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Manual Transmission Assembly: Disassembly

  1. REMOVE BACK-UP LIGHT SWITCH WITH GASKET 
    1. Remove the bolt and disconnect the back-up light switch clamp.
      1. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf) 
    2. Remove the back-up light switch with the gasket.
      1. Torque: 41 N.m (410 kgf.cm, 30 ft.lbf) 
  2. REMOVE BOLT AND VEHICLE SPEED SENSOR DRIVEN GEAR 
    1. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 
  3. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE 

    Remove the 9 bolts and clutch housing.

    1. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 
  4. REMOVE CONTROL SHIFT LEVER RETAINER ASSEMBLY 
    1. Remove the 6 bolts.
      1. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) 
    2. Remove the control shift lever retainer assembly and oil deflector.
      Fig 1: Removing Control Shift Lever Retainer Assembly And Deflector
      G02948952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of installation, please refer to the following item.

      Be sure to spline the small ball portion of inner lever into the shift lever housing.

      (At this time, pay attention so that the retainer assy will not move to forth and back.)

    3. Using a hexagon wrench (10 mm), remove the straight screw plug.
      1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
      2. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 
      Fig 2: Removing Straight Screw Plug
      G02948953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a magnetic finger, remove the compression spring and lock ball pin.
  5. REMOVE 2 RESTRICT PINS AND GASKETS 
    1. Remove the restrict pin (color: black) with the gasket.
      1. Torque: 41 N.m (418 kgf.cm, 30 ft.lbf) 

      HINT:

      Install the black pin on the reverse gear/5th gear side.

    2. Remove the restrict pin (color: white) with the gasket.
      1. Torque: 41 N.m (418 kgf.cm, 30 ft.lbf) 
    Fig 3: Removing Restrict Pins And Gaskets
    G02948954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE EXTENSION HOUSING 
    1. Remove the shift lever housing set bolt.
      1. Torque: 33 N.m (337 kgf.cm, 24 ft.lbf) 
      Fig 4: Removing Shift Lever Housing Set Bolt
      G02948955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 9 bolts and wire harness clamp from the extension housing.
      1. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 
      Fig 5: Removing Bolts And Wire Harness Clamp From Extension Housing
      G02948956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, carefully tap the extension housing.
    4. Pull out the extension housing and inner lever.
      1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
  7. REMOVE SHIFT AND SELECT LEVER 
  8. REMOVE FRONT BEARING RETAINER AND BEARING SNAP RING 
    1. Remove the 7 bolts.

      Sealant: Part No.08833-00080, THREE BOND 1344, 

      LOCTITE 242 or equivalent 

      1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
    2. Remove the front bearing retainer.
      1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
    3. Using a snap ring expander, remove the 2 bearing snap rings.
      4. Fig 6: Removing Front Bearing Retainer And Bearing Snap Ring
      G02948957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE 
    1. Using a plastic hammer, carefully tap the transmission case.
    2. Pull the transmission case from the intermediate plate.
    Fig 7: Separating Intermediate Plate From Transmission Case
    G02948958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of installation, please refer to the following item. Align each bearing outer race and each shift fork shaft end with the case holes.

    FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 

  10. MOUNT INTERMEDIATE PLATE IN VISE 
    1. Use the 2 long clutch housing bolts, plate washers and suitable nuts, as shown.
      NOTE: Increase or decrease plate washers so that the bolt tip does not protrude from the nut.
    2. Mount the intermediate plate in a vise.
    Fig 8: Mounting Intermediate Plate In Vise
    G02948959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE OIL SEPARATOR 

    Remove the 2 bolts and oil separator.

    1. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) 
  12. REMOVE FRONT MAGNET 
  13. REMOVE LOCKING BALL AND SPRING 
    1. Using a hexagon wrench (6 mm), remove the 4 straight screw plugs.

      Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
    2. Using a magnetic finger, remove the 3 springs and balls.
      Fig 9: Removing Locking Ball And Spring
      G02948960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE SHIFT FORK, SHIFT FORK SHAFT AND REVERSE IDLER GEAR 
    1. Remove the No. 1 and No. 2 shift forks set bolts.
      1. Torque: 20 N.m (203 kgf.cm, 15 ft.lbf) 
      2. Fig 10: Removing No. 1 And No. 2 Shift Forks Set Bolts
      G02948961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and reverse idler gear shaft stopper.
      1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
    3. Remove the reverse idler gear and shaft with the snap ring.
    4. Remove the No. 1 shift fork and shaft.
    5. Using a magnetic finger, remove the No. 1 and No. 2 interlock pins.

      HINT:

      At the time of installation, please refer to the following item.

      Apply MP grease to the No. 1 and No. 2 interlock pins.

      Fig 11: Using Magnetic Finger To Remove No. 1 And No. 2 Interlock Pins
      G02948962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using 2 screwdrivers and a hammer, tap out the No. 2 shift fork shaft snap ring.
    7. Remove the No. 2 shift fork and shaft.
    8. Using a magnetic finger, remove the No. 3 interlock pin.

      HINT:

      At the time of installation, please refer to the following item.

      Apply MP grease to the No. 3 interlock pin.

      Fig 12: Using Magnetic Finger To Remove No. 3 Interlock Pin
      G02948963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Using a pin punch (5 mm) and hammer, drive out the No. 3 shift fork pin.

      HINT:

      At the time of installation, please refer to the following item.

      Using a pin punch (5 mm) and a hammer, install the No. 3 shift fork pin.

      1. Drive in depth: 0-0.5 mm (0-0.020 in.) 
      Fig 13: Driving Out No. 3 Fork Pin Using Pin Punch And Hammer
      G02948964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a hexagon wrench (6 mm), remove the straight screw plug.
      1. Sealant: Part No.08833-00080, THREE BOND 1344, 
      2. LOCTITE 242 or equivalent 
      3. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
    11. Using a magnetic finger, remove the spring and ball.
    12. Pull out the No. 4 shift fork shaft.
      Fig 14: Pulling Out No. 4 Shift Fork Shaft
      G02948965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the pin from the reverse shift head.

      HINT:

      At the time of installation, please refer to the following item.

      Apply MP grease to the pin.

    14. Remove the No. 3 shift fork, fork shaft and reverse shift arm with the snap ring.

      HINT:

      At the time of installation, please refer to the following item.

      Align the No. 3 shift fork with the No. 3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove.

    15. Using a screwdriver, remove the E-ring, separate the reverse shift head and reverse shift arm.
      Fig 15: Removing E-Ring To Separate Reverse Shift Head And Reverse Shift Arm
      G02948966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR 

    Pry out both ends of the clip and remove the drive gear.

    Fig 16: Removing Vehicle Speed Sensor Drive Gear
    G02948967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT COUNTER 5TH GEAR THRUST CLEARANCE 

    Using a feeler gauge, measure the counter 5th gear thrust clearance.

    1. Standard clearance: 0.10-0.41 mm (0.0039-0.0161 in.) 
    2. Maximum clearance: 0.41 mm (0.0161 in.) 
    Fig 17: Inspecting Counter 5th Gear Thrust Clearance
    G02948968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE COUNTER REAR BEARING, SPACER, COUNTER 5TH GEAR AND NEEDLE ROLLER BEARING 
    1. Using a snap ring expander, remove the snap ring.
      Fig 18: Removing Snap Ring
      G02948969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of installation, please refer to the following item.

      Select a snap ring that will allow minimum axial play.

      SNAP RING THICKNESS REFERENCE

      Mark Thickness mm (in.)
      1 1.90-1.95 (0.0748-0.0768)
      2 1.96-2.01 (0.0772-0.0791)
      3 2.02-2.07 (0.0795-0.0815)
      4 2.08-2.13 (0.0819-0.0839)
      5 2.14-2.19 (0.0843-0.0862)
      6 2.20-2.25 (0.0866-0.0886)
      7 2.26-2.31 (0.0890-0.0909)
    2. Using SST, remove the rear bearing, spacer, counter 5th gear and bearing.

      SST 09950-40011 (09951-04020,09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)

      NOTE: Be careful not to catch the output shaft rear bearing roller on the counter 5th gear.
      Fig 19: Using SST To Remove Rear Bearing, Spacer, Counter 5th Gear And Bearing
      G02948970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the spacer.
      Fig 20: Removing Spacer
      G02948971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of installation, please refer to the following items.

    • Install the counter 5th gear with the 5th gear gaps aligned with the synchronizer cone ring pin.
    • Using a socket wrench and hammer, drive in the bearing.
    • When driving in the bearing support the counter shaft in front with a 1.4-2.3 kg (3-5 lb) hammer or equivalent.
  18. REMOVE SYNCHRONIZER RING ASSEMBLY WITH NO. 3 HUB SLEEVE AND NO. 3 CLUTCH HUB 
    1. Remove the synchronizer ring assembly with the No. 3 hub sleeve from the No. 3 clutch hub.
      Fig 21: Removing Synchronizer Ring Assembly With No. 3 Hub Sleeve From No. 3 Clutch Hub
      G02948972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the spacer.
    3. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 22: Tapping Out Snap Ring
      G02948973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of installation, please refer to the following item.

      Select a snap ring that will allow minimum axial play.

      SNAP RING THICKNESS REFERENCE

      Mark Thickness mm (in.)
      2 2.06-2.11 (0.0811-0.0831)
      3 2.12-2.17 (0.0835-0.0854)
      4 2.18-2.23 (0.0858-0.0878)
      5 2.24-2.29 (0.0882-.0902)
    4. Using SST, remove the No. 3 clutch hub.
      1. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04051, 09957-04010, 09958-04011) 09950-60010 (09951-00200) 
      Fig 23: Using SST To Remove No. 3 Clutch Hub
      G02948974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of installation, please refer to the following items.

    • Using SST and a hammer, drive in the No. 3 clutch hub. SST 09316-60011 (09316-00011, 09316-00071)
    • When installing the No. 3 clutch hub, support the counter shaft in front with a 1.4-2.3 kg (3-5 lb) hammer or equivalent.
      • Fig 24: Driving In No. 3 Clutch Hub
      G02948975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE REAR MAGNET 
  20. REMOVE OUTPUT SHAFT REAR BEARING AND 5TH GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      At the time of installation, please refer to the following item.

      Select a snap ring that will allow minimum axial play.

      Fig 25: Tapping Out Snap Ring
      G02948976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS REFERENCE

      Mark Thickness mm (in.)
      8 2.31-2.36 (0.0909-0.0929)
      9 2.37-2.42 (0.0933-0.0953)
      10 2.43-2.48 (0.0957-0.0976)
      11 2.49-2.54 (0.0980-0.1000)
      12 2.55-2.60 (0.1004-0.1024)
      13 2.61-2.66 (0.1028-0.1047)
      14 2.68-2.73 (0.1055-0.1075)
      15 2.74-2.79 (0.1079-0.1098)
    2. Using SST, remove the rear bearing and 5th gear.

      SST 09312-20012 (09313-00030, 09313-00040, 09313-00050)

      Fig 26: Removing Rear Bearing And 5th Gear
      G02948977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of installation, please refer to the following item.

    Using SST, install the 5th gear and rear bearing.

    SST 09312-20012 (09313-00010, 09313-00030, 09313-00040, 09313-00050)

    Fig 27: Installing 5th Gear And Rear Bearing
    G02948978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REVERSE GEAR 
    1. Using a snap ring expander, remove the snap ring.
      Fig 28: Using Snap Ring Expander To Remove Snap Ring
      G02948979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of installation, please refer to the following item.

      Select a snap ring that will allow minimum axial play.

      SNAP RING THICKNESS REFERENCE

      Mark Thickness mm (in.)
      5 2.25-2.30 (0.0886-0.0906)
      11 2.30-2.35 (0.0906-0.0925)
      12 2.35-2.40 (0.0925-0.0945)
      13 2.40-2.45 (0.0945-0.0965)
      14 2.45-2.50 (0.0965-0.0984)
      15 2.50-2.55 (0.0984-0.1004)
      16 2.55-2.60 (0.1004-0.1024)
      17 2.61-2.66 (0.1028-0.1047)
      18 2.67-2.72 (0.1051-0.1071)
      19 2.73-2.78 (0.1075-0.1094)
      20 2.79-2.84 (0.1098-0.1118)
      21 2.85-2.90 (0.1122-0.1142)
      22 2.91-2.96 (0.1146-0.1165)
      23 2.97-3.02 (0.1169-0.1189)
    2. Using SST, remove the reverse gear.
      1. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04040, 09955-04051, 09958-04011) 
      Fig 29: Removing Reverse Gear
      G02948980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of installation, please refer to the following item.

    Using SST, install the reverse gear.

    SST 09312-20012 (09313-00030, 09313-00040, 09313-00050)

    Fig 30: Installing Reverse Gear
    G02948981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REAR BEARING RETAINER 
    1. Using a torx socket wrench (T40), unscrew the 4 torx screws and remove the rear bearing retainer.
      1. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) 
    2. Using a snap ring expander, remove the 2 snap rings.

    HINT:

    At the time of installation, please refer to the following item. Be sure the snap ring is flush with the intermediate plate surface.

  23. REMOVE OUTPUT SHAFT AND COUNTER GEAR FROM INTERMEDIATE PLATE 
    1. Remove the output shaft, input shaft and counter gear as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.
    2. Remove the input shaft from the output shaft.
      3. Fig 31: Removing Output Shaft And Counter Gear From Intermediate Plate
      G02948982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of installation, please refer to the following items.

    • Before installing the output shaft, use SST to remove the counter gear center bearing outer race.

      SST 09950-60010 (09951-00510), 09950-70010 (09951-07150)

      Fig 32: Removing Counter Gear Center Bearing Outer Race
      G02948983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Install the outer race after installing the counter gear.
    • Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.

    HINT:

    At the time of installation, please refer to the following items.

    • Apply gear oil to the needle roller bearing.
    • Install the needle roller bearing to the input shaft.
    • Install the input shaft and counter gear together.
    • Using SST and a hammer, install the counter gear center bearing outer race.

      SST 09316-60011 (09316-00011)

      Fig 33: Installing Counter Gear Center Bearing Outer Race
      G02948984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Be careful not to damage the bearing rollers.
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