbf
Install the lock ball pin and shift and select lever shaft compression spring to the manual transmission case.
Note:Be careful not to drop the lock ball pin into the manual transmission case.
-
Coat the threads of the shift and select lever shaft straight screw with head plug with adhesive and install it using a 10 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
24.5 N*m
250 kgf*cm
18 ft.*lbf
INSTALL REVERSE IDLER GEAR SHAFT BOLT
-
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
-
INSTALL RELEASE CYLINDER BLEEDER PLUG
Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.
8.4 N*m
86 kgf*cm
74 in.*lbf
INSTALL RELEASE CYLINDER BLEEDER PLUG CAP
Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSPECT CLUTCH PIPE LINE
INSTALL CLUTCH RELEASE W/BEARING CYLINDER ASSEMBLY
INSTALL CONTROL CABLE BRACKET ASSEMBLY
-
Install the control cable bracket assembly to the manual transmission case with the 3 bolts.
17 N*m
173 kgf*cm
13 ft.*lbf
-
INSTALL TRANSMISSION CASE PLUG
-
Install a new gasket and the transmission case plug to the manual transmission case.
39.2 N*m
400 kgf*cm
29 ft.*lbf
-
INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
-
Using a 27 mm deep socket wrench, install a new gasket and the back-up light switch assembly to the manual transmission case.
40.2 N*m
410 kgf*cm
30 ft.*lbf
-
INSTALL MANUAL TRANSMISSION FILLER PLUG
-
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
-
INSTALL MANUAL TRANSMISSION DRAIN PLUG
-
Install a new gasket and the manual transmission drain plug to the front transaxle case.
39.2 N*m
400 kgf*cm
29 ft.*lbf
-