Manual Transaxle ASSY (C59): Overhaul

1. Remove the manual transmission filler plug and gasket from the manual transmission case.

Fig 1: Removing Manual Transmission Filler Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.

Fig 2: Removing Drain (MTM) Plug Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and speedometer sensor from the transaxle case.
2. Remove the O-ring from the speedometer sensor.

1. Remove the clip and speedometer driven (MTM) gear sub-assy from the speedometer sensor.

1. Remove the bolt and speedometer driven hole cover sub-assy from the transaxle case.
2. Remove the O-ring from the speedometer driven hole cover.

1. Remove the clutch release fork sub-assy with clutch release bearing assy from the transaxle case.

Fig 3: Removing Clutch Release Fork Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release bearing clip and clutch release bearing assy from the clutch release fork sub-assy.

Fig 4: Removing Clutch Release Bearing Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release fork support from the transaxle case.

Fig 5: Removing Release Fork Support

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release fork boot from the transaxle case.

Fig 6: Removing Clutch Release Fork Boot

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the back up lamp switch assy and gasket from the manual transmission case.

Fig 7: Removing Back Up Lamp Switch Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.

Fig 8: Removing Floor Shift Control Lever Housing Support Bracket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and selecting bellcrank assy from the manual transmission case.
2. Remove the control shift lever bush.

Fig 9: Removing Selecting Bell Crank Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 wooden blocks, fix the manual transaxle assy.

Fig 10: Fixing Manual Transaxle Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the lock ball assy No. 1 from the manual transmission case.

Fig 11: Removing Lock Ball Assy No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts, shift & select lever shaft assy and gasket from the manual transmission case.

Fig 12: Removing Shift & Select Lever Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 9 bolts.
   Fig 13: Removing Manual Transmission Case Cover Sub-Assy Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assy to remove it from the manual transmission case.

Fig 14: Removing Manual Transmission Case Cover Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
   Fig 15: Loosening Staked Part Of Manual Transmission Output Shaft Rear Set Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the gear to the double meshing.
3. Remove the manual transmission output shaft rear set nut.
   Fig 16: Removing Manual Transmission Output Shaft Rear Set Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disengage the double meshing of the gear.

1. Remove the gear shift fork lock bolt from the gear shift fork No. 3.
   Fig 17: Removing Gear Shift Fork Lock Bolt From Gear Shift Fork No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the transmission hub sleeve No. 3 with gear shift fork No. 3 from the transmission clutch hub No. 3.

Fig 18: Removing Transmission Hub Sleeve No. 3 With Gear Shift Fork No. 3

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the 5th gear thrust clearance.
   Fig 19: 5th Gear Thrust Clearance Specifications

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5th gear thrust clearance: 

Fig 20: Measuring 5th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the 5th gear radial clearance.
   Fig 21: 5th Gear Radial Clearance Specifications

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5th gear radial clearance: 

Fig 22: Measuring 5th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Using a waste to prevent the snap ring from being scattered.

   Fig 23: Removing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the transmission clutch hub No. 3, 5th gear and synchronizer ring No. 3 from the input shaft.

   SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010), 09950-60010 (09951-00200)

   Fig 24: Removing Transmission Clutch Hub No. 3, 5th Gear And Synchronizer Ring No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No. 3.

Fig 25: Removing Synchromesh Shifting Keys And Synchromesh Shifting Key Springs

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.

Fig 26: Removing 5th Gear Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the 5th driven gear from the output shaft.

   SST 09953-00012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190)

Fig 27: Removing 5th Driven Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.

Fig 28: Removing Bearing Retainer Rear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.

Fig 29: Removing Output Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.

Fig 30: Removing Input Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.

Fig 31: Removing Reverse Idler Gear Shaft Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 2.

Fig 32: Removing Shift Fork Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
   Fig 33: Removing Shift Detent Ball Plugs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the 2 seats, 2 springs and 2 shift detent balls from the manual transmission case.
   Fig 34: Removing Seats, Springs And Shift Detent Balls

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.
   Fig 35: Removing Shift Detent Ball Plugs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a magnetic finger, remove the seat, spring and shift detent ball from the transaxle case.

Fig 36: Removing Seats, Springs And Shift Detent Balls

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a hexagon wench, remove the lock ball assy No. 1 from the manual transmission case.

Fig 37: Removing Lock Ball Assy No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts from the transaxle case side.
   Fig 38: Removing Bolts From Transaxle Case Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the manual transmission case side.
   Fig 39: Removing Bolts From Manual Transmission Case Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, carefully tap the projection of the manual transmission case to remove it from the transaxle case.

Fig 40: Tapping Projection Of Manual Transmission Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft from the transaxle case.

Fig 41: Removing Reverse Idler Gear Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and reverse shift arm bracket assy from the transaxle case.

Fig 42: Removing Reverse Shift Arm Bracket Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts from the gear shift fork No. 2 and gear shift head No. 1.
   Fig 43: Removing Bolts From Gear Shift Fork No. 2 And Gear Shift Head No. 1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork shaft No. 2 and gear shift head No. 1 from the transaxle case.

Fig 44: Removing Gear Shift Fork Shaft No. 2 And Gear Shift Head No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap out the snap rings.
   NOTE:

   Using a waste to prevent the snap ring from being scattered.

   Fig 45: Removing Snap Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assy No. 1 from the gear shift fork No. 1.
   Fig 46: Removing Gear Shift Fork Lock Bolt And Gear Shift Fork Shaft Sub-Assy No. 1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the gear shift fork No. 1.

Fig 47: Removing Gear Shift Fork No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 3.
   NOTE:

   Using a waste to prevent the snap ring from being scattered.

   Fig 48: Removing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift fork shaft No. 3 with reverse shift fork and gear shift fork No. 2 from the transaxle case.
   Fig 49: Removing Shift Fork Shaft No. 3 With Reverse Shift Fork And Gear Shift Fork No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
   Fig 50: Removing Balls From Reverse Shift Fork

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using 2 screwdrivers and a hammer, tap out the snap ring.
   NOTE:

   Using a waste to prevent the snap ring from being scattered.

5. Remove the reverse shift fork from the gear shift fork shaft No. 3.

Fig 51: Removing Reverse Shift Fork From Gear Shift Fork Shaft No. 3

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the input and output shaft assy from the transaxle case.

Fig 52: Removing Input Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the differential case assy from the transaxle case.

Fig 53: Removing Differential Case Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and manual transaxle case receiver from the transaxle case.

Fig 54: Removing Manual Transaxle Case Receiver

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
   Fig 55: Removing Reverse Restrict Pin Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (phi 5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assy from the manual transmission case.

Fig 56: Removing Slotted Spring Pin And Reverse Restrict Pin Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and oil receiver pipe No. 1 (MTM) from the manual transmission case.

Fig 57: Removing Oil Receiver Pipe No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and oil receiver pipe No. 2 (MTM) from the manual transmission case.

Fig 58: Removing Oil Receiver Pipe No. 2

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and bearing lock plate from the transaxle case.

Fig 59: Removing Bearing Lock Plate

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the transmission magnet from the transaxle case.

Fig 60: Removing Transmission Magnet

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the input shaft front bearing from the transaxle case.

   SST 09612-65014 (09612-01050, 09612-01060)

Fig 61: Removing Input Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.

Fig 62: Removing Front Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the output shaft front bearing from the transaxle case.

   SST 09308-00010

Fig 63: Removing Output Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the output shaft (MTM) cover from the transaxle case.

Fig 64: Removing Output Shaft Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the FR differential case front tapered roller bearing (outer race) and shim from the transaxle case.

   SST 09612-65014 (09612-01040, 09612-01050)

   Fig 65: Removing FR Differential Case Front Tapered Roller Bearing (Outer Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove FR differential case front tapered roller bearing (inner race) from the front differential case.

   SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)

Fig 66: Removing FR Differential Case Front Tapered Roller Bearing (Inner Race)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, drive out the transaxle case oil seal from the transaxle case.

   SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)

Fig 67: Removing Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the FR differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.

   SST 09612-65014 (09612-01040, 09612-01050)

   Fig 68: Removing FR Differential Case Rear Tapered Roller Bearing (Outer Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.

   SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)

Fig 69: Removing FR Differential Case Rear Tapered Roller Bearing (Inner Race)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.

   SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)

Fig 70: Removing Transmission Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone, check that the ring locks.

   If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

   NOTE: Ensure the file lapping compound is completely washed off after rubbing.
3. Check again the breaking effect of the synchronizer ring.
   Fig 71: Inspecting Synchronizer Ring No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
   1. Minimum clearance: 0.75 mm (0.0295 in.) 

If the clearance is less than minimum, replace the synchronizer ring and gear cone by applying a small amount of the fine lapping compound on gear cone.

Fig 72: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the sliding condition between the transmission hub sleeve No. 3 and transmission clutch hub No. 3.
2. Check that spline gear's of the transmission hub sleeve No. 3 is not worn down.
   Fig 73: Inspecting Transmission Hub Sleeve No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier calipers, inspect the transmission hub sleeve No. 3 and gear shift fork No. 3 as shown in Fig 74 .
   1. Standard clearance: 0.3 - 0.5 mm (0.012 - 0.0197 in.) 

   If the clearance is out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3.

Fig 74: Inspecting Transmission Hub Sleeve No. 3 And Gear Shift Fork No. 3

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a caliper gauge, inspect 5th gear as shown in Fig 76 .

5th gear inner diameter: 

Fig 75: 5th Gear Inner Diameter Specifications

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 76: Inspecting 5th Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the inner diameter exceeds the maximum, replace the 5th gear.

1. Using a caliper gauge, inspect the reverse idler gear sub-assy as shown in Fig 76 .

   Reverse idler gear sub-assy inner diameter: 

   Fig 77: Reverse Idler Gear Sub-Assy Inner Diameter Specifications

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assy.

2. Using a micrometer, inspect the reverse idler gear shaft as shown in Fig 79 .

Reverse idler gear shaft outer diameter: 

Fig 78: Reverse Idler Gear Sub-Assy Outer Diameter Specifications

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the outer diameter is below the minimum, replace the reverse idler gear shaft.

Fig 79: Inspecting Reverse Idler Gear Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the output shaft (MTM) cover with MP grease, install it to the transaxle case.

Fig 80: Installing Output Shaft Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new output shaft front bearing with gear oil, using SST and a press, install it to the transaxle case.

   SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)

Fig 81: Installing Output Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.

   SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)

   1. Drive in depth: 15.6 - 16.0 mm (0.6142 - 0.6299 in.) 
2. Coat the lip of the front transaxle case oil seal with MP grease.

Fig 82: Installing Front Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new input shaft front bearing with MP grease, using SST and a press, install it to the transaxle case.

   SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)

   1. Drive in depth: 0 - 0.3 mm (0 - 0.012 in.) 

Fig 83: Installing Input Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install a new FR differential case front tapered roller bearing (inner race) to the front differential case.

   SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)

   Fig 84: Installing FR Differential Case Front Tapered Roller Bearing (Inner Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new FR differential case front tapered roller bearing (outer race) with shim to the transaxle case.

   SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)

Fig 85: Installing FR Differential Case Front Tapered Roller Bearing (Outer Race)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install a new FR differential case rear tapered roller bearing (inner race) to the front differential case.

   SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)

   Fig 86: Installing FR Differential Case Front Tapered Roller Bearing (Inner Race)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new FR differential case rear tapered roller bearing (outer race) with shim to the manual transmission case.

   SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)

Fig 87: Installing FR Differential Case Front Tapered Roller Bearing (Outer Race)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the differential case assy with gear oil, install it to the transaxle case.
2. Install the manual transmission case with 16 bolts.
   1. Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf) 
   Fig 88: Installing Differential Case Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a torque wrench, turn the differential case assy to the right and left 2 or 3 times to allow the bearings to settle.
4. Using SST and a torque wrench, measure the preload.

   SST 09564-32011

   Fig 89: Measuring Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Preload (at starting): 
      1. New bearing:0.78 - 1.57 N.m (8 - 16 kgf.cm, 6.9 - 13.9 in.lbf) 
         Fig 90: Shim Thickness Specifications

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

         If the preload is out of specification, select another shim.

         Shim thickness: 

         NOTE:

         The preload will change by about 0.3 - 0.4 N.m (3 - 4 kgf.cm, 2.6 - 3.5 in.lbf) corresponding to a change of 0.05 mm (0.0020 in.) in shim thickness.

5. Remove the 16 bolts and manual transmission case from the transaxle case.
6. Remove the differential case assy from the transaxle case.

SST 09564-32011

Fig 91: Adjusting Differential Side Bearing Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.

   SST 09316-60011 (09316-00011)

   1. Drive in depth: 9.9 +/- 0.3 mm (0.390 +/- 0.012 in.) 
2. Coat the lip of the transmission case oil seal with MP grease.

Fig 92: Installing Transmission Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, install a new transaxle case oil seal in the transaxle case.

   SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)

   1. Drive in depth: 1.9 +/- 0.3 mm (0.075 +/- 0.012 in.) 
2. Coat the lip of the transaxle case oil seal with MP grease.

Fig 93: Installing Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the transmission magnet, install it to the transmission case.

Fig 94: Installing Transmission Magnet

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the bearing lock plate with the bolt.
   1. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 

Fig 95: Installing Bearing Lock Plate

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil receiver pipe No. 1 (MTM) with bolt to the manual transmission case.
   1. Torque: 17.2 N.m (175 kgf.cm, 13 ft.lbf) 

Fig 96: Installing Oil Receiver Pipe No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil receiver pipe No. 2 (MTM) with bolt to the manual transmission case.
   1. Torque: 17.2 N.m (175 kgf.cm, 13 ft.lbf) 

Fig 97: Installing Oil Receiver Pipe No. 2

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the reverse restrict pin assy to the manual transmission case.
   NOTE: Do not set the reverse restrict pin assy in incorrect orientation.
   Fig 98: Installing Reverse Restrict Pin Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (phi 5 mm) and hammer, install the slotted pin to the reverse restrict pin assy.
   1. Standard clearance (A):15.5 - 16.5 mm (0.6102 - 0.6496 in.) 
3. Apply sealant to the reverse restrict pin plug.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   Fig 99: Installing Slotted Pin To Reverse Restrict Pin Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.
   1. Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf) 

Fig 100: Installing Reverse Restrict Pin Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the manual transaxle case receiver with the bolt to the transaxle case.
   1. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 

Fig 101: Installing Manual Transaxle Case Receiver

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the differential case tapered roller bearing with gear oil, install the differential case assy to the transaxle case.

Fig 102: Installing Differential Case Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the sliding and rotating surface of the input and out put shafts with gear oil, install them to the transaxle case.

Fig 103: Installing Input Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft with gear oil, install them as shown in Fig 104 .

Fig 104: Installing Reverse Idler Gear Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the gear shift fork No. 1 and gear shift fork No. 2 with gear oil, install them.
   Fig 105: Installing Gear Shift Fork No. 1 And Gear Shift Fork No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift fork shaft sub-assy No. 1 with gear oil, install it.
3. Apply sealant to the shift fork lock bolt.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
4. Install the gear shift fork lock bolt.
   1. Torque: 15.7 N.m (160 kgf.cm, 12 ft.lbf) 
   Fig 106: Installing Gear Shift Fork Shaft Sub-Assy No. 1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No. 1.

Fig 107: Installing Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 2 balls with MP grease, install them to the reverse shift fork.
2. Install the reverse shift fork to the gear shift fork shaft No. 3.
   Fig 108: Installing Reverse Shift Fork To Gear Shift Fork Shaft No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft No. 3.
   Fig 109: Installing Shift Fork Shaft Snap Rings To Gear Shift Fork Shaft No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the gear shift fork shaft No. 3 with gear oil, install it.

Fig 110: Installing Gear Shift Fork Shaft No. 3

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the gear shift head No. 1 and gear shift fork shaft No. 2 with gear oil, install them.
   Fig 111: Installing Gear Shift Head No. 1 And Gear Shift Fork Shaft No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: To avoid the interference of the 2 shift fork balls, lift up the gear shift fork shaft No. 3 at the position shown in Fig 112 .
   Fig 112: Lifting Up Gear Shift Fork Shaft No. 3 (Sectional View)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift lock bolts with sealant, install then to the gear shift fork No. 2 and gear shift head No. 1.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 15.7 N.m (160 kgf.cm, 12 ft.lbf) 

Fig 113: Installing Shift Lock Bolts To Gear Shift Fork No. 2 And Gear Shift Head No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the reverse shift arm bracket assy with 2 bolts to the transaxle case.
   1. Torque: 17.2 N.m (175 kgf.cm, 13 ft.lbf) 

Fig 114: Installing Reverse Shift Arm Bracket Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply FIPG to the manual transmission case, as shown in Fig 115 .
   1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
   Fig 115: Applying FIPG To Manual Transmission Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
2. Coat the 13 bolts with sealant, install them to the manual transmission case.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf) 
   Fig 116: Installing Manual Transmission Case Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 3 bolts with sealant, install them to the transaxle case.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf) 

Fig 117: Installing Transaxle Case Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the reverse idler gear shaft bolt with sealant, install it with a new gasket.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf) 

Fig 118: Installing Reverse Idler Gear Shaft Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the lock ball assy No. 1 with sealant, install it with using a hexagon wrench.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 

Fig 119: Installing Lock Ball Assy No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 shift detent balls, 2 springs with 2 seats to the manual transmission case.
   Fig 120: Installing Shift Detent Balls, Springs With Seats

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift detent ball plugs with sealant, install them with using a hexagon wrench.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 
   Fig 121: Installing Shift Detent Ball Plugs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the shift detent ball, spring and seat to the transaxle case.
   Fig 122: Installing Shift Detent Ball, Spring And Seat To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the shift detent ball plug with sealant, install it with using a hexagon wrench.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

Fig 123: Installing Shift Detent Ball Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.

Fig 124: Installing Input Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.

Fig 125: Installing Output Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No. 2.

Fig 126: Installing Shift Fork Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 5 bolts with sealant, install them and bearing retainer rear (MTM) to the manual transmission case.
   1. Torque: 27.4 N.m (279 kgf.cm, 20 ft.lbf) 
      Fig 127: Installing Bearing Retainer Rear

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the 5th driven gear to the output shaft.

   SST 09309-12020

Fig 128: Installing 5th Driven Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, install them to the input shaft.

Fig 129: Installing 5th Gear Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 5th gear with gear oil, install it to the input shaft.

Fig 130: Installing 5th Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the synchronizer ring No. 3 with gear oil, install it to the 5th gear. 

Fig 131: Installing Synchronizer Ring No. 3

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the transmission clutch hub No. 3.
   NOTE:

   Do not set both openings of the shifting key springs in the same position.

   Fig 132: Installing Synchromesh Shifting Keys And Synchromesh Shifting Key Springs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, install the transmission clutch hub No. 3 to the input shaft.

   SST 09636-20010

   NOTE:

   • Before driving in the No. 3 clutch hub assy, place the suitable sized wooden block on the rear side of the input shaft, as shown in Fig 133 .
   • When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded, it might be damaged.
   Fig 133: Installing Transmission Clutch Hub No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 3 below 0.1 mm (0.004 in.).

   Snap ring thickness: 

   Fig 134: Snap Ring Thickness Specifications

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 135: Installing Snap Ring To Input Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a brass bar and a hammer, install the snap ring to the input shaft.

1. Using a dial indicator, measure the 5th gear thrust clearance.

Fig 136: 5th Gear Thrust Clearance Specifications

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5th gear thrust clearance: 

Fig 137: Measuring 5th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the 5th gear radial clearance.

Fig 138: 5th Gear Radial Clearance Specifications

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

5th gear radial clearance: 

Fig 139: Measuring 5th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Coat the transmission clutch hub sleeve No. 3 with gear oil, install it and gear shift fork No. 3 to the transmission clutch hub No. 3.
   NOTE:

   Do not set the transmission clutch hub No. 3 in incorrect orientation.

   Fig 140: Installing Gear Shift Fork No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift lock fork ball with sealant, install it to the gear shift fork No. 3.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 15.7 N.m (160 kgf.cm, 12 ft.lbf) 

Fig 141: Installing Gear Shift Lock Fork Ball

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Engage the gear double meshing.
2. Install a new manual transmission output shaft rear set nut.
   1. Torque: 117.6 N.m (1,200 kgf.cm, 87 ft.lbf) 
   Fig 142: Installing Manual Transmission Output Shaft Rear Set Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
4. Disengage the gear double meshing.

Fig 143: Staking Manual Transmission Output Shaft Rear Set Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply FIPG to the manual transmission case cover sub-assy as shown in Fig 144 .
   1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
   NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
   Fig 144: Applying FIPG To Manual Transmission Case Cover Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the manual transmission case cover sub-assy with the 9 bolts to the manual transmission case.
   1. Torque: 18.1 N.m (185 kgf.cm, 13 ft.lbf) 

Fig 145: Installing Manual Transmission Case Cover Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 4 bolts with sealant, install them, new gasket and shift & select lever shaft assy to the manual transmission case.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 19.6 N.m (200 kgf.cm, 14 ft.lbf) 

Fig 146: Installing Shift & Select Lever Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the lock ball assy No. 1 with sealant, install it to the manual transmission case.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
   1. Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf) 

Fig 147: Installing Lock Ball Assy No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the selecting bellcrank assy with control shift lever bush with the 2 bolts to the manual transmission case.
   1. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

Fig 148: Installing Selecting Bell Crank Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case.
   1. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 

Fig 149: Installing Floor Shift Control Lever Housing Support Bracket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the back up lamp switch assy with a new gasket to the manual transmission case.
   1. Torque: 40.2 N.m (411 kgf.cm, 30 ft.lbf) 

   SST 09817-16011

Fig 150: Installing Back Up Lamp Switch Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring to the speedometer driver hole cover sub-assy.
2. Install the speedometer driver hole cover sub-assy with the bolt.
   1. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 

1. Install the speedometer driven (MTM) gear sub-assy with clip to the speedometer sensor.

1. Install a new O-ring to the speedometer sensor.
2. Install the speedometer sensor with the bolt.
   1. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 

1. Install the release fork support to the transaxle case.
   1. Torque: 36.8 N.m (375 kgf.cm, 27 ft.lbf) 

Fig 151: Installing Release Fork Support

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clutch release fork boot to the transaxle case.

Fig 152: Installing Clutch Release Fork Boot

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the clutch release bearing assy with the release hub grease, install it to the clutch release fork sub-assy.
   1. Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent 

Fig 153: Installing Clutch Release Bearing Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clutch release fork sub-assy to the input shaft.
2. Apply clutch spline grease to spline of the input shaft.
   1. Sealant: Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent 

Fig 154: Installing Clutch Release Fork Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket with the drain (MTM) plug sub-assy.
   1. Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 

Fig 155: Installing Manual Transmission Filler Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new gasket with the manual transmission filler plug.
   1. Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 

Fig 156: Installing Drain Plug Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002