Reassembly [08/2013 - 08/2016]: Procedure
- INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
- Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the differential case assembly.
- SST: 09309-37010
- SST: 09506-35010
- Using SST and a press, install a new front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer to the front transaxle case.
- SST: 09950-60020
- 09951-00680
- SST: 09950-70010
- 09951-07200
- SST: 09950-60020
- Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the differential case assembly.
- INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
- Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the differential case assembly.
- SST: 09636-20010
- SST: 09726-40010
- Using SST and a press, install a new front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer to the manual transmission case.
- SST: 09309-36010
- SST: 09950-60020
- 09951-00730
- SST: 09950-70010
- 09951-07100
HINT:
Use a front differential case rear plate washer of the same thickness as the removed one.
- Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the differential case assembly.
- ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
- Coat the differential case assembly with gear oil and install it to the front transaxle case.
- Install the manual transmission case with the 16 bolts.
Torque: 29.4 N*m (300 kgf*cm, 22 ft.*lbf)
- Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
*1 Front Differential Case Rear Plate Washer - SST: 09564-32011
- Using SST and a torque wrench, measure the preload.
- SST: 09564-32011
Preload (at starting)
New Bearing
1.0 to 1.6 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf)
Used Bearing
0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 12 in.*lbf)
If the preload is out of specification, replace the front differential case rear plate washer with one of a different thickness. Use the table below to select a front differential case rear plate washer which will ensure that the preload is within the specification.
Front Differential Case Rear Plate Washer Thickness
Mark Thickness mm (in.) Mark Thickness mm (in.) 10 2.100 (0.0827) 26 2.500 (0.0984) 11 2.125 (0.0837) 27 2.525 (0.0994) 12 2.150 (0.0846) 28 2.550 (0.100) 13 2.175 (0.0856) 29 2.575 (0.101) 14 2.200 (0.0866) 30 2.600 (0.102) 15 2.225 (0.0876) 31 2.625 (0.103) 16 2.250 (0.0886) 32 2.650 (0.104) 17 2.275 (0.0896) 33 2.675 (0.105) 18 2.300 (0.0906) 34 2.700 (0.106) 19 2.325 (0.0915) 35 2.725 (0.107) 20 2.350 (0.0925) 36 2.750 (0.108) 21 2.375 (0.0935) 37 2.775 (0.109) 22 2.400 (0.0945) 38 2.800 (0.110) 23 2.425 (0.0955) 39 2.825 (0.111) 24 2.450 (0.0965) 40 2.850 (0.112) 25 2.475 (0.0974) - - HINT:
- Select a thicker front differential case rear plate washer to increase the preload or a thinner front differential case rear plate washer to decrease the preload.
- Make a memo as the torque values will be needed to adjust output shaft bearing preload.
- Remove the 16 bolts and manual transmission case.
- Remove the differential case assembly from the front transaxle case.
- Coat the differential case assembly with gear oil and install it to the front transaxle case.
- INSTALL FRONT OUTPUT SHAFT BEARING (OUTER RACE)
- INSTALL REAR OUTPUT SHAFT BEARING (OUTER RACE)
- ADJUST OUTPUT SHAFT BEARING PRELOAD
- Coat the differential case assembly with gear oil and install it to the front transaxle case.
- Coat the output shaft assembly with gear oil and install it to the front transaxle case.
- Install the manual transmission case with the 16 bolts.
Torque: 29.4 N*m (300 kgf*cm, 22 ft.*lbf)
- Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
*1 Rear Output Shaft Bearing Shim - SST: 09564-32011
- Using SST and a torque wrench, measure the preload. Calculate the rear output shaft bearing preload using the following formula.
- SST: 09564-32011
Formula
Measured preload - Differential side bearing preload = Output shaft bearing preload
Bearing Preload (at starting) New bearing 4.3 to 7.4 N*m (44 to 75 kgf*cm, 38 to 65 in.*lbf) Used bearing 2.8 to 4.7 N*m (29 to 48 kgf*cm, 25 to 42 in.*lbf) If the preload is out of specification, replace the rear output shaft bearing shim with one of a different thickness. Use the table below to select a rear output shaft bearing shim which will ensure that the preload is within the specification.
Rear Output Shaft Bearing Shim Thickness
Mark Thickness mm (in.) Mark Thickness mm (in.) 50 1.750 (0.0689) 72 2.300 (0.0906) 51 1.775 (0.0699) 73 2.325 (0.0915) 52 1.800 (0.0709) 74 2.350 (0.0925) 53 1.825 (0.0719) 75 2.375 (0.0935) 54 1.850 (0.0728) 76 2.400 (0.0945) 55 1.875 (0.0738) 77 2.425 (0.0955) 56 1.900 (0.0748) 78 2.450 (0.0965) 57 1.925 (0.0758) 79 2.475 (0.0974) 58 1.950 (0.0768) 80 2.500 (0.0984) 59 1.975 (0.0778) 81 2.525 (0.0994) 60 2.000 (0.0787) 82 2.550 (0.100) 61 2.025 (0.0797) 83 2.575 (0.101) 62 2.050 (0.0807) 84 2.600 (0.102) 63 2.075 (0.0817) 85 2.625 (0.103) 64 2.100 (0.0827) 86 2.650 (0.104) 65 2.125 (0.0837) 87 2.675 (0.105) 66 2.150 (0.0846) 88 2.700 (0.106) 67 2.175 (0.0856) 89 2.725 (0.107) 68 2.200 (0.0866) 90 2.750 (0.108) 69 2.225 (0.0876) 91 2.775 (0.109) 70 2.250 (0.0886) 92 2.800 (0.110) 71 2.275 (0.0896) - - HINT:
Select a thicker rear output shaft bearing shim to increase the preload or a thinner rear output shaft bearing shim to decrease the preload.
- Remove the 16 bolts and manual transmission case.
- Remove the output shaft assembly from the front transaxle case.
- Remove the differential case assembly from the front transaxle case.
- Coat the differential case assembly with gear oil and install it to the front transaxle case.
- INSTALL OUTER SHIFT LEVER OIL SEAL
- INSTALL OUTER NO. 1 SHIFT LEVER
- Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.
*a Mark *b Depth Standard Depth
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
HINT:
Install the inner No. 1 shift lever with its mark facing the outside of the manual transmission case.
- Using a 5 mm pin punch and a hammer, install the inner shift lever slotted spring pin to the inner No. 1 shift lever.
- Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.
- INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY
- INSTALL TRANSMISSION OIL SEPARATOR
- INSTALL NO. 1 OIL RECEIVER PIPE
- INSTALL STRAIGHT PIN
- INSTALL REVERSE RESTRICT PIN ASSEMBLY
- INSTALL BREATHER PLUG
- INSTALL TRANSMISSION OIL SEPARATOR
- INSTALL FRONT TRANSAXLE CASE OIL SEAL
- INSTALL TRANSMISSION MAGNET
- INSTALL INPUT SHAFT COVER
- INSTALL REAR INPUT SHAFT BEARING SHIM
- Install the rear input shaft bearing shim to the manual transmission case.NOTE:
Apply MP grease to the rear input shaft bearing shim to prevent it from falling out of the manual transmission case during reassembly.
- Measure the distance between the end of the manual transmission case and the rear input shaft bearing shim (Dimension A).
*1 Manual Transmission Case *2 Input Shaft Assembly *3 Front Transaxle Case - - *a Dimension A *b Dimension B *c Dimension C - - - Measure the distance between the end of the front transaxle case and the installation surface of the front input shaft bearing (Dimension B).
- Measure the distance between both input shaft bearing outer races (Dimension C).NOTE:
Measure Dimension C with each bearing having no axial clearance.
- Calculate the rear input shaft bearing shim value using the following formula.
Formula
(Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = 0.02 mm (0.000787 in.) to 0.14 mm (0.00551 in.)
If the preload is out of specification, replace the rear input shaft bearing shim with one of a different thickness. Use the table below to select a rear input shaft bearing shim which will ensure that the preload is within the specification.
Rear Input Shaft Bearing Shim Thickness
Mark Thickness mm (in.) Mark Thickness mm (in.) 08 1.30 (0.0512) 14 1.60 (0.0630) 09 1.35 (0.0531) 15 1.65 (0.0650) 10 1.40 (0.0551) 16 1.70 (0.0669) 11 1.45 (0.0571) 17 1.75 (0.0689) 12 1.50 (0.0591) 18 1.80 (0.0709) 13 1.55 (0.0610) 19 1.85 (0.0728) - Coat the rear input shaft bearing shim with MP grease and install it to the manual transmission case.NOTE:
- Do not apply MP grease to the oil grooves.
- The shim should be cleaned before assembly.
- Install the rear input shaft bearing shim to the manual transmission case.
- INSTALL DIFFERENTIAL CASE ASSEMBLY
- INSTALL INPUT SHAFT ASSEMBLY
- Apply gear oil to all sliding and rotating parts.
- Coat the No. 1 gear shift fork shaft assembly with gear oil and install it to the output shaft assembly.
*1 No. 1 Gear Shift Fork Shaft Assembly *2 Output Shaft Assembly - Coat the No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly with gear oil and install them to the input shaft assembly.
*1 No. 2 Gear Shift Fork Shaft Assembly *2 No. 3 Gear Shift Fork Shaft Assembly *3 Input Shaft Assembly - Temporarily install the output shaft assembly, input shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly, and tie them with a rope or string.
- Install the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly to the front transaxle case.
- INSTALL OUTER SELECT LEVER OIL SEAL
- INSTALL OUTER SELECT LEVER
- INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
- Turn the shift and select lever shaft assembly and the shift inter lock plate counterclockwise, and install them to the front transaxle case.
*1 Shift and Select Lever Shaft Assembly *2 Inner Select Lever *3 Shift Inter Lock Plate HINT:
When installing the inner select lever, make sure to engage it with the shift inter lock plate.
- Coat the threads of the inner select lever set bolt with adhesive and install the bolt using a 6 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
- Turn the shift and select lever shaft assembly and the shift inter lock plate counterclockwise, and install them to the front transaxle case.
- INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
- INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY
- INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
- Coat the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.
*a Parallel *b Reverse Idler Gear Shaft Bolt Installation Surface *c Screw Hole NOTE:Make sure that the reverse idler gear shaft bolt installation surface of the reverse idler gear is parallel to the screw hole on the front transaxle case.
HINT:
Raise the edge of the reverse shift arm bracket assembly and install it to the reverse shift fork shaft assembly.
- Coat the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.
- INSTALL MANUAL TRANSMISSION CASE
- Apply FIPG to the manual transmission case as shown in the illustration.
FIPG
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTE:- Remove any oil from the contact surfaces.
- Install the parts within 10 minutes of application. Otherwise, the seal packing (FIPG) must be removed and reapplied.
*a FIPG
(Seal Diameter 1.2 mm (0.0472 in.)) - Push the outer No. 1 shift lever and temporarily install the manual transmission case.
HINT:
Pushing on the outer No. 1 shift lever allows the manual transmission case to be temporarily installed.
- Pull the outer No. 1 shift lever out and turn it counterclockwise.
- Install the manual transmission case with the 16 bolts.
Torque: 29.4 N*m (300 kgf*cm, 22 ft.*lbf)
- Apply FIPG to the manual transmission case as shown in the illustration.
- INSTALL OUTER SHIFT LEVER E RING
- INSTALL FRONT DRIVE SHAFT OIL SEAL LH
- INSTALL FRONT DRIVE SHAFT OIL SEAL RH
- Using SST and a hammer, install a new front drive shaft oil seal RH to the front transaxle case.
- SST: 09630-24014
- 09620-24051
- SST: 09950-60010
- 09951-00410
- 09951-00530
- 09952-06010
- SST: 09950-70010
- 09951-07100
*a Depth Standard Depth
1.2 to 2.2 mm (0.0472 to 0.0866 in.)
NOTE:Do not damage the oil seal lip.
- SST: 09630-24014
- Coat the lip of the front drive shaft oil seal RH with MP grease.
- Using SST and a hammer, install a new front drive shaft oil seal RH to the front transaxle case.
- INSTALL SHIFT DETENT BALL
- Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.
- Coat the threads of the 2 shift detent ball plugs with adhesive and install them using a 6 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
NOTE:Be careful not to drop the shift detent balls into the manual transmission case.
- Install the shift detent ball and shift detent ball compression spring to the manual transmission case.
- Coat the threads of the shift detent ball plug with adhesive and install it using a 6 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
NOTE:Be careful not to drop the shift detent ball into the manual transmission case.
- Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.
- INSTALL LOCK BALL PIN
- Install the lock ball pin and shift and select lever shaft compression spring to the manual transmission case.
- Coat the threads of the shift and select lever shaft straight screw with head plug with adhesive and install it using a 10 mm hexagon socket wrench.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
- Install the lock ball pin and shift and select lever shaft compression spring to the manual transmission case.
- INSTALL REVERSE IDLER GEAR SHAFT BOLT
- INSTALL NO. 1 LOCK BALL ASSEMBLY
- INSTALL TRANSMISSION CASE PLUG
- INSTALL NO. 1 CLUTCH HOUSING COVER
- INSTALL RELEASE CYLINDER BLEEDER PLUG
- Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
- Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.
- INSTALL RELEASE CYLINDER BLEEDER PLUG CAP
- Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.
- INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
Refer to PROCEDURE - Step 4 Refer to PROCEDURE - Step 4
- REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
Refer to PROCEDURE - Step 5 Refer to PROCEDURE - Step 5
- INSPECT CLUTCH PIPE LINE
Refer to PROCEDURE - Step 6 Refer to PROCEDURE - Step 6
- INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
Refer to PROCEDURE - Step 7 Refer to PROCEDURE - Step 7
- INSTALL CONTROL CABLE BRACKET ASSEMBLY
- INSTALL TRANSMISSION CASE PLUG
- INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
- INSTALL MANUAL TRANSMISSION FILLER PLUG
- INSTALL MANUAL TRANSMISSION DRAIN PLUG