Manual Transaxle Unit: Reassembly

INSTALL SYNCHRONIZER PULL RING
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: Removing No 5 Synchronizer Ring Middle, No 5 Synchronizer Ring Outer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 5 SYNCHRONIZER RING MIDDLE
1. Check that the No. 5 synchronizer ring middle rotates smoothly.
  
  Fig 2: Checking No. 5 Synchronizer Ring Middle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub.
  
  Fig 3: Checking No. 5 Synchronizer Ring Middle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 SYNCHROMESH SHIFTING KEY SPRING
1. Install the No. 3 synchromesh shifting key spring to the No. 3 transaxle 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 transaxle clutch hub.
  
  Fig 4: Installing No 3 Synchromesh Shifting Key Spring To No 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
  - Align the projection of the shifting key spring with the hole of the No. 3 clutch hub and install it.
INSTALL TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, tap in a new front transaxle case cover oil seal.
  SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150)
  
  Standard depth: -0.5 to 0.5 mm (-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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a hammer, tap in the front tapered roller bearing (outer race) to the front differential case.
  SST 09950-60020 (09951-00910), 09950-70010 (09951-07100, 09951-07150)
  
  Fig 6: Tapping In Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Pressing In Rear Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, tap in a new oil seal to the transaxle 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 Transaxle Case With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING
1. Using SST and a hammer, tap in the rear bearing (outer race) to the transaxle 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: Tapping Rear Bearing (Outer Race) To Transaxle Case With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT COVER
1. Coat the shaft cover with MP grease, and install it to the transaxle case.
  NOTE: Align the projection of the output shaft with the transaxle groove and install it.
  
  Fig 12: Installing Output Shaft Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT FRONT BEARING
1. Using SST and a hammer, tap in the front bearing (outer race).
  SST 09950-60020 (09951-00730), 09950-70010 (09951-07100)
  
  Fig 13: Installing Output Shaft Front Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST OUTPUT SHAFT BEARING PRELOAD

Install the output shaft to the transaxle case.

Fig 14: Installing Output Shaft To Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the transaxle case to the transaxle case with the 14 bolts.
Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)

Fig 15: Installing Transmission Case To Transaxle Case With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 3 bolts on the transaxle side.
Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)

Fig 16: Installing Bolts On Transaxle Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the output shaft rear bearing shim to the output shaft.

Fig 17: Installing Output Shaft Rear Bearing Shim To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a T45 "TORX" socket, install the rear bearing retainer to the transaxle case with the 7 "TORX" screws.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

Fig 18: Installing Rear Bearing Retainer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Turn the output shaft in both directions and check that it turns smoothly.
Temporarily install the output shaft rear set nut.

Using a socket wrench and torque wrench, inspect the preload.

Standard preload

BEARING SPECIFICATION

Bearing	Specified Condition
New	0.8 to 1.6 Nm (8.16 to 16.32 kgfcm, 7.1 to 14.2 in.lbf)
Used	0.5 to 1.0 Nm (5.10 to 10.20 kgfcm, 4.4 to 8.9 in.lbf)

Fig 19: Checking Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

THICKNESS CHART

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 (0.0669 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 (0.787 in.)
90564-59016	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	P	2.45 mm (0.0965 in.)
90564-59025	Q	2.50 mm (0.0984 in.)

Remove the output shaft rear set nut from the output shaft.
Using a T45 "TORX" socket, remove the 7 "TORX" screws and rear bearing retainer from the manual transaxle case.

Fig 20: Removing Torx Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the output shaft rear bearing shim from the output shaft.

Fig 21: Removing Output Shaft Rear Bearing Shim From Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 3 bolts.

Fig 22: Removing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 14 bolts and transaxle case from the transaxle case.

Fig 23: Removing Bolts And Transmission Case From Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the output shaft assembly from the front transaxle case.

Fig 24: Removing Output Shaft Assembly From Front Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST TAPERED ROLLER BEARING PRELOAD

Install the bearing to the transaxle case.

Fig 25: Installing Differential Case Assembly To Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 14 bolts and transaxle case to the transaxle case.
Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)

Fig 26: Installing Bolts And Transmission Case To Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 3 bolts on the front transaxle case side.
Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
Turn the differential case in both directions and check that it turns smoothly.

Fig 27: Installing Bolts On Front Transaxle Case Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a torque wrench, measure the preload.

SST 09564-32011

Standard preload

BEARING SPECIFICATION

Bearing	Specified Condition
New	0.8 to 1.6 Nm (8.16 to 16.32 kgfcm, 7.1 to 14.2 in.*lbf)
Used	0.5 to 1.0 Nm (5.10 to 10.2 kgfcm, 4.4 to 8.9 in.*lbf)

Fig 28: Measuring Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

THICKNESS CHART

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.)

Remove the 14 bolts and transaxle case from the transaxle case.

Fig 30: Removing Bolts And Transmission Case From Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the bearing from the transaxle case.

Fig 31: Removing Differential Case Assembly From Transaxle Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT TRANSAXLE CASE OIL SEAL
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 (0.039 to 0.079 in.)
2. Coat the lip of the oil seal with MP grease.
  
  Fig 32: Installing Oil Seal To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT FRONT BEARING
1. Coat the input shaft front bearing with gear oil, and using SST, tap in 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: Installing Front Input Shaft Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSAXLE CASE RECEIVER
1. Install the receiver to the transaxle case with the 3 bolts.
  Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  
  Fig 34: Installing Bolts And Receiver To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL CASE ASSEMBLY
1. Coat the differential case tapered roller bearing with gear oil, and install the differential case to the transaxle case.
  
  Fig 35: Installing Differential Case Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT ASSEMBLY
1. Apply gear oil to each sliding part of the output shaft.
2. Slightly lift up on the differential case at an angle, and install the output shaft to the transaxle case.
  
  Fig 36: Installing Output Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT ASSEMBLY
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: Installing Input Shaft To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 GEAR SHIFT FORK
1. Coat the No. 2 gear shift fork with gear oil, and install it to the input shaft assembly.
  
  Fig 38: Installing No. 2 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 GEAR SHIFT FORK
1. Install the reverse shift fork to the No. 3 gear shift fork shaft.
2. Using a brass bar and hammer, tap in the 2 shift fork shaft snap rings to the No. 3 gear shift fork shaft.
  
  Fig 39: Installing Reverse Shift Fork To No. 3 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Installing No. 3 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 GEAR SHIFT FORK
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: Installing No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 GEAR SHIFT FORK
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: Installing No. 2 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf)
  
  Fig 43: Installing Shift Fork Set Bolt And Shift Head Set Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE SHIFT FORK ROLLER
1. Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.
  
  Fig 44: Installing Reverse Shift Fork Roller
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 GEAR SHIFT FORK SHAFT
1. Using a brass bar and hammer, tap in the shaft snap ring to the No. 1 shift fork shaft.
  
  Fig 45: Installing No. 1 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 gear shift fork shaft to the transaxle case.
  
  Fig 46: Installing No. 1 Gear Shift Fork Shaft To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Installing Shift Fork Set Bolt To No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
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: Installing Reverse Shift Arm Bracket To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
1. Coat the reverse idler gear and thrust washer with gear oil, and install them to the reverse idler gear shaft.
  
  Fig 49: Installing Reverse Idler Gear Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Installing Reverse Idler Gear With Reverse Idler Gear Shaft To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE MAGNET
1. Clean the transaxle magnet, and install it to the transaxle case.
  
  Fig 51: Installing Transmission Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE RESTRICT PIN ASSEMBLY
1. Install the transmission oil baffle and reverse restrict pin with the bolt.
  Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
  
  Fig 52: Removing Bolt, Transmission Oil Baffle And Reverse Restrict Pin Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the reverse restrict pin to the transaxle case.
3. Using a 5 mm pin punch and hammer, tap in the slotted spring pin.
  Standard clearance: 12.5 to 13.5 mm (0.492 to 0.531 in.)
  
  Fig 53: Locating Slotted Spring Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the reverse restrict pin plug with adhesive. Using a 6 mm hexagon wrench, install the plug to the manual transaxle case.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 54: Locating Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 OIL RECEIVER PIPE
1. Install the oil receiver pipe to the transaxle case with the bolt.
  Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
  
  NOTE: Do not damage the pipe.
  
  Fig 55: Locating No. 1 Oil Receiver Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 OIL RECEIVER PIPE
1. Install the oil receiver pipe to the transaxle case with the bolt.
  Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
  
  NOTE: Do not damage the pipe.
  
  Fig 56: Locating No. 2 Oil Receiver Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE
1. Apply seal packing to the transaxle case in a continuous line, as shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  NOTE: Install the part within 10 minutes after applying packing material.
  
  Fig 57: Identifying Seal Packing To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transaxle case to the transaxle case with the 14 bolts.
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Fig 58: Installing Transmission Case To Transaxle Case With 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
INSTALL CLUTCH TUBE BRACKET
1. Install the clutch tube bracket with the bolt.
  Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
  
  Fig 59: Installing Clutch Tube Bracket With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SHAFT BOLT
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 transaxle case.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  Fig 60: Installing Reverse Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT FORK SHAFT SNAP RING
1. Using a brass bar and hammer, tap in the shaft snap ring to the No. 1 gear shift fork shaft.
  
  Fig 61: Installing Shift Fork Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and hammer, tap in the shaft snap ring to the No. 2 gear shift fork shaft.
  
  Fig 62: Tapping In Shaft Snap Ring To No. 2 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING
1. Using a snap ring expander, install the shaft snap ring.
  
  Fig 63: Installing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING SHIM
1. Install the output shaft rear bearing shim to the output shaft.
  
  Fig 64: Installing Output Shaft Rear Bearing Shim To Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR BEARING RETAINER
1. Coat the 7 bolts with adhesive. 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 65: Installing Bearing Retainer With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH DRIVEN GEAR
1. Using SST, install the 5th driven gear to the output shaft.
SST 09309-12020

Fig 66: Installing 5Th Driven Gear To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR NEEDLE ROLLER BEARING
1. Coat the needle roller bearing with gear oil, and install it to the input shaft.
  
  Fig 67: Installing 5Th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR
1. Coat the 5th gear with gear oil, and install it to the input shaft.
  
  Fig 68: Installing 5Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 3 TRANSAXLE CLUTCH HUB

Using SST, install the No. 3 transaxle 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 69: Installing No. 3 Transmission Clutch Hub To Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the No. 3 transaxle hub sleeve and No. 3 gear shift fork to the No. 3 transaxle clutch hub.

Fig 70: Installing No. 3 Transmission Hub Sleeve And No. 3 Gear Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 71: Installing Gear Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select an appropriate No. 3 transaxle clutch hub shaft snap ring that allows the minimum amount of axial play. Using a brass bar and hammer, tap in the No. 3 transaxle clutch hub shaft snap ring.

Fig 72: Tapping No 3 Transmission Clutch Hub Shaft Snap Ring

Standard clearance:

0.1 mm (0.004 in.) or less

Standard snap ring

THICKNESS CHART

Part No.	Mark	Thickness
90520-27061	a	1.75 to 1.80 mm (0.0689 to 0.0709 in.)
90520-27062	b	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
90520-27063	c	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
90520-27064	d	1.90 to 1.95 mm (0.0748 to 0.0768 in.)
90520-27065	e	1.95 to 2.00 mm (0.0768 to 0.0787 in.)
90520-27066	f	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
90520-27067	g	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
90520-27068	h	2.10 to 2.15 mm (0.0827 to 0.0846 in.)
90520-27069	j	2.15 to 2.20 mm (0.0846 to 0.0866 in.)

INSPECT 5TH GEAR RADIAL CLEARANCE
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 the specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.
  
  Fig 73: Measuring 5Th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR THRUST CLEARANCE
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 the specification, replace the No. 3 transaxle clutch hub, 5th gear or input shaft rear radial ball bearing.
  
  Fig 74: Measuring 5Th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE OUTPUT SHAFT REAR SET NUT
1. Engage the 2 gears simultaneously to lock the transaxle.
  
  Fig 75: Engaging Gears Simultaneously To Lock Transmission
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new transaxle output shaft rear set nut.
  Torque: 123 N*m (1254 kgf*cm, 90 ft.*lbf)
  
  Fig 76: Installing Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a chisel and hammer, stake the rear set nut.
4. Disengage the 2 gears.
  
  Fig 77: Staking Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSAXLE CASE COVER SUB-ASSEMBLY
1. Apply seal packing to the transaxle case cover, as shown in the illustration.
  Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  NOTE: Install the part within 10 minutes after applying packing material.
  
  Fig 78: Identifying Seal Packing To Transaxle Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transaxle case cover to the transaxle case with the 10 bolts.
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Fig 79: Identifying Transaxle Case Cover To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN PLUG SUB-ASSEMBLY
1. Install a new gasket and the drain plug to the transaxle case.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  
  Fig 80: Installing Drain Plug Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION FILLER PLUG
1. Install a new gasket and the filler plug to the transaxle case.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  
  Fig 81: Installing Gasket And Filler Plug To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Coat the shift and select lever shaft with gear oil, and install it to the transaxle case.
  
  Fig 82: Removing Shift And Select Lever Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONTROL SHAFT COVER
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 83: Installing Control Shaft Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
1. Install a new gasket and the back-up light switch to the manual transaxle case.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 84: Installing Back-Up Light Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT GATE PIN
1. Install a new gasket and shift gate pin to the case.
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Fig 85: Identifying Shift Gate Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 LOCK BALL ASSEMBLY
1. Install the No. 1 lock ball to the transaxle case.
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Fig 86: Locating No. 1 Lock Ball To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONTROL SHIFT LEVER
1. Install the control shift lever with the shift outer lever lock pin to the shift and select lever shaft.
2. Install the spring washer with the nut.
  Torque: 12 N*m (120 kgf*cm, 9 in.*lbf)
  
  Fig 87: Installing Spring Washer With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SELECTING BELLCRANK ASSEMBLY
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 transaxle case with the bolts.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 88: Installing Selecting Bellcrank To Transmission Case With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
1. Install a new O-ring to the hole cover.
2. Install the hole cover to the transaxle case with the bolt.
  Torque: 5.5 N*m (56 kgf*cm, 49 ft.*lbf)