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Sequential Manual Transmission Assembly: Disassembly

  1. REMOVE FILLER PLUG AND DRAIN PLUG WITH GASKETS 
    1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
  2. REMOVE 2 BACK-UP LIGHT SWITCHES WITH GASKETS 
    1. Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 
  3. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    NOTE: At the time of reassembly, set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
    1. Remove the neutral start switch.
      1. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 
    2. Remove the 4 bolts, shift and select lever shaft assembly and gasket.
      1. Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
      2. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 
    Fig 1: Removing Bolts, Shift And Select Lever Shaft Assembly And Gasket
    G00928039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSMISSION CASE COVER 
    1. Remove the 9 bolts.
      1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 
    2. Using a brass bar and a hammer, carefully tap the projection of the transmission case cover to remove the transmission case cover from the transmission case.

    HINT:

    At the time of reassembly, apply FIPG to the transmission case cover as shown in the illustration.

    Fig 2: Removing Transmission Case Cover
    G00928040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. FIPG:Part No. 08826-00090, THREE BOND 1281 or equivalent 
    Fig 3: Applying FIPG To Transmission Case Cover
    G00928041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT 6TH GEAR THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance.

    1. Standard clearance: 0.10 to 0.60 mm (0.0039 to 0.0236 in.) 
    2. Maximum clearance: 0.60 mm (0.0236 in.) 
    Fig 4: Measuring Thrust Clearance Using Dial Indicator
    G00928042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT 6TH GEAR RADIAL CLEARANCE 

    Using a dial indicator, measure the radial clearance.

    1. Standard clearance: 0.009 to 0.050 mm (0.0003 to 0.0020 in.) 
    2. Maximum clearance: 0.050 mm (0.0020 in.) 

    If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

    Fig 5: Measuring Radial Clearance Using Dial Indicator
    G00928043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING, 6TH DRIVEN GEAR AND SPACER 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 6: Identifying Tap Out Snap Ring Using Screwdrivers And Hammer
      G00928044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of reassembly, please refer to the following item. Select a snap ring from the figure below that will make the thrust clearance of the output shaft rear radial ball bearing less than 0.1 mm (0.0039 in.).

      Fig 7: Thickness Specification Chart
      G00928045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rear radial ball bearing and 6th driven gear.

      SST 09950-40011 (09951-04010, 09952-04010,09953-04030, 09954-04010, 09955-04021,09957-04010, 09958-04011)

      Fig 8: Removing Rear Radial Ball Bearing And 6Th Driven Gear Using SST
      G00928046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

      • Using SST and a hammer, drive in the 6th driven gear.

        SST 09325-12010

        NOTE: Be sure to install the 6th driven gear in the correct direction, as shown in the illustration.
        Fig 9: Identifying Drive In 6Th Driven Gear Using SST And Hammer
        G00928047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer.

      SST 09517-12010

    3. Remove the spacer.
    Fig 10: Removing Spacer Using SST
    G00928048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE INPUT SHAFT REAR RADIAL BALL BEARING AND 6TH GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 11: Identifying Tap Out Snap Ring Using Screwdrivers And Hammer,
      G00928049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of reassembly, please refer to the following item. Select a snap ring from the figure below that will make the thrust clearance of the No. 3 clutch hub less than 0.1 mm (0.0039 in.).

      Fig 12: Thickness Specification Chart
      G00928050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rear radial ball bearing and 6th gear.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011)

      Fig 13: Removing Rear Radial Ball Bearing And 6Th Gear Using SST
      G00928051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of reassembly, please refer to the following item. Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer.

      SST 09517-12010

    3. Remove the needle roller bearing and spacer.
    Fig 14: Removing Needle Roller Bearing And Spacer Using SST
    G00928052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 3 SYNCHRONIZER RING (FOR 6TH GEAR) 
    NOTE: At the time of reassembly, please refer to the following items.
    • Align the No. 3 synchronizer ring slots with the No. 3 shifting keys. 
    • Distinguish the No. 3 synchronizer ring (for the 6th gear) by the teeth on the synchronizer ring. 
    Fig 15: Removing Synchronizer Ring (For 6Th Gear)
    G00928053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 3 GEAR SHIFT FORK AND NO. 3 HUB SLEEVE 

    Remove the bolt, No. 3 gear shift fork and No. 3 hub sleeve.

    1. Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    2. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 
    Fig 16: Removing Bolt, Gear Shift Fork And Hub Sleeve
    G00928054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT 5TH GEAR THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance.

    1. Standard clearance: 0.10 to 0.62 mm (0.0039 to 0.0244 in.) 
    2. Maximum clearance: 0.62 mm (0.0244 in.) 
    Fig 17: Measuring Thrust Clearance Using Dial Indicator
    G00928055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT 5TH GEAR RADIAL CLEARANCE 

    Using a dial indicator, measure the radial clearance.

    1. Standard clearance: 0.015 to 0.056 mm (0.0006 to 0.0022 in.) 
    2. Maximum clearance: 0.056 mm (0.0022 in.) 

    If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

    Fig 18: Measuring Radial Clearance Using Dial Indicator
    G00928056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE 5TH GEAR, NO. 3 SYNCHRONIZER RING (FOR 5TH GEAR) AND NO. 3 CLUTCH HUB ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 19: Identifying Tap Out Snap Ring Using Screwdrivers And Hammer
      G00928057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of reassembly, please refer to the following item. Select a snap ring from the figure below that will make the thrust clearance of the No. 3 clutch hub less than 0.1 mm (0.0039 in.).

      Fig 20: Thickness Specification Chart
      G00928058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the No. 3 clutch hub assembly.

      SST 09950-30012 (09951-03010, 09953-03010), 09950-50013 (09954-05031)

      Fig 21: Removing Clutch Hub Assembly Using SST
      G00928059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

      • Before driving in the No. 3 clutch hub assembly and input shaft rear radial ball bearing, place the suitable sized wooden block on the rear side of the input shaft, as shown in the illustration. When driving them in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft center bearing is overloaded, it might be damaged.
        Fig 22: Placing Suitable Sized Wooden Block
        G00928060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • .

      SST 09612-22011

      NOTE:
      • Align the No. 3 synchronizer ring slots with the No. 3 shifting keys.
      • Be sure to install the No. 3 clutch hub assembly in the correct direction, as shown in the illustration.
      Fig 23: Identifying Drive In Clutch Hub Assembly Using SST And Hammer
      G00928061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 3 synchronizer ring (for the 5th gear) and 5th gear from the input shaft.
      NOTE: At the time of reassembly, please refer to the following item.

      Distinguish the No. 3 synchronizer ring (for the 5th gear) by the teeth on the synchronizer ring. 

    4. Using 2 screwdrivers and a hammer, tap out the snap ring.
    5. Remove the needle roller bearing and 2 spacers.
    Fig 24: Removing Synchronizer Ring And 5Th Gear From Input Shaft
    G00928062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE 5TH DRIVEN GEAR 

    Using SST, remove the 5th driven gear.

    SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03021)

    Fig 25: Removing 5Th Driven Gear Using SST
    G00928063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of reassembly, please refer to the following item. Using SST and a hammer, drive in the 5th driven gear.

    SST 09612-22011

    Fig 26: Assembling Drive In 5Th Driven Gear Using SST And Hammer
    G00928064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR BEARING RETAINER 

    Remove the 5 bolts and rear bearing retainer.

    1. Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    2. Torque: 27 N.m (280 kgf.cm, 20 ft.lbf) 
    Fig 27: Removing 5 Bolts And Rear Bearing Retainer
    G00928065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BEARING SNAP RING 

    Using a snap ring expander, remove the 2 snap rings.

    HINT:

    If it is difficult to remove and install the snap rings, pull up the shafts.

    Fig 28: Removing Snap Rings Using Snap Ring Expander
    G00928066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET 
    1. Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    2. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 
  18. REMOVE SNAP RING FROM NO. 2 SHIFT FORK SHAFT 

    Using 2 screwdrivers and a hammer, tap out the snap ring.

    Fig 29: Removing Reverse Idler Gear Shaft Lock Bolt And Gasket
    G00928067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND BALL 
    1. Using a hexagon wrench, remove the 3 straight screw plugs.
      1. Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
      2. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 
    2. Using a magnetic finger, remove the 3 seats, springs and balls.
    Fig 30: Removing Seats, Springs And Balls Using Magnetic Finger
    G00928068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE STRAIGHT SCREW PLUG 

    Using a hexagon wrench, remove the 2 straight screw plugs.

    1. Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    2. Torque: 
      1. Plug A: 13 N.m (130 kgf.cm, 9 ft.lbf) 
      2. Plug B: 29 N.m (300 kgf.cm, 22 ft.lbf) 
    Fig 31: Removing Straight Screw Plugs
    G00928069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSMISSION CASE 
    1. Remove the 16 bolts.
      1. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 
    2. Using a plastic-faced hammer, carefully tap the projection of the transmission case to remove the transmission case from the transaxle case.
    Fig 32: Removing Transmission Case Bolts
    G00928070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of reassembly, apply FIPG to the transaxle case as shown in the illustration.

    1. FIPG:Part No. 08826-00090, THREE BOND 1281 or equivalent 
    Fig 33: Applying FIPG To Transaxle Case
    G00928071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE OIL RECEIVER PIPE 

    Remove the 2 bolts and 2 oil receiver pipes from the transmission case.

    1. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 
    NOTE: At the time of reassembly, please refer to the following items.
    • Prevent the oil receiver pipes from being deformed. 
    • Install the oil receiver pipes while placing it against the transmission case, as shown in the illustration. 
    Fig 34: Removing Bolts And Oil Receiver Pipes From Transmission Case
    G00928072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REVERSE SHIFT ARM BRACKET 

    Remove the 2 bolts and reverse shift arm bracket.

    1. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 
    Fig 35: Removing Bolts And Reverse Shift Arm Bracket
    G00928073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: At the time of reassembly, please refer to the following items.
    • Set the pin on the top of the reverse shift arm into a groove on the reverse idler gear. 
    • Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing. 
    Fig 36: Fitting Claw Of Reverse Shift Arm Bracket
    G00928074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT 
    NOTE: At the time of reassembly, please refer to the following item.

    Install the reverse idler gear, thrust washer and shaft, as shown in the illustration. 

    Fig 37: Installing Reverse Idler Gear, Thrust Washer And Shaft
    G00928075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK SHAFT 
    1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from each gear shift fork shaft.
    2. Remove the 3 bolts from the No. 1 gear shift head, No. 1 and No. 2 gear shift forks.
      1. Sealant:Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
      2. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 
    Fig 38: Removing Bolts From Gear Shift Head
    G00928076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: At the time of reassembly, please refer to the following item.

    Make sure that the 3 gear shift heads are positioned, as shown in the illustration. 

    Fig 39: Reassembling Gear Shift Heads
    G00928077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 GEAR SHIFT FORK SHAFT 

    Remove the No. 2 gear shift fork shaft from the No. 2 gear shift fork, No. 1 gear shift head, No. 1 gear shift fork, reverse shift fork and transaxle case.

    Fig 40: Removing No. 2 Gear Shift Fork Shaft
    G00928078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 1 GEAR SHIFT FORK SHAFT 

    Remove the No. 1 gear shift fork shaft from the No. 1 gear shift fork and transaxle case.

    Fig 41: Removing No. 1 Gear Shift Fork Shaft
    G00928079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 1 GEAR SHIFT HEAD 
    Fig 42: Removing No. 1 Gear Shift Head
    G00928080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 GEAR SHIFT FORK FROM REVERSE GEAR GROOVE 
    Fig 43: Removing No. 1 Gear Shift Fork From Reverse Gear Groove
    G00928081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 3 GEAR SHIFT FORK SHAFT AND REVERSE SHIFT FORK 
    1. Remove the No. 3 gear shift fork shaft from the reverse shift fork and transaxle case.
    2. Remove the reverse shift fork.
    Fig 44: Removing Reverse Shift Fork
    G00928082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO.2 GEAR SHIFT FORK FROM NO.2 HUB SLEEVE GROOVE 
  32. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE 
  33. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    NOTE: At the time of reassembly, please refer to the following item.
    Before reassembly, inspect the differential tapered roller bearing preload. (See REASSEMBLY )
    Fig 45: Removing No.2 Gear Shift Fork From No.2 Hub Sleeve Groove
    G00928083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE MAGNET FROM TRANSAXLE CASE 
  35. REMOVE TRANSAXLE CASE RECEIVER 
    1. Remove the bolt and transaxle case receiver from the transaxle case.
  36. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY 
    1. Using a screwdriver, remove the 2 shifting key springs.
      NOTE: At the time of reassembly, please refer to the following item.
      Position the shifting key springs so that their end gaps are not aligned.
    2. Remove the 3 No. 3 shifting keys from the No. 3 clutch hub.
    Fig 46: Disassembling No. 3 Clutch Hub Assembly
    G00928084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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