FixVault
Home › Scion › 2009 › xD Standard › Repair and Diagnosis › Transmission › C50 Manual Transaxle › Manual Transaxle Unit › Reassembly

Manual Transaxle Unit: Reassembly

  1. INSTALL OUTPUT SHAFT COVER 
    1. Coat the output shaft cover with MP grease and install it onto the front transaxle case.
      NOTE: Insert the output shaft cover projection into the case side hollow.
      Fig 1: Installing Output Shaft Cover
      G05400584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL OUTPUT SHAFT FRONT BEARING 
    1. Coat a new output shaft front bearing with gear oil. Using SST and a press, install it onto the front transaxle case.

      SST 09950-60010 (09951 -00550), 09950-70010 (09951-07150) 

      NOTE: Install the new bearing in the correct direction, as shown in the illustration.
      Fig 2: Installing Output Shaft Front Bearing
      G05400585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new front transaxle case oil seal onto the front transalxe case.

      SST 09950-60010 (09951 -00370), 09950-70010 (09951-07150) 

      Drive in depth: 

      15.6 to 16.0 mm (0.6141 to 0.6299 in.) 

      Fig 3: Installing Front Transaxle Case Oil Seal
      G05400586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 front transaxle case.

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

      Drive in depth: 

      0 to 0.3 mm (0 to 0.0118 in.) 

      Fig 4: Installing Input Shaft Front Bearing
      G05400587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING 
    1. Using SST and a hammer, install the shift and select lever shaft slide ball bearing onto the transmission case.

      SST 09950-60010 (09951 -00220), 09950-70010 (09951-07100) 

      Drive in depth: 

      0 to 0.5 mm (0 to 0.0020 in.) 

      Fig 5: Installing Shift And Select Lever Shaft Slide Ball Bearing
      G05400588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SHIFT AND SELECT LEVER SHAFT OIL SEAL 
    1. Using SST, install the shift and select lever shaft oil seal onto the transmission case.

      SST 09950-70010 (09951 -07150), 09950-60010 (09951-00240) 

      Drive in depth: 

      9.7 to 10.3 mm (0.382 to 0.406 in.) 

      Fig 6: Installing Shift And Select Lever Shaft Oil Seal
      G05400589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case front tapered roller bearing (inner race) onto the front differential case.

      SST 09350-32014 (09351 -32120), 09950-60010 (09951-00530) 

      Fig 7: Installing Front Differential Case
      G05400590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the front transaxle case.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) 

      Fig 8: Installing Front Differential Case Front Tapered Roller Bearing
      G05400591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the front differential case rear tapered roller bearing (inner race) onto the differential case.

      SST 09350-32014 (09351-32120), 09950-60010 (09951-00530) 

      Fig 9: Installing Front Differential Case Rear Tapered Roller Bearing Onto Differential Case
      G05400592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with plate washer onto the transmission case.

      SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150) 

      HINT:

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

      Fig 10: Installing Front Differential Case Rear Tapered Roller Bearing With Plate Washer Onto Transmission Case
      G05400593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Coat the differential case assembly with gear oil, and install it onto the front transaxle case.
      2. Fig 11: Identifying Differential Case Assembly
      G05400594Courtesy 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 to the right and left 2 or 3 times to allow the bearings to settle.

      SST 09564-32011 

      Fig 12: Turning Differential Case Assembly With SST
      G05400595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a torque wrench, measure the preload.

      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) 

      Fig 13: Turning Differential Case Assembly With SST
      G05400596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the preload is outside the specifications, select another plate washer.

      Plate washer thickness 

      THICKNESS SPECIFICATIONS

      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 (0.0020 in.) change in plate washer thickness.

    5. Remove the 16 bolts and the manual transmission case.
    6. Remove the differential case assembly from the front 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.

      SST 09309-37010 

      Drive in depth: 

      9.6 to 10.2 mm (0.378 to 0.402 in.) 

      Fig 14: Installing Transmission Case Oil Seal With SST
      G05400597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 front transaxle case.

      SST 09710-26011 (09710-05061) 

      Drive in depth: 

      1.6 to 2.2 mm (0.063 to 0.087 in.) 

      Fig 15: Installing Transmission Case Oil Seal With SST
      G05400598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 front transaxle case.
      Fig 16: Locating Transmission Magnet Of Front Transaxle Case
      G05400599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL BEARING LOCK PLATE 
    1. Install the bearing lock plate onto the front transaxle case with the bolt.

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

      Fig 17: Locating Bearing Lock Plate Bolt
      G05400600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 1 OIL RECEIVER PIPE 
    1. Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt.

      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.
        Fig 18: Identifying No. 1 Oil Receiver Pipe
        G05400601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL NO. 2 OIL RECEIVER PIPE 
    1. Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt.

      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.
        Fig 19: Locating No. 2 Oil Receiver Pipe
        G05400602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    1. Install the reverse restrict pin assembly onto the manual transmission case.
      NOTE: Set the reverse restrict pin assembly in the correct orientation.
      Fig 20: Installing Reverse Restrict Pin Assembly
      G05400603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (ø5 mm) and a hammer, install the slotted pin onto the reverse restrict pin assembly.

      Drive in depth: 

      15.5 to 16.5 mm (0.6102 to 0.6496 in.) 

      Fig 21: Identifying Slotted Pin
      G05400604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply sealant to the reverse restrict pin plug.

      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) 

      Fig 22: Installing Reverse Restrict Pin Plug Onto Manual Transmission Case
      G05400605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    1. Install the manual transaxle case receiver onto the front transaxle case with the bolt.

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

      Fig 23: Locating Manual Transaxle Case Receiver
      G05400606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.
      Fig 24: Identifying Differential Case Assembly
      G05400607Courtesy 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
      G05400608Courtesy 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.

      HINT:

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

      Fig 26: Aligning Mark On Reverse Idler Gear Shaft With Bolt Hole
      G05400609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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
      G05400610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the No. 1 gear shift fork shaft with gear oil and install it.
      3. Fig 28: Identifying No. 1 Gear Shift Fork Shaft
      G05400611Courtesy 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: Installing Shaft Snap Ring Onto No. 1 Gear Shift Fork Shaft
      G05400612Courtesy 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.
    2. Install the reverse shift fork onto the No. 3 gear shift fork shaft.
      Fig 30: Locating No. 3 Gear Shift Fork Shaft
      G05400613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Locating Shift Fork Shaft Snap Rings
      G05400614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the No. 3 gear shift fork shaft with gear oil and install it.
      Fig 32: Identifying No. 3 Gear Shift Fork Shaft
      G05400615Courtesy 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.
      NOTE: To avoid interference by the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.
      Fig 33: Installing No. 2 Gear Shift Fork Shaft
      G05400616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 2 shift lock bolts with sealant and install them onto the No. 2 gear shift fork and No. 1 shift head.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

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

      Fig 34: Locating No. 2 Gear Shift Fork Shaft Bolts
      G05400617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Install the reverse shift arm bracket assembly onto the front transaxle case with the 2 bolts.

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

      Fig 35: Locating Shift Arm Bracket Assembly Of Front Transaxle Case
      G05400618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL MANUAL TRANSMISSION CASE 
    1. Apply FIPG to the manual transmission case, as shown in the illustration.

      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.
      Fig 36: Identifying FIPG To Manual Transmission Case
      G05400619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 13 bolts onto the manual transmission side.

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

      Fig 37: Locating Manual Transmission Side Bolts
      G05400620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts onto the manual transaxle side.

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

      Fig 38: Locating Front Transaxle Case
      G05400621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the reverse idler gear shaft bolt with sealant and install it with a new gasket.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

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

      Fig 39: Locating Idler Gear Shaft Bolt
      G05400622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 2 LOCK BALL ASSEMBLY 
    1. Coat the No. 2 lock ball assembly with sealant and install it with a hexagon wrench.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

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

      Fig 40: Installing No. 2 Lock Ball Assembly
      G05400623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL SHIFT DETENT BALL 
    1. Install the 2 shift detent balls, 2 shift detent ball springs and 2 No. 1 shift detent ball spring seats onto the manual transmission case.
      Fig 41: Identifying Shift Detent Ball
      G05400624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 2 shift detent ball plugs with sealant and install them using a hexagon wrench.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

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

      Fig 42: Identifying Shift Detent Ball
      G05400625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift detent ball, shift detent ball compression spring and No. 1 shift detent ball spring seat onto the front transaxle case.
      Fig 43: Identifying Shift Detent Ball Compression Spring And No. 1 Shift Detent Ball Spring Seat
      G05400626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the shift detent ball plug with sealant and install it using a hexagon wrench.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

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

      Fig 44: Identifying Shift Detent Ball Plug Of Front Transaxle Case
      G05400627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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
      G05400628Courtesy 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: Installing Output Shaft Rear Bearing Hole Snap Ring
      G05400629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING 
    1. Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring onto the No. 2 shift fork shaft.
      Fig 47: Installing Shift Fork Shaft Shaft Snap Ring
      G05400630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL BEARING RETAINER REAR 
    1. Coat the 5 bolts with sealant, and install the bearing retainer rear onto the manual transmission case with the 5 bolts.

      Torque: 27 N*m (279 kgf*cm, 20 ft.*lbf) 

      Fig 48: Identifying Manual Transmission Case With Bolts
      G05400631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL 5TH DRIVEN GEAR 
    1. Using SST, install the 5th driven gear onto the output shaft.

      SST 09309-12020 

      Fig 49: Installing 5Th Driven Gear
      G05400632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 And 5Th Gear Bearing Spacer With Gear Oil
      G05400633Courtesy 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
      G05400634Courtesy 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: Installing No. 3 Synchronizer Ring
      G05400635Courtesy 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.
      NOTE: Do not set the 2 shifting key spring openings in the same position.
      Fig 53: Installing No. 3 Transmission Clutch Hub
      G05400636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft.

      SST 09636-20010 

      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 No. 3 synchromesh shifting key aligned.
      • Check that the 5th gear is rotating.
      • Place a suitable sized wooden block to support the input shaft.
        Fig 54: Identifying No. 3 Transmission Clutch Hub Onto Input Shaft
        G05400637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Select a clutch hub No. 3 shaft snap ring that will allow minimum axial play.
      Fig 55: Identifying Clutch Hub No. 3 Shaft Snap Ring
      G05400638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Clearance: 

      0.1 mm or less 

      Snap ring thickness 

      THICKNESS SPECIFICATIONS

      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 the new snap ring onto the input shaft.
  38. INSPECT 5TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance: 

      0.1 to 0.55 mm (0.0039 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.

      Fig 56: Measuring 5Th Gear Thrust Clearance
      G05400639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSPECT 5TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance: 

      KOYO made: 

      0.015 to 0.058 mm (0.0006 to 0.0023 in.) 

      NSK made: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

      Maximum clearance: 

      KOYO made: 

      0.058 mm (0.0023 in.) 

      NSK made: 

      0.056 mm (0.0022 in.) 

      If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.

      Fig 57: Measuring 5Th Gear Radial Clearance
      G05400640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.

      HINT:

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

      Fig 58: Installing No. 3 Transmission Clutch Hub Sleeve
      G05400641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the gear shift fork lock bolt with sealant, and install it onto the No. 3 gear shift fork.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

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

      Fig 59: Installing No. 3 Gear Shift Fork
      G05400642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Engage the 2 gears simultaneously to lock the transmission.
    2. Coat a new manual transmission output shaft rear set nut with sealant.

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 60: Installing Manual Transmission Output Shaft Rear Set Nut
      G05400643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new manual transmission output shaft rear set nut.

      Torque: 118 N*m (1199 kgf*cm, 87 ft.*lbf) 

    4. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
      5. Fig 61: Staking Manual Transmission Output Shaft Rear Set Nut
      G05400644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the 2 gears.
  42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Apply FIPG to the manual transaxle case cover sub-assembly as shown in the illustration.

      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.
      Fig 62: Identifying FIPG To Manual Transaxle Case Cover Sub-Assembly
      G05400645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.

      Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

      Fig 63: Identifying Manual Transmission Case Cover Sub-Assembly Bolts
      G05400646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 Select Lever Shaft Assembly And Shift
      G05400647Courtesy 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.

      Drive in depth: 

      0.2 to 1.2 mm (0.0079 to 0.0472 in.) 

      SST 09950-60010 (09951 -00280), 09950-70010 (09951-07150) 

      Fig 65: Installing Control Shaft Cover Oil Seal
      G05400648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the control shaft cover oil seal with MP grease.
  45. INSTALL CONTROL SHAFT COVER 
    1. Coat the 4 bolts with sealant. Install a new gasket and control shaft cover onto the manual transmission case with the 4 bolts.

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      NOTE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
      Fig 66: Locating Control Shaft Cover Bolts
      G05400649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL SHIFT GUIDE PIN 
    1. Coat the shift guide pin with sealant.
    2. Install the washer and shift guide pin.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 67: Locating Shift Guide Pin
      G05400650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL NO. 1 LOCK BALL ASSEMBLY 
    1. Coat the No. 1 lock ball assembly with sealant and install it onto the manual transmission case.

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

      Sealant: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 68: Locating No. 1 Lock Ball Assembly
      G05400651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL SHIFT LEVER DAMPER 
    1. Install the dust boot onto the control shaft cover.
    2. Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.
    3. Install the spring washer with the nut.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 69: Locating Spring Washer And Nut
      G05400652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER 
    1. Install the dust boot onto the shift and select lever shaft oil seal.
    2. Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.
    3. Install the spring washer with the nut.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 70: Locating Floor Shift Control Shift Lever Nut
      G05400653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL SELECTING BELL CRANK ASSEMBLY 
    1. Install the selecting bell crank assembly together with the control shift lever bush onto the manual transmission case with the 2 bolts and nut.

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

      12 N*m (120 kgf*cm, 9 ft.*lbf) for nut 

      NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush.
      Fig 71: Locating Selecting Bell Crank Assembly Bolts
      G05400654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.

      SST 09817-16011 

      Torque: 40 N*m (410 kgf*cm, 30 ft.*lbf) 

      Fig 72: Locating Back-Up Light Switch With SST
      G05400655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      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.

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

      Fig 73: Identifying Manual Transmission Filler Plug
      G05400656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL DRAIN PLUG SUB-ASSEMBLY 
    1. Install the drain plug onto the manual transmission case with a new gasket.

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

      Fig 74: Identifying Drain Plug Sub-Assembly
      G05400657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
About FixVault