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Manual Transaxle Unit: Reassembly: Reassembly

  1. INSTALL OUTPUT SHAFT COVER 
    1. Coat the output shaft cover with MP grease and install it onto the transaxle case.
      Fig 1: Installing Output Shaft Cover
      GTY163079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insert the output shaft cover key into the case groove.

  2. INSTALL OUTPUT SHAFT FRONT BEARING 
    1. Coat a new output shaft front bearing with gear oil.
      Fig 2: Installing Output Shaft Front Bearing
      GTY166369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install it onto the transaxle case.
      • SST: 09950-60010 
        • 09951-00550
      • SST: 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.
  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.
      Fig 3: Installing Front Transaxle Case Oil Seal
      GTY159170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00370
      • SST: 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.
  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.
      Fig 4: Installing Input Shaft Front Bearing
      GTY165435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00420
      • SST: 09950-70010 
        • 09951-07150

      Driven in depth

      0 to 0.3 mm (0 to 0.0118 in.)

  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.
      Fig 5: Installing Shift And Select Lever Shaft Slide Ball Bearing
      GTY158817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00220
      • SST: 09950-70010 
        • 09951-07100

      Driven in depth

      0 to 0.5 mm (0 to 0.0197 in.)

  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.
      Fig 6: Installing Shift And Select Lever Shaft Oil Seal
      GTY204940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-70010 
        • 09951-07150
      • SST: 09950-60010 
        • 09951-00240

      Driven in depth

      9.7 to 10.3 mm (0.382 to 0.406 in.)

  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.
      Fig 7: Identifying SST, Press & Front Differential Case Front Tapered Roller Bearing (Inner Race)
      GTY159175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-32014 
        • 09351-32120
      • SST: 09950-60010 
        • 09951-00530
    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.
      Fig 8: Installing Front Differential Case
      GTY176755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        • 09951-00680
      • SST: 09950-70010 
        • 09951-07150
  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.
      Fig 9: Identifying SST, Press & Front Differential Case Rear Tapered Roller Bearing (Inner Race)
      GTY159176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-32014 
        • 09351-32120
      • SST: 09950-60010 
        • 09951-00530
    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.
      Fig 10: Identifying SST, Press & Front Differential Case Rear Tapered Roller Bearing (Outer Race)
      GTY159171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09309-36010 
      • SST: 09950-60020 
        • 09951-00710
      • SST: 09950-70010 
        • 09951-07150

      HINT: 

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

  9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Coat the differential case assembly with gear oil and install it onto the transaxle case.
      Fig 11: Identifying Differential Case Assembly
      GTY165423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case with the 16 bolts.

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

    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.
      Fig 12: Measuring Preload
      GTY200661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-32011 
    4. Using SST and a torque wrench, measure the preload.
      Fig 13: Measuring Preload
      GTY200661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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)

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

      Plate Washer Thickness

      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.
      Fig 14: Installing Transmission Case Oil Seal
      GTY183576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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.
  11. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new transaxle case oil seal onto the transaxle case.
      Fig 15: Installing Transaxle Case Oil Seal
      GTY174901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09710-20011 
        • 09710-06071
      • SST: 09950-70010 
        • 09951-07150

      Driven in depth

      1.4 to 2.0 mm (0.0551 to 0.0787 in.)

    2. Coat the lip of the transaxle case oil seal with MP grease.
  12. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet and install it onto the transaxle case.
      Fig 16: Identifying Transmission Magnet
      GTY200597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL BEARING LOCK PLATE 
    1. Install the bearing lock plate onto the transaxle case with the bolt.
      Fig 17: Locating Bearing Lock Plate Bolt
      GTY159489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  14. INSTALL NO. 1 OIL RECEIVER PIPE 
    1. Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt.
      Fig 18: Identifying Oil Receiver Pipe No. 1 Bolt
      GTY159393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
  15. INSTALL NO. 2 OIL RECEIVER PIPE 
    1. Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt.
      Fig 19: Identifying Oil Receiver Pipe No. 2 Bolt
      GTY165657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
  16. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    1. Install the reverse restrict pin assembly onto the manual transmission case.
      Fig 20: Installing Reverse Restrict Pin Assembly
      GTY159218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Set the reverse restrict pin assembly in the correct direction.

    2. Using a pin punch (5 mm) and a hammer, install the slotted spring pin onto the reverse restrict pin assembly.
      Fig 21: Identifying Pin Punch, Hammer & Slotted Pin
      GTY159219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Drive in depth

      15.5 to 16.5 mm (0.6102 to 0.6496 in.)

    3. Apply sealant to the reverse restrict pin plug.
      Fig 22: Installing Reverse Restrict Pin Plug Onto Manual Transmission Case
      GTY158805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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) 

  17. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    1. Install the manual transaxle case receiver onto the transaxle case with the bolt.
      Fig 23: Identifying Manual Transaxle Case Receiver & Bolts
      GTY159488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  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
      GTY165423Courtesy 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 Shaft Assembly
      GTY164235Courtesy 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.
      Fig 26: Aligning Mark On Reverse Idler Gear Shaft With Bolt Hole
      GTY242695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  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
      GTY200654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the No. 1 gear shift fork shaft with gear oil and install it.
      Fig 28: Locating Shift Fork Set Bolt
      GTY200655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

    5. Using a brass bar and a hammer, install a new shaft snap ring onto the No. 1 gear shift fork shaft.
      Fig 29: Identifying Brass Bar, Hammer & New Shaft Snap Ring
      GTY165710Courtesy 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.
      Fig 30: Identifying Gear Shift Fork Shaft No. 3
      GTY159229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the reverse shift fork onto the No. 3 gear shift fork shaft.
    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: Identifying Brass Bar, Hammer & New Shift Fork Shaft Snap Rings
      GTY159221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the No. 3 gear shift fork shaft with gear oil and install it.
      Fig 32: Identifying Gear Shift Fork Shaft No. 3
      GTY159222Courtesy 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.
      Fig 33: Identifying Gear Shift Fork Shaft No. 2
      GTY158849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

    2. Coat the 2 shift lock bolts with sealant and install them onto the No. 2 gear shift fork and No. 1 shift head.
      Fig 34: Locating Shift Lock Bolts
      GTY163753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Install the reverse shift arm bracket assembly onto the front transaxle case with the 2 bolts.
      Fig 35: Locating Reverse Shift Arm Bracket Assembly Bolts
      GTY159207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  25. INSTALL MANUAL TRANSMISSION CASE 
    1. Apply FIPG to the manual transmission case as shown in the illustration.
      Fig 36: Applying FIPG To Manual Transmission Case
      GTY177240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

    2. Install the 13 bolts onto the manual transmission side.
      Fig 37: Locating Manual Transmission Side Bolts
      GTY166834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Coat the 3 bolts with sealant and install them onto the manual transaxle side.
      Fig 38: Locating Transaxle Case Side Bolts
      GTY159205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  26. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the reverse idler gear shaft bolt with sealant and install it with a new gasket.
      Fig 39: Locating Reverse Idler Gear Shaft Bolt
      GTY159486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  27. INSTALL NO. 2 LOCK BALL ASSEMBLY 
    1. Coat the No. 2 lock ball assembly with sealant and install it using a hexagon wrench.
      Fig 40: Identifying Lock Ball Assembly No. 2
      GTY166431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  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 Ball
      GTY164288Courtesy 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.
      Fig 42: Identifying Shift Detent Ball Plugs
      GTY165097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

    3. Install the shift detent ball, shift detent ball compression spring, and spring seat onto the transaxle case.
      Fig 43: Identifying Shift Detent Ball Compression Spring
      GTY162221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the threads of the shift detent ball plug with sealant and install it using a hexagon wrench.
      Fig 44: Identifying Shift Detent Ball Plug
      GTY159204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  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
      GTY159202Courtesy 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: Removing Output Shaft Rear Bearing Hole Snap Ring
      GTY159201Courtesy 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: Identifying Shift Fork Shaft Snap Ring
      GTY165702Courtesy 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.
      Fig 48: Identifying Bearing Retainer Rear
      GTY165952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  33. INSTALL 5TH DRIVEN GEAR 
    1. Using SST, install the 5th driven gear onto the output shaft.
      Fig 49: Identifying 5th Driven Gear Onto Output Shaft
      GTY159086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09309-12020 
  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
      GTY162217Courtesy 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
      GTY165703Courtesy 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 Synchronizer Ring No. 3
      GTY157681Courtesy 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.
      Fig 53: Identifying Synchromesh Shifting Keys And Synchromesh Shifting Key Springs
      GTY203046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not set the 2 shifting key spring openings in the same position.

    2. Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft.
      • SST: 09636-20010 
      Fig 54: Installing No. 3 Transmission Clutch Hub
      GTY168448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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

      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) - -
    4. Using a brass bar and a hammer, install a new snap ring onto the input shaft.
      Fig 55: Identifying Clutch Hub No. 3 Shaft Snap Ring
      GTY165637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSPECT 5TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 5th gear thrust clearance.
      Fig 56: Measuring 5Th Gear Thrust Clearance
      GTY167003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  39. INSPECT 5TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 5th gear radial clearance.
      Fig 57: Measuring 5Th Gear Radial Clearance
      GTY162215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.)

      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.
      Fig 58: Installing Gear Shift Fork No. 3
      GTY159225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    2. Coat the gear shift fork lock bolt with sealant and install it onto the No. 3 gear shift fork.
      Fig 59: Installing Gear Shift Fork Lock Bolt
      GTY165627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Engage the 2 gears simultaneously to lock the transmission.
      Fig 60: Installing Manual Transmission Output Shaft Rear Set Nut
      GTY159226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new manual transmission output shaft rear set nut.

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

    3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
      Fig 61: Staking Manual Transmission Output Shaft Rear Set Nut
      GTY159227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 gears.
  42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Apply FIPG to the manual transmission case cover sub-assembly as shown in the illustration.
      Fig 62: Applying FIPG To Manual Transaxle Case Cover Sub-Assembly
      GTY159243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

    2. Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.
      Fig 63: Identifying Manual Transmission Case Cover Sub-Assembly
      GTY159242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  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 & Select Lever Shaft Assembly
      GTY164028Courtesy 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.
      Fig 65: Identifying SST, Hammer & New Control Shaft Cover Oil Seal
      GTY158804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00280
      • SST: 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.
  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.
      Fig 66: Locating Control Shaft Cover Bolts
      GTY166015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  46. INSTALL SHIFT GUIDE PIN 
    1. Coat the threads of the shift guide pin with sealant.
      Fig 67: Locating Shift Gate Pin & Washer
      GTY165134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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) 

  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.
      Fig 68: Locating No. 1 Lock Ball Assembly
      GTY158810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  48. INSTALL SHIFT LEVER DAMPER 
    1. Install the dust boot onto the control shaft cover.
      Fig 69: Identifying Nut And Washer
      GTY202984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER 
    1. Install the dust boot onto the shift and select lever shaft oil seal.
      Fig 70: Locating Floor Shift Control Shift Lever Nut
      GTY158813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  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.
      Fig 71: Locating Selecting Bell Crank Assembly
      GTY162538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      for bolt

      Torque: 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.

  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.
      Fig 72: Removing Back-Up Light Switch Assembly
      GTY183173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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.
    2. Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt.
      Fig 73: Identifying Speedometer Driven Hole Cover Sub-Assembly And Bolts
      GTY204136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  53. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install the manual transmission filler plug onto the manual transmission case with a new gasket.
      Fig 74: Identifying Manual Transmission Filler Plug
      GTY159240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  54. INSTALL DRAIN PLUG SUB-ASSEMBLY 
    1. Install the drain plug onto the manual transmission case with a new gasket.
      Fig 75: Identifying Drain Plug Sub-Assembly
      GTY159241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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