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Manual Transaxle Unit: Reassembly

  1. INSTALL OUTPUT SHAFT COVER 
    1. Coat the output shaft cover with MP grease and install it onto the transaxle case.
      NOTE: Insert the output shaft cover key into the case groove.
      Fig 1: Installing Output Shaft Cover
      G04831761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL OUTPUT SHAFT FRONT BEARING 
    1. Coat a new output shaft front bearing with gear oil.
    2. Using SST and a press, install it onto the transaxle case.

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

      NOTE:
      • Install the new bearing in the correct direction as shown in the illustration.
      • When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.
        Fig 2: Installing Output Shaft Front Bearing
        G04831762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new front transaxle case oil seal onto the transaxle case.

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

      Driven in depth: 15.6 to 16.0 mm (0.6141 to 0.6299 in.) 

    2. Coat the lip of the front transaxle case oil seal with MP grease.
      Fig 3: Installing Front Transaxle Case Oil Seal
      G04831763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL INPUT SHAFT FRONT BEARING 
    1. Coat a new input shaft front bearing with gear oil, and using SST and a press, install it onto the transaxle case.

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

      Driven in depth: 0 to 0.3 mm (0 to 0.0118 in.) 

      Fig 4: Installing Input Shaft Front Bearing
      G04831764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING 
    1. Using SST and a hammer, install a new shift and select lever shaft slide ball bearing onto the manual transmission case.

      SST 09950-60010 (09951 -00220), 09950-70010 (09951-07100) 

      Driven in depth: 0 to 0.5 mm (0 to 0.0197 in.) 

      Fig 5: Installing Shift And Select Lever Shaft Slide Ball Bearing
      G04831765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SHIFT AND SELECT LEVER SHAFT OIL SEAL 
    1. Using SST, install a new shift and select lever shaft oil seal onto the manual transmission case.

      SST 09950-70010 (09951 -07150), 09950-60010 (09951-00240) 

      Driven in depth: 9.7 to 10.3 mm (0.382 to 0.406 in.) 

      Fig 6: Installing Shift And Select Lever Shaft Oil Seal
      G06012814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case front tapered roller bearing (inner race) onto the front differential case.

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

      Fig 7: Installing Front Differential Case Front Tapered Roller Bearing (Inner Race) Onto Front Differential Case
      G04831767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the transaxle case.

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

      Fig 8: Installing Front Differential Case Front Tapered Roller Bearing (Outer Race) Together With Plate Washer Onto Transaxle Case
      G06012816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the differential case.

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

      Fig 9: Installing Front Differential Case Rear Tapered Roller Bearing (Inner Race) To Differential Case
      G04831769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with the plate washer onto the manual transmission case.

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

      HINT:

      Use a plate washer of the same thickness as the removed one.

      Fig 10: Installing Front Differential Case Rear Tapered Roller Bearing (Outer Race) With Plate Washer Onto Manual Transmission Case
      G04831770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Coat the differential case assembly with gear oil and install it onto the transaxle case.
    2. Install the manual transmission case with the 16 bolts.

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 11: Identifying Differential Case Assembly
      G04831735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      SST 09564-32011 

      Fig 12: Turning Differential Case Assembly Clockwise And Counterclockwise 2 Or 3 Times To Allow Bearings To Settle
      G06012821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a torque wrench, measure the preload.

      SST 09564-32011 

      Preload (at starting): 

      New bearing: 

      0.78 to 1.57 N*m (7.95 to 16.0 kgf*cm, 6.9 to 13.89 in.*lbf) 

      Used bearing: 

      0.49 to 0.98 N*m (5.0 to 10.0 kgf*cm, 4.34 to 8.67 in.*lbf) 

      Fig 13: Measuring Preload
      G06012821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the preload is out of specification, select a different plate washer.

      Plate Washer Thickness 

      PLATE WASHER THICKNESS REFERENCE CHART

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      AA 2.10 (0.0827) LL 2.60 (0.1024)
      BB 2.15 (0.0846) MM 2.65 (0.1043)
      CC 2.20 (0.0866) NN 2.70 (0.1063)
      DD 2.25 (0.0886) PP 2.75 (0.1083)
      EE 2.30 (0.0906) QQ 2.80 (0.1102)
      FF 2.35 (0.0925) RR 2.85 (0.1122)
      GG 2.40 (0.0945) SS 2.90 (0.1142)
      HH 2.45 (0.0965) TT 2.95 (0.1161)
      JJ 2.50 (0.0984) UU 3.00 (0.1181)
      KK 2.55 (0.1004) - -

      HINT:

      The preload changes by approximately 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) per each 0.05 mm (0.00197 in.) change in the plate washer thickness.

    5. Remove the 16 bolts and the manual transmission case.
    6. Remove the differential case assembly from the transaxle case.
  10. INSTALL TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, install a new transmission case oil seal onto the manual transmission case.

      SST 09316-60011 (09316-00011) 

      Driven in depth: 

      9.6 to 10.2 mm (0.378 to 0.402 in.) 

    2. Coat the lip of the front transmission case oil seal with MP grease.
      Fig 14: Installing Transmission Case Oil Seal Onto Manual Transmission Case
      G06012822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new transaxle case oil seal onto the transaxle case.

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

      Driven in depth: 1.6 to 2.2 mm (0.0630 to 0.0866 in.) 

    2. Coat the lip of the transaxle case oil seal with MP grease.
      Fig 15: Installing Transaxle Case Oil Seal Onto Transaxle Case
      G06012823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet and install it onto the transaxle case.
      Fig 16: Identifying Transmission Magnet
      G04831776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL BEARING LOCK PLATE 
    1. Install the bearing lock plate onto the transaxle case with the bolt.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

      Fig 17: Locating Bearing Lock Plate Bolt
      G04831741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 1 OIL RECEIVER PIPE 
    1. Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt.

      Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) 

      NOTE:
      • Do not deform the No. 1 oil receiver pipe.
      • Install the No. 1 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.
        Fig 18: Identifying No. 1 Oil Receiver Pipe Bolt
        G04831778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL NO. 2 OIL RECEIVER PIPE 
    1. Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt.

      Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) 

      NOTE:
      • Do not deform the No. 2 oil receiver pipe.
      • Install the No. 2 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.
        Fig 19: Locating No. 2 Oil Receiver Pipe Bolt
        G04831779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    1. Install the reverse restrict pin assembly onto the manual transmission case.
      NOTE: Set the reverse restrict pin assembly in the correct direction.
      Fig 20: Installing Reverse Restrict Pin Assembly Onto Manual Transmission Case
      G04831780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (ø5 mm) and a hammer, install the slotted spring pin onto the reverse restrict pin assembly.

      Drive in depth: 15.5 to 16.5 mm (0.6102 to 0.6496 in.) 

      Fig 21: Installing Slotted Spring Pin Onto Reverse Restrict Pin Assembly
      G04831781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply sealant to the reverse restrict pin plug.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

    4. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Fig 22: Installing Reverse Restrict Pin Plug Onto Manual Transmission Case
      G04831782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    1. Install the manual transaxle case receiver onto the transaxle case with the bolt.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

      Fig 23: Locating Manual Transaxle Case Receiver Bolt
      G04831736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the transaxle case.
      Fig 24: Identifying Differential Case Assembly
      G04831735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL INPUT SHAFT ASSEMBLY 
    1. Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.
      Fig 25: Identifying Input And Output Shafts Assembly
      G04831734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

      HINT:

      Align the mark on the reverse idler gear shaft with the bolt hole as shown in the illustration.

      Fig 26: Aligning Mark On Reverse Idler Gear Shaft With Bolt Hole
      G06045217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL NO. 1 GEAR SHIFT FORK SHAFT 
    1. Coat the No. 1 gear shift fork and No. 2 gear shift fork with gear oil and install them.
      Fig 27: Identifying No. 1 Gear Shift Fork And No. 2 Gear Shift Fork
      G06012835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the No. 1 gear shift fork shaft with gear oil and install it.
    3. Apply sealant to the shift fork set bolt.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

    4. Install the shift fork set bolt.

      Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) 

      Fig 28: Locating Shift Fork Set Bolt
      G06012836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a brass bar and a hammer, install a new shaft snap ring onto the No. 1 gear shift fork shaft.
      Fig 29: Installing Shaft Snap Ring Onto No. 1 Gear Shift Fork Shaft
      G04831789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT 
    1. Coat the 2 shift fork balls with MP grease and install them onto the reverse shift fork.
    2. Install the reverse shift fork onto the No. 3 gear shift fork shaft.
      Fig 30: Locating Shift Fork Balls
      G04831790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, install 2 new shift fork shaft snap rings onto the No. 3 shift fork shaft.
      Fig 31: Installing Shift Fork Shaft Snap Rings Onto No. 3 Shift Fork Shaft
      G04831791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the No. 3 gear shift fork shaft with gear oil and install it.
      Fig 32: Identifying No. 3 Gear Shift Fork Shaft
      G04831792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL NO. 2 GEAR SHIFT FORK SHAFT 
    1. Coat the No. 1 gear shift head and No. 2 gear shift fork shaft with gear oil and install them.
      NOTE: To avoid interference from the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.
      Fig 33: Identifying No. 1 Gear Shift Head And No. 2 Gear Shift Fork Shaft
      G04831793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 2 shift lock bolts with sealant and install them onto the No. 2 gear shift fork and No. 1 shift head.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) 

      Fig 34: Locating Shift Lock Bolts
      G04831725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Install the reverse shift arm bracket assembly onto the front transaxle case with the 2 bolts.

      Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) 

      Fig 35: Locating Reverse Shift Arm Bracket Assembly Bolts
      G04831724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL MANUAL TRANSMISSION CASE 
    1. Apply FIPG to the manual transmission case as shown in the illustration.

      FIPG: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      NOTE: Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
      Fig 36: Applying FIPG To Manual Transmission Case
      G06012844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 13 bolts onto the manual transmission side.

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 37: Locating Manual Transmission Side Bolts
      G04831721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 3 bolts with sealant and install them onto the manual transaxle side.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 38: Locating Manual Transaxle Side Bolts
      G04831720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the reverse idler gear shaft bolt with sealant and install it with a new gasket.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 39: Locating Reverse Idler Gear Shaft Bolt
      G04831713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 2 LOCK BALL ASSEMBLY 
    1. Coat the No. 2 lock ball assembly with sealant and install it using a hexagon wrench.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 40: Installing No. 2 Lock Ball Assembly
      G04831719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL SHIFT DETENT BALL 
    1. Install the 2 shift detent balls, 2 shift detent ball springs, and 2 shift spring seats onto the manual transmission case.
      Fig 41: Identifying Shift Detent Balls, Shift Detent Ball Springs And Shift Spring Seats
      G04831801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the threads of the 2 shift detent ball plugs with sealant and install them using a hexagon wrench.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

      Fig 42: Installing Shift Detent Ball Plugs
      G04831715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift detent ball, shift detent ball compression spring, and spring seat onto the transaxle case.
      Fig 43: Identifying Shift Detent Ball, Shift Detent Ball Compression Spring And Spring Seat
      G04831803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the threads of the shift detent ball plug with sealant and install it using a hexagon wrench.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

      Fig 44: Installing Shift Detent Ball Plug
      G04831717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, install a new input shaft rear bearing hole snap ring onto the input shaft.
      Fig 45: Installing Input Shaft Rear Bearing Hole Snap Ring Onto Input Shaft
      G04831712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, install a new output shaft rear bearing hole snap ring onto the output shaft.
      Fig 46: Installing Output Shaft Rear Bearing Hole Snap Ring Onto Output Shaft
      G04831711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL SHIFT FORK SHAFT SNAP RING 
    1. Using a brass bar and a hammer, install a new shift fork shaft snap ring onto the No. 2 shift fork shaft.
      Fig 47: Installing Shift Fork Shaft Snap Ring Onto No. 2 Shift Fork Shaft
      G04831807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL REAR BEARING RETAINER 
    1. Coat the 5 bolts with sealant and install the rear bearing retainer onto the manual transmission case with the 5 bolts.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 27 N*m (280 kgf*cm, 20 ft.*lbf) 

      Fig 48: Identifying Rear Bearing Retainer Bolts
      G04831808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL 5TH DRIVEN GEAR 
    1. Using SST, install the 5th driven gear onto the output shaft.

      SST 09309-12020 

      Fig 49: Installing 5Th Driven Gear Onto Output Shaft
      G04831809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL 5TH GEAR NEEDLE ROLLER BEARING 
    1. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.
      Fig 50: Identifying 5Th Gear Needle Roller Bearing
      G04831708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL 5TH GEAR 
    1. Coat the 5th gear with gear oil and install it onto the input shaft.
      Fig 51: Identifying 5Th Gear
      G04831811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL NO. 3 SYNCHRONIZER RING 
    1. Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.
      Fig 52: Identifying No. 3 Synchronizer Ring
      G04831812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL NO. 3 TRANSMISSION CLUTCH HUB 
    1. Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the No. 3 transmission clutch hub as shown in the illustration.
      NOTE: Do not set the 2 shifting key spring openings in the same position.
      Fig 53: Identifying Synchromesh Shifting Keys And Synchromesh Shifting Key Springs
      G06012861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft.

      SST 09636-20010 

      NOTE:
      • Do not install the No. 3 transmission clutch hub in the wrong direction.
      • Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key aligned.
      • Check that the 5th gear can rotate smoothly.
      • Place a suitable sized wooden block to support the input shaft.
    3. Select a snap ring that will allow minimum axial play.

      Clearance: 

      0.1 mm (0.00394 in.) or less 

      Snap Ring Thickness 

      SNAP RING THICKNESS REFERENCE CHART

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 2.25 (0.0886) E 2.49 (0.0980)
      B 2.31 (0.0909) F 2.55 (0.1004)
      C 2.37 (0.0933) G 2.61 (0.1028)
      D 2.43 (0.0957) - -
      Fig 54: Installing No. 3 Transmission Clutch Hub Onto Input Shaft
      G06012862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brass bar and a hammer, install a new snap ring onto the input shaft.
      Fig 55: Installing Snap Ring Onto Input Shaft
      G04831815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSPECT 5TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance: 

      0.10 to 0.55 mm (0.00394 to 0.0217 in.) 

      Maximum clearance: 

      0.55 mm (0.0217 in.) 

      If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

      Fig 56: Measuring 5Th Gear Thrust Clearance
      G04831703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSPECT 5TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance: 

      NSK made bearing: 

      0.015 to 0.056 mm (0.000591 to 0.00220 in.) 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.000591 to 0.00228 in.) 

      Maximum clearance: 

      NSK made bearing: 

      0.056 mm (0.00220 in.) 

      KOYO made bearing: 

      0.058 mm (0.00228 in.) 

      Fig 57: Measuring 5Th Gear Radial Clearance
      G04831704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.

  40. INSTALL NO. 3 GEAR SHIFT FORK 
    1. Coat the No. 3 transmission clutch hub sleeve with gear oil and install it together with the No. 3 gear shift fork onto the No. 3 transmission clutch hub.

      HINT:

      Set the No. 3 transmission clutch hub in the correct direction.

      Fig 58: Installing No. 3 Transmission Clutch Hub Sleeve With No. 3 Gear Shift Fork Onto No. 3 Transmission Clutch Hub
      G04831818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the gear shift fork lock bolt with sealant and install it onto the No. 3 gear shift fork.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) 

      Fig 59: Installing Gear Shift Fork Lock Bolt Onto No. 3 Gear Shift Fork
      G04831819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Engage the 2 gears simultaneously to lock the transmission.
    2. Install a new manual transmission output shaft rear set nut.

      Torque: 118 N*m (1200 kgf*cm, 87 ft.*lbf) 

      Fig 60: Installing Manual Transmission Output Shaft Rear Set Nut
      G04831820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
    4. Disengage the 2 gears.
      Fig 61: Staking Manual Transmission Output Shaft Rear Set Nut
      G04831821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Apply FIPG to the manual transmission case cover sub-assembly as shown in the illustration.

      FIPG: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      NOTE: Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
      Fig 62: Applying FIPG To Manual Transmission Case Cover Sub-Assembly
      G04831822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 63: Identifying Manual Transmission Case Cover Sub-Assembly Bolts
      G04831697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Coat the shift and select lever shaft assembly with gear oil and install it onto the transmission case.
      Fig 64: Identifying Shift And Select Lever Shaft Assembly
      G04831696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CONTROL SHAFT COVER OIL SEAL 
    1. Using SST and a hammer, install a new control shaft cover oil seal onto the control shaft cover.

      SST 09950-60010 (09951 -00280), 09950-70010 (09951-07150) 

      Driven in depth: 0.2 to 1.2 mm (0.00787 to 0.0472 in.) 

    2. Coat the control shaft cover oil seal with MP grease.
      Fig 65: Installing Control Shaft Cover Oil Seal Onto Control Shaft Cover
      G04831825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL CONTROL SHAFT COVER 
    1. Coat the threads of the 4 bolts with sealant. Install a new gasket and the control shaft cover onto the manual transmission case with the 4 bolts.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      NOTE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
      Fig 66: Locating Control Shaft Cover Bolts
      G04831694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL SHIFT GUIDE PIN 
    1. Coat the threads of the shift guide pin with sealant.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

    2. Install the washer and shift guide pin.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Fig 67: Locating Shift Guide Pin
      G04831693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL NO. 1 LOCK BALL ASSEMBLY 
    1. Coat the threads of the No. 1 lock ball assembly with sealant and install it onto the manual transmission case.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 68: Locating No. 1 Lock Ball Assembly
      G04831692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL SHIFT LEVER DAMPER 
    1. Install the dust boot onto the control shaft cover.
    2. Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.
    3. Install the washer with the nut.

      Torque: 12 N*m (120 kgf*cm, 8 ft.*lbf) 

      Fig 69: Locating Shift Lever Damper Lock Pin Nut
      G06012736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER 
    1. Install the dust boot onto the shift and select lever shaft oil seal.
    2. Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.
    3. Install the washer with the nut.

      Torque: 12 N*m (120 kgf*cm, 8 ft.*lbf) 

      Fig 70: Locating Floor Shift Control Shift Lever Lock Pin Nut
      G04831687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL SELECTING BELLCRANK ASSEMBLY 
    1. Install the selecting bellcrank assembly together with the control bellcrank dust cover onto the manual transmission case with the 2 bolts and nut.

      Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) for bolt 

      12 N*m (120 kgf*cm, 8 ft.*lbf) for nut 

      NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush.
      Fig 71: Locating Selecting Bellcrank Assembly Bolts And Nut
      G04831686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Using SST, install the back-up light switch assembly onto the manual transmission case with a new gasket.

      SST 09817-16011 

      Torque: 40 N*m (410 kgf*cm, 30 ft.*lbf) 

    2. Install the back-up light switch wire harness into the 2 clamps.
  52. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Install a new O-ring onto the speedometer driven hole cover sub-assembly.
      Fig 72: Installing Back-Up Light Switch Assembly Onto Manual Transmission Case
      G06012732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

      Fig 73: Identifying Speedometer Driven Hole Cover Sub-Assembly Bolt
      G06012731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install the manual transmission filler plug onto the manual transmission case with a new gasket.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

      Fig 74: Identifying Manual Transmission Filler Plug And Gasket
      G04831683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL DRAIN PLUG SUB-ASSEMBLY 
    1. Install the drain plug onto the manual transmission case with a new gasket.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

      Fig 75: Identifying Drain Plug And Gasket
      G04831684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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