Manual Transaxle Unit: Installation

1. Install the No. 5 synchronizer ring middle, No. 5 synchronizer ring outer and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, fix them in place with the synchronizer pull ring snap ring.

Fig 1: Installing Synchronizer Pull Ring

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1. Check that the No. 5 synchronizer ring middle rotates smoothly.
   Fig 2: Rotating No. 5 Synchronizer Ring Middle

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2. Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub.

Fig 3: Identifying No. 5 Synchronizer Ring Middle Does Not Rotate

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1. Install the No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.
   NOTE: Align the projection of the shifting key spring with the hole of the No. 3 clutch hub and install it.
2. Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.

Fig 4: Identifying No. 3 Synchromesh Shifting Key Spring

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1. Using SST and a hammer, install a ndw front transaxle case cover oil seal.

   SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150) 

   Standard depth: -0.5 to 0.5mm (-0.020 to 0.020 in)

2. Coat the lip of the oil seal with MP grease.

Fig 5: Installing Front Transaxle Case Cover Oil Seal

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1. Using SST and a hammer, tap in the front tapered roller bearing (outer race) to the front transaxle case.

   SST 09950-60020 (09951 -00910), 09950-70010 (09951-07100, 09951-07150) 

   Fig 6: Tapping In Front Tapered Roller Bearing

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2. Using SST and a press, press in the front tapered roller bearing (inner race) to the front differential case.

SST 09950-70010 (09951-07100, 09951-07150), 09608-10010 

Fig 7: Pressing In Front Tapered Roller Bearing

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1. Install the rear shim.
2. Using SST and a hammer, tap in the rear tapered roller bearing (outer race).

   SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) 

   Fig 8: Tapping In Rear Tapered Roller Bearing (Outer Race)

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3. Using SST and a press, press in the rear tapered roller bearing (inner race).

SST 09631-12090, 09950-60010 (09951-00600), 09950-70010 (09951-07100) 

Fig 9: Identifying Rear Tapered Roller Bearing (Inner Race)

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1. Using SST and a hammer, tap in a new oil seal to the transmission case.

   SST 09608-32010, 09950-70010 (09951-07150) 

   Standard depth: 

   3.0 to 4.0 mm (0.118 to 0.158 in.) 

2. Coat the oil seal lip with MP grease.

Fig 10: Tapping Oil Seal To Transmission Case

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1. Using SST and a hammer, tap in the rear bearing (outer race) to the transmission case.

SST 09950-60020 (09951 -00680), 09950-70010 (09951-07100) 

Standard clearance: 

3.8 to 4.4 mm (0.150 to 0.173 in.) 

Fig 11: Identifying Tapping Rear Bearing To Transmission Case

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1. Coat the shaft cover with MP grease, and install it to the transaxle case.

Fig 12: Identifying Output Shaft Cover

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1. Using SST and a hammer, tap in the front bearing (outer race).

SST 09950-60020 (09951 -00730), 09950-70010 (09951-07100) 

Fig 13: Identifying Output Shaft Front Bearing (Outer Race)

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1. Install the output shaft to the transaxle case.
   Fig 14: Identifying Output Shaft To Transaxle Case

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2. Install the transmission case to the transaxle case with the 14 bolts.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 15: Identifying Transmission Case And Bolts

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3. Install the 3 bolts on the transaxle side.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 16: Identifying Transaxle Side Bolts

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4. Install the output shaft rear bearing shim to the output shaft.
   Fig 17: Identifying Output Shaft Rear Bearing Shim

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5. Using a T45 "TORX" socket, install the rear bearing retainer with the 7 "TORX" screws to the transmission case.

   Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

   Fig 18: Identifying Rear Bearing Retainer Torx Screws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
7. Temporarily install the output shaft rear set nut.
8. Using a socket wrench and torque wrench, inspect the preload.

   Standard preload 

   PRELOAD SPECIFICATION
   
   

   Bearing	Torque
   New	0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm 7.1 to 14.2 in.lbf)
   Used	0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm 4.4 to 8.9 in.lbf)

   Fig 19: Identifying Preload

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9. If preload is out of specification, select a proper output shaft rear bearing shim and adjust it.

   HINT:

   The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf)

   Standard shim thickness 

   SHIM THICKNESS SPECIFICATION
   
   

   Part No	Mark	Thickness
   90564-59001	0	1.30 mm (0.0512 in.)
   90564-59002	1	1.35 mm (0.0531 in.)
   90564-59003	2	1.40 mm (0.0551 in.)
   90564-59004	3	1.45 mm (0.0571 in.)
   90564-59005	4	1.50 mm (0.0591 in.)
   90564-59006	5	1.55 mm (0.0610 in.)
   90564-59007	6	1.60 mm (0.0630 in.)
   90564-59008	7	1.65 mm (0.0650 in.)
   90564-59009	8	1.70 mm (0.0669 in.)
   90564-59010	9	1.75 mm (0.0689 in.)
   90564-59011	A	1.80 mm (0.0709 in.)
   90564-59012	B	1.85 mm (0.0728 in.)
   90564-59013	C	1.90 mm (0.0748 in.)
   90564-59014	D	1.95 mm (0.0768 in.)
   90564-59015	E	2.00 mm (0.0787 in.)
   90564-59016 j F	F	2.05 mm (0.0807 in.)
   90564-59017	G	2.10 mm (0.0827 in.)
   90564-59018	H	2.15 mm (0.0846 in.)
   90564-59019	J	2.20 mm (0.0866 in.)
   90564-59020	K	2.25 mm (0.0886 in.)
   90564-59021	L	2.30 mm (0.0906 in.)
   90564-59022	M	2.35 mm (0.0925 in.)
   90564-59023	N	2.40 mm (0.0945 in.)
   90564-59024	0	2.45 mm (0.0965 in.)
   90564-59025	P	2.50 mm (0.0984 in.)

10. Remove the output shaft rear set nut from the output shaft.
11. Using a T45 "TORX" socket, remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case.
    Fig 20: Identifying Manual Transmission Case Torx Screws

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12. Remove the output shaft rear bearing shim from the output shaft.
    Fig 21: Identifying Output Shaft Rear Bearing Shim

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13. Remove the 3 bolts.
    Fig 22: Identifying Bolts

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14. Remove the 14 bolts and transmission case from the transaxle case.
    Fig 23: Identifying Transmission Case Bolts

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15. Remove the output shaft assembly from the front transaxle case.

Fig 24: Identifying Output Shaft Assembly

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1. Install the differential case assembly to the transaxle case.
   Fig 25: Identifying Differential Case Assembly

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2. Install the 14 bolts and transmission case to the transaxle case.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 26: Identifying Transmission Case Bolts

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3. Install the 3 bolts on the front transaxle case side.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 27: Identifying Bolts On Front Transaxle Case Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Turn the differential case in both directions to make sure that it starts to turn smoothly.
5. Using SST and a torque wrench, measure the preload.

   Standard preload 

   PRELOAD SPECIFICATION
   
   

   Bearing	Torque
   New	0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf)
   Used	0.5 to 1.0 N*m (5.10 to 10.2 kgf*cm, 4.4 to 8.9 in.*lbf)

   Fig 28: Measuring Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the preload is out of specification, select a proper front differential case rear shim and adjust it.

   HINT:

   The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf).

   Standard shim thickness 

   SHIM THICKNESS SPECIFICATION
   
   

   Part No.	Mark	Thickness
   90564-56055	0	2.00 mm (0.0787 in.)
   90564-56056	1	2.05 mm (0.0807 in.)
   90564-56057	2	2.10 mm (0.0827 in.)
   90564-56058	3	2.15 mm (0.0846 in.)
   90564-56059	4	2.20 mm (0.0866 in.)
   90564-56060	5	2.25 mm (0.0886 in.)
   90564-56061	6	2.30 mm (0.0906 in.)
   90564-56062	7	2.35 mm (0.0925 in.)
   90564-56063	8	2.40 mm (0.0945 in.)
   90564-56064	9	2.45 mm (0.0965 in.)
   90564-56065	A	2.50 mm (0.0984 in.)
   90564-56066	B	2.55 mm (0.1004 in.)
   90564-56067	C	2.60 mm (0.1024 in.)
   90564-56068	D	2.65 mm (0.1043 in.)
   90564-56069	E	2.70 mm (0.1063 in.)
   90564-56070	F	2.75 mm (0.1083 in.)
   90564-56071	G	2.80 mm (0.1102 in.)
   90564-56072	H	2.85 mm (0.1122 in.)

6. Remove the 3 bolts.
   Fig 29: Identifying Bolts

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7. Remove the 14 bolts and transmission case from the transaxle case.
   Fig 30: Identifying Transmission Case Bolts

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8. Remove the differential case assembly from the transaxle case.

Fig 31: Identifying Differential Case Assembly

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

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

   Standard distance: 

   1 to 2 mm (0.04 to 0.08 in.) 

Fig 32: Identifying Tapping In Oil Seal To Transaxle Case
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2. Coat the lip of the oil seal with MP grease.

1. Coat the input shaft front bearing with gear oil, and using SST, install it to the transaxle case.

SST 09950-60010(09951-00570), 09950-70010 (09951-07150) 

Standard distance: 

4.28 to 4.60 mm (0.1685 to 0.1811 in.) 

Fig 33: Identifying Front Input Shaft Bearing

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1. Install the 3 bolts and the receiver to the transaxle case.

Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

Fig 34: Identifying Manual Transaxle Case Receiver Bolts

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1. Coat the differential case tapered roller bearing with gear oil, and install the differential case to the transaxle case.
   Fig 35: Identifying Differential Case Assembly

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1. Apply gear oil to each sliding part of the output shaft.
Fig 36: Identifying Output Shaft Assembly
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2. Slightly lift up on the differential case at an angle, and install the output shaft to the transaxle case.

1. Apply gear oil to each sliding part of the input shaft.
2. Install the input shaft to the transaxle case while tilting the output shaft.

Fig 37: Identifying Input Shaft To Transaxle Case

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1. Coat the No. 2 gear shift fork with gear oil, and install it to the input shaft assembly.

Fig 38: Identifying No. 2 Gear Shift Fork

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1. Install the reverse shift fork to the No. 3 gear shift fork shaft.
Fig 39: Identifying Reverse Shift Fork To No. 3 Gear Shift Fork Shaft
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2. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the No. 3 gear shift fork shaft.
3. Apply gear oil to each sliding part of the No. 3 gear shift fork shaft, and install it to the transaxle case.
   Fig 40: Identifying No. 3 Gear Shift Fork Shaft

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1. Apply gear oil to each sliding part of the No. 1 gear shift fork, and install it to the output shaft assembly.

Fig 41: Identifying No. 1 Gear Shift Fork

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1. Apply gear oil to each sliding part of the No. 2 gear shift fork shaft and No. 1 gear shift head, and install them to the transaxle case.
   Fig 42: Identifying No. 2 Gear Shift Fork

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2. Install the shift fork set bolt and shift head set bolt to the No. 1 gear shift head and No. 2 gear shift fork.

Fig 43: Identifying Shift Fork Set Bolt And Shift Head Set Bolt

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1. Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.

Fig 44: Identifying Reverse Shift Fork Roller

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1. Using a brass bar and hammer, tap in the shaft snap ring to the No. 1 shift fork shaft.
   Fig 45: Identifying No. 1 Gear Shift Fork Shaft

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2. Install the No. 1 gear shift fork shaft to the transaxle case.
   Fig 46: Identifying No. 1 Gear Shift Fork Shaft To Transaxle Case

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3. Install the shift fork set bolt to the No. 1 gear shift fork.

Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

Fig 47: Identifying Shift Fork Set Bolt

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1. Install the reverse shift arm bracket to the transaxle case with the 2 bolts.

Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

Fig 48: Identifying Reverse Shift Arm Bracket Bolts

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1. Coat the reverse idler gear and thrust washer with gear oil, and install them to the reverse idler gear shaft.
   Fig 49: Identifying Reverse Idler Gear Sub-Assembly

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2. Install the reverse idler gear with the reverse idler gear shaft to the transaxle case.

   HINT:

   Align the mark of the reverse idler gear shaft with the hole of the bolts.

   Fig 50: Identifying Mark Of Reverse Idler Gear Shaft

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

Fig 51: Identifying Transmission Magnet

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1. Install the reverse restrict pin to the transaxle case.
2. Using a 5 mm pin punch, install the slotted spring pin.

   Standard clearance: 

   12.5 to 13.5 mm (0.492 to 0.531 in.) 

   Fig 52: Identifying Slotted Spring Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the reverse restrict pin plug with adhesive 1324, and using a 6 mm hexagon wrench, install it to the manual transmission case.

Torque: 13 N*m (133 kgf*cm, 9.6 ft.*lbf) 

Fig 53: Identifying Reverse Restrict Pin Plug

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1. Install the oil receiver pipe to the transmission case with the bolt.

Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

Fig 54: Identifying Oil Receiver Pipe To Transmission Case With Bolt

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1. Install the oil receiver pipe to the transmission case with the bolt.

Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

Fig 55: Identifying Oil Receiver Pipe To Transmission Case With Bolt

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1. Apply FIPG to the transmission case in a continuous line, as shown in the illustration.

   FIPG: 

   Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

   NOTE: Install the part within 10 minutes after applying the packing material (FIPG).
   Fig 56: Identifying FIPG To Transmission Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transmission case to the transaxle case with the 14 bolts.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 57: Identifying Transaxle Case Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 3 bolts with adhesive, and install them on the transaxle case side.

Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

Adhesive: 

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

1. Install the clutch tube bracket with the bolt.

Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

Fig 58: Identifying Clutch Tube Bracket With Bolt

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1. Coat the reverse idler gear shaft bolt with adhesive, and install a new reverse idler gear shaft gasket and the reverse idler gear shaft bolt to the transmission case.

Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

Adhesive: 

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

Fig 59: Identifying Reverse Idler Gear Shaft Bolt

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1. Using a brass bar and hammer, tap in the shaft snap ring to the No. 1 gear shift fork shaft.
   Fig 60: Identifying Shift Fork Shaft Shaft Snap Ring

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2. Using a brass bar and hammer, tap in the shaft snap ring to the No. 2 gear shift fork shaft.

Fig 61: Identifying Tapping In Shaft Snap Ring

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1. Using a snap ring expander, install the shaft snap ring.

Fig 62: Identifying Shaft Snap Ring

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1. Install the output shaft rear bearing shim to the output shaft.

Fig 63: Identifying Output Shaft Rear Bearing Shim

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1. Coat the 7 bolts with adhesive, and using a T45 "TORX" socket, install the bearing retainer with the bolts.

Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

Adhesive: 

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

Fig 64: Identifying Bearing Retainer With Bolts

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

SST 09309-12020 

Fig 65: Identifying 5Th Driven Gear To Output Shaft

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1. Coat the needle roller bearing with gear oil, and install it to the input shaft.

Fig 66: Identifying 5th Gear Needle Roller Bearing

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

Fig 67: Identifying 5th Gear

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1. Using SST, install the No. 3 transmission clutch hub to the input shaft.

   SST 09950-30012 (09951-03010, 09953-03010, 09954-03010) 

   NOTE: Align the projection of the synchronizer ring with the hole of the 5th gear and install it.
   Fig 68: Identifying No. 3 Transmission Clutch Hub To Input Shaft

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2. Install the No. 3 transmission hub sleeve and No. 3 gear shift fork to the No. 3 transmission clutch hub.
   Fig 69: Identifying No. 3 Transmission Hub Sleeve And No. 3 Gear Shift Fork

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the shift fork set bolt with adhesive, and install it to the No. 3 gear shift fork.

   Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

   Adhesive: 

   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

   Fig 70: Identifying Gear Shift Fork Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Select the No. 3 transmission clutch hub shaft snap ring that allows the minimum amount of axial play. Using a brass bar and hammer, tap in the No. 3 transmission clutch hub shaft snap ring.

Standard clearance: 

0.1 mm (0.004 in.) or less 

Standard snap ring 

Fig 71: Identifying No. 3 Transmission Clutch Hub Shaft Snap Ring

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

Standard clearance: 

0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

If the clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.

Fig 72: Measuring 5th Gear Radial Clearance

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

Standard clearance: 

0.10 to 0.65 mm (0.0039 to 0.0260 in.) 

If the clearance is out of specification, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

Fig 73: Measuring 5th Gear Thrust Clearance

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1. Engage the 2 gears simultaneously to lock the transmission.
   Fig 74: Identifying Gears

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2. Install a new transmission output shaft rear set nut.

   Torque: 123 N*m (1,254 kgf*cm, 90 ft.*lbf) 

   Fig 75: Identifying Transmission Output Shaft Rear Set Nut

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3. Using a chisel and hammer, stake the rear set nut.
4. Disengage the 2 gears.

Fig 76: Identifying Rear Set Nut

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1. Apply FIPG to the transaxle case cover, as shown in the installation.

   FIPG: 

   Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

   NOTE: Install the part within 10 minutes after applying the packing material (FIPG).
   Fig 77: Applying FIPG To Transaxle Case Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transmission case cover to the transaxle case with the 10 bolts.

Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

Fig 78: Identifying Transmission Case Cover Bolts

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1. Install a new gasket and the drain plug to the transmission case.

Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

Fig 79: Identifying Drain Plug Sub-Assembly

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1. Install a new gasket and the filler plug to the transaxle case.

Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

Fig 80: Identifying Gasket And Filler Plug

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1. Coat the shift and select lever shaft with gear oil, and install it to the transmission case.

Fig 81: Identifying Shift And Select Lever Shaft

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1. Coat the 4 bolts with adhesive, and install a new gasket and the control shaft cover with the 4 bolts.

Adhesive: 

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

Fig 82: Identifying Control Shaft Cover With Bolts

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1. Install a new gasket and the back-up light switch to the manual transmission case.

   Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

   Fig 83: Identifying Back-Up Light Switch

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1. Install a new gasket and the breather plug to the case.

Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

Fig 84: Identifying Breather Plug

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1. Install the No. 1 lock ball to the transmission case.

Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

Fig 85: Identifying No. 1 Lock Ball

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1. Install the control shift lever with the shift outer lever lever lock pin to the shift and select lever shaft.
2. Install the spring washer with the nut.

Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

Fig 86: Identifying Control Shift Lever With Nut

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1. Install the shift and select lever bush to the selecting bellcrank.
2. Coat the 2 bolts with adhesive, and install the selecting bellcrank to the transmission case with the 2 bolts.

Adhesive: 

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

Fig 87: Selecting Bellcrank To Transmission Case With Bolts

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1. Install a new O-ring to the hole cover.
2. Install the hole cover to the transmission case with the bolt.

Torque: 5.5 N*m (56 kgf*cm, 48 ft.*lbf) 

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

1. Using a deep socket wrench, install the release fork support to the transaxle case.

Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf) 

Fig 88: Identifying Release Fork Support

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1. Coat the clutch release bearing with release hub grease, and install it to the clutch release fork with the clutch release bearing clip.

Sealant: 

Toyota Genuine Release Hub Grease or equivalent