Reassembly [08/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.

INSTALL FRONT INPUT SHAFT BEARING

Using a press, install the front input shaft bearing to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 3RD GEAR NEEDLE ROLLER BEARING

Coat the 3rd gear needle roller bearing with gear oil and install it to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 3RD GEAR

Coat the 3rd gear with gear oil and install it to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 3 SYNCHRONIZER RING

Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 TRANSMISSION CLUTCH HUB

Coat the No. 2 transmission clutch hub with gear oil.

Position the No. 2 transmission clutch hub on the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Position the No. 2 transmission clutch hub correctly as shown in the illustration.

Using SST and a press, install the No. 2 transmission clutch hub to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09527-21011
SST: 09316-60011
1. 09316-00011

NOTE:

When installing the No. 2 transmission clutch hub, align the protrusion of the No. 3 synchronizer ring with the cutout of the No. 2 transmission clutch hub.

INSTALL NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

Select a No. 2 clutch hub setting shaft snap ring that will allow minimal axial play.

Standard Clearance

0.1 mm (0.00394 in.) or less

No. 2 Clutch Hub Setting Shaft Snap Ring Thickness

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
0	2.27 (0.0894)	4	2.47 (0.0972)
1	2.32 (0.0913)	5	2.52 (0.0992)
2	2.37 (0.0933)	6	2.57 (0.101)
3	2.42 (0.0953)	7	2.62 (0.103)

Using a snap ring expander, install a new No. 2 clutch hub setting shaft snap ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Be sure to properly install the No. 2 clutch hub setting shaft snap ring because it easily expands.
Do not damage the journal surface of the No. 2 clutch hub setting shaft snap ring.

INSTALL NO. 2 SYNCHROMESH SHIFTING KEY

Install the 3 No. 2 synchromesh shifting keys to the No. 2 transmission clutch hub.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 TRANSMISSION HUB SLEEVE

Coat the No. 2 transmission hub sleeve with gear oil.

Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Align

NOTE:

When installing the No. 2 transmission hub sleeve, align the protrusion of the No. 2 transmission hub sleeve with the cutout of the No. 2 transmission clutch hub.

INSTALL 4TH GEAR BEARING SPACER

Install the 4th gear bearing spacer to the No. 2 transmission clutch hub.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 4TH GEAR NEEDLE ROLLER BEARING

Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install the 4th gear needle roller bearing to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OUTER 2ND SYNCHRONIZER RING

Coat the outer 2nd synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

When installing the outer 2nd synchronizer ring, align the protrusion of the outer 2nd synchronizer ring with the cutout of the No. 2 transmission clutch hub.

INSTALL 4TH GEAR

Coat the 4th gear with gear oil and install it to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Install the 4th gear as shown in the illustration.

INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL

Coat the inner 5th gear bearing race lock ball with gear oil and install it to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INNER 5TH GEAR BEARING RACE

Coat the inner 5th gear bearing race with gear oil and install it to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Align the groove of the inner 5th gear bearing race with the ball.

INSTALL 5TH GEAR NEEDLE ROLLER BEARING

Coat the 5th gear needle roller bearing and inner 5th gear bearing race with gear oil and install the inner 5th gear bearing race to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 5TH GEAR

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Install the 5th gear as shown in the illustration.

INSTALL NO. 5 SYNCHRONIZER RING (for 5th Gear)

Coat the No. 5 synchronizer ring (for 5th gear) with gear oil and install it to the 5th gear.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 3 TRANSMISSION CLUTCH HUB

Coat the No. 3 transmission clutch hub with gear oil.

Position the No. 3 transmission clutch hub on the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Position the No. 3 transmission clutch hub correctly as shown in the illustration.

Using SST and a press, install the No. 3 transmission clutch hub to the input shaft.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09309-37010
SST: 09527-21011

NOTE:

When installing the No. 3 transmission clutch hub, align the protrusion of the No. 5 synchronizer ring (for 5th gear) with the cutout of the No. 3 transmission clutch hub.

INSTALL NO. 3 SYNCHROMESH SHIFTING KEY

Install the 3 No. 3 synchromesh shifting keys to the No. 3 transmission clutch hub.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL

Coat the inner 6th gear bearing race lock ball with gear oil and install it to the input shaft.

INSTALL NO. 3 TRANSMISSION HUB SLEEVE

Coat the No. 3 transmission hub sleeve with gear oil.

Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub.

NOTE:

Install the No. 3 transmission hub sleeve as shown in the illustration.

INSTALL INNER 6TH GEAR BEARING RACE

Coat the inner 6th gear bearing race with gear oil and install it to the input shaft.

NOTE:

Align the groove of the inner 6th gear bearing race with the ball.

INSTALL 6TH GEAR NEEDLE ROLLER BEARING

Coat the 6th gear needle roller bearing with gear oil and install the 6th gear needle roller bearing to the input shaft.

INSTALL NO. 5 SYNCHRONIZER RING (for 6th Gear)

Coat the No. 5 synchronizer ring (for 6th gear) with gear oil and install it to the No. 3 transmission clutch hub.

NOTE:

When installing the No. 5 synchronizer ring (for 6th gear), align the protrusion of the No. 5 synchronizer ring (for 6th gear) with the cutout of the No. 3 transmission clutch hub.

INSTALL 6TH GEAR SUB-ASSEMBLY

Coat the 6th gear sub-assembly with gear oil and install it to the input shaft.

NOTE:

Install the 6th gear sub-assembly as shown in the illustration.

INSTALL REAR INPUT SHAFT RADIAL BALL BEARING

Using SST and a press, install the rear input shaft radial ball bearing to the input shaft.

SST: 09527-21011
SST: 09608-04031

INSTALL REAR INPUT SHAFT BEARING SHAFT SNAP RING

Select a new rear input shaft bearing shaft snap ring that will allow minimal axial play.

Standard Clearance

0.1 mm (0.00394 in.) or less

Rear Input Shaft Bearing Shaft Snap Ring Thickness

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	1.65 (0.0649)	H	2.00 (0.0787)
B	1.70 (0.0669)	J	2.05 (0.0807)
C	1.75 (0.0689)	K	2.10 (0.0827)
D	1.80 (0.0709)	L	2.15 (0.0846)
E	1.85 (0.0728)	M	2.20 (0.0866)
F	1.90 (0.0748)	N	2.25 (0.0886)
G	1.95 (0.0768)	P	2.30 (0.0906)

Using a snap ring expander, install a new rear input shaft bearing shaft snap ring.

NOTE:

Be sure to properly install the rear input shaft bearing shaft snap ring because it easily expands.
Do not damage the journal surface of the rear input shaft bearing shaft snap ring.

INSPECT 3RD GEAR RADIAL CLEARANCE
See step 8
INSPECT 4TH GEAR RADIAL CLEARANCE
See step 7
INSPECT 5TH GEAR RADIAL CLEARANCE
See step 6
INSPECT 6TH GEAR RADIAL CLEARANCE
See step 5
INSPECT 3RD GEAR THRUST CLEARANCE
See step 4
INSPECT 4TH GEAR THRUST CLEARANCE
See step 3
INSPECT 5TH GEAR THRUST CLEARANCE
See step 2
INSPECT 6TH GEAR THRUST CLEARANCE
See step 1