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Manual Transmission Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL TRANSMISSION UPPER COVER SUBASSEMBLY 
    1. Install the transmission upper cover sub-assembly with the 2 bolts.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 1: Identifying Transmission Upper Cover Sub-Assembly Bolts
      G04046411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR 
    1. Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      2. Fig 2: Identifying Rear No. 1 Engine Mounting Insulator Bolts
      G04046412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL CLUTCH COVER ASSEMBLY (See step 4 in  INSTALLATION  ) 
  4. INSTALL CLUTCH DISC ASSEMBLY (See step 5 in  INSTALLATION  ) 
  5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY 
    1. Apply release hub grease to the contact surface between, the release fork and release bearing hub, the contact surface between the release fork and push rod, and release fork pivot points.

      Sealant: 

      Part No. 08887-01806, RELEASE HUB GREASE or equivalent 

    2. Install the clutch release fork sub-assembly to the release fork support.
      Fig 3: Installing Clutch Release Fork Sub-Assembly To Release Fork Support
      G04046413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not use excess force to install the clutch release fork sub-assembly.
      • After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.
  6. INSTALL MANUAL TRANSMISSION ASSEMBLY 
    1. Install the manual transmission to the engine with the 9 bolts.

      Torque:  

      Bolt A: 72 N*m (730 kgf*cm, 53 ft.*lbf) 

      Bolt B: 37 N*m (380 kgf*cm, 28 ft.*lbf) 

      Fig 4: Identifying Manual Transmission To Engine With Bolts
      G04046414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Temporarily tighten bolt *1, fully tighten bolt *2, lift the rear end of the transmission, and fully tighten bolt *1 and the other bolts. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.
  7. INSTALL ENGINE REAR MOUNTING MEMBER 
    1. Install the engine rear mounting member with the 4 bolts and 4 nuts.

      Torque:  

      Nut: 13 N*m (130 kgf*cm, 10 ft.*lbf) 

      Bolt: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Fig 5: Identifying Engine Rear Mounting Member With Bolts & Nuts
      G04046415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FLOOR SHIFT LEVER ASSEMBLY 
    1. Install the 2 bushings to the shift lever assembly.
    2. Install the washer to the floor shift lever assembly.
      Fig 6: Installing Washer To Floor Shift Lever Assembly
      G04046416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift lever assembly with a new E-ring.
    4. Install the shift and select lever boot.
      Fig 7: Identifying Shift & Select Lever Boot
      G04046417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY 
    1. Install the floor shift control shift lever retainer subassembly with the 2 nuts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 8: Identifying Floor Shift Control Shift Lever Retainer Sub-Assembly Nuts
      G04046418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL CLUTCH COVER ASSEMBLY 
    1. Align the matchmarks on the clutch cover assembly and the flywheel sub-assembly.
    2. Install the clutch cover to the flywheel sub-assembly with the new 6 bolts.

      Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

      NOTE: Tighten the bolts a little at a time in a diagonal pattern until they are all tightened.
      Fig 9: Aligning Matchmarks On Clutch Cover Assembly & Flywheel Sub-Assembly
      G04046419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 CLUTCH HOUSING COVER 
    1. Install the No. 1 clutch housing cover with the 4 bolts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Bolt length: 20 mm (0.79 in.) 

      Fig 10: Identifying No. 1 Clutch Housing Cover With Bolts
      G04046420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 2 CLUTCH HOUSING COVER 
    1. Install the No. 2 clutch housing cover with the 4 bolts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Bolt length: 16 mm (0.63 in.) 

      Fig 11: Identifying No. 2 Clutch Housing Cover Bolts
      G04046421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT WIRE HARNESS 
    1. Connect the back-up light switch connector and install the wire harness.
      Fig 12: Connecting Back-Up Light Switch Connector & Install Wire Harness
      G04046422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT GROUND CABLE 
    1. Connect the ground cable with the bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 13: Connecting Ground Cable Bolt
      G04046423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY 
    1. Install the clutch release cylinder assembly with the 2 bolts.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 14: Identifying Clutch Release Cylinder Assembly Bolts
      G04046424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL CLUTCH ACCUMULATOR ASSEMBLY 
    1. Install the clutch accumulator assembly with the 2 bolts and 2 nuts.

      Torque:  

      Bolt: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Nut: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  17. INSTALL STARTER ASSEMBLY 

    (See INSTALLATION )

    Fig 15: Identifying Clutch Accumulator Assembly With Bolts & Nuts
    G04046425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET 
    1. Install the engine under cover air guide bracket with the 2 bolts.

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      Fig 16: Identifying Engine Under Cover Air Guide Bracket Bolts
      G04046426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (See  INSTALLATION  ) 
  20. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (See step 2 in  INSTALLATION  ) 
  21. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR (See step 3 in  INSTALLATION  ) 
  22. INSTALL OUTSIDE AIR GUIDE PLATE RH (See step 4 in  INSTALLATION  ) 
  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See step 4 in  INSTALLATION  ) 
  24. INSTALL HEATED OXYGEN SENSOR (See step 5 in  INSTALLATION  ) 
  25. INSTALL FRONT CENTER FLOOR BRACE (See step 7 in  INSTALLATION  ) 
  26. INSTALL NO. 1 REAR FLOOR PANEL BRACE (See step 8 in  INSTALLATION  ) 
  27. INSTALL NO. 2 ENGINE UNDER COVER 
  28. INSTALL ENGINE UNDER COVER 
  29. INSTALL SHIFT LEVER CAP 
    1. Move the shift lever to the 2nd gear position. Adjust the guide plate so that dimension A is with the shift lever cap pushed toward neutral (select direction).

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 17: Adjusting Guide Plate That Dimension A With Shift Lever Cap Pushed Toward Neutral
      G04046427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT 
    1. Install the shift lever boot with the 4 bolts.
  31. INSTALL NO. 2 CONSOLE BOX DUCT (See step 5 in  INSTALLATION  ) 
  32. INSTALL CONSOLE BOX (See step 42 in  INSTALLATION  ) 
  33. INSTALL CONSOLE BOX REGISTER ASSEMBLY (See step 43 in  INSTALLATION  ) 
  34. INSTALL FRONT ASH RECEPTACLE SUB-ASSEMBLY (See step 44 in  INSTALLATION  ) 
  35. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY (See step 45 in  INSTALLATION  ) 
  36. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY (See step 46 in  INSTALLATION  ) 
  37. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY 
  38. ADD MANUAL TRANSMISSION OIL (See step 19 in  REPLACEMENT   ) 
  39. INSPECT AND ADJUST MANUAL TRANSMISSION OIL LEVEL (See  ON-VEHICLE INSPECTION   ) 
  40. CHECK FOR EXHAUST GAS LEAKS (See step 9 in INSTALLATION  ) 
Fig 18: Identifying Shift Lever Boot With Bolts
G04046428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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