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Manual Transaxle Unit: Reassembly: Reassembly

  1. INSTALL OUTPUT SHAFT COVER 
    Fig 1: Installing Output Shaft Cover
    GTY163079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  2. INSTALL OUTPUT SHAFT FRONT BEARING 
    Fig 2: Installing Output Shaft Front Bearing
    GTY166369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      • SST: 09950-70010 
        • 09951-07150
      NOTE:

      Install the new bearing in the correct direction, as shown in the illustration.

  3. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    Fig 3: Installing Front Transaxle Case Oil Seal
    GTY159170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, install a new front transaxle case oil seal onto the front transalxe case.
      • SST: 09950-60010 
        • 09951-00370
      • SST: 09950-70010 
        • 09951-07150

      Drive in depth

      15.6 to 16.0 mm (0.6141 to 0.6299 in.)

    2. Coat the lip of the front transaxle case oil seal with MP grease.
  4. INSTALL INPUT SHAFT FRONT BEARING 
    Fig 4: Installing Input Shaft Front Bearing
    GTY165435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      • SST: 09950-70010 
        • 09951-07150

      Drive in depth

      0 to 0.3 mm (0 to 0.0118 in.)

  5. INSTALL SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING 
    Fig 5: Installing Shift And Select Lever Shaft Slide Ball Bearing
    GTY158817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      • SST: 09950-70010 
        • 09951-07100

      Drive in depth

      0 to 0.5 mm (0 to 0.0020 in.)

  6. INSTALL SHIFT AND SELECT LEVER SHAFT OIL SEAL 
    Fig 6: Installing Shift And Select Lever Shaft Oil Seal Using SST
    GTY158814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, install the shift and select lever shaft oil seal onto the transmission case.
      • SST: 09950-70010 
        • 09951-07150
      • SST: 09950-60010 
        • 09951-00240

      Drive in depth

      9.7 to 10.3 mm (0.382 to 0.406 in.)

  7. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    Fig 7: Installing Front Differential Case Front Tapered Roller Bearing (Inner Race) Using SST
    GTY159175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      • SST: 09950-60010 
        • 09951-00530
    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.
      Fig 8: Installing Front Differential Case Front Tapered Roller Bearing Using SST
      GTY159217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        • 09951-00680
      • SST: 09950-70010 
        • 09951-07150
  8. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    Fig 9: Installing Front Differential Case Rear Tapered Roller Bearing (Inner Race) Using SST
    GTY159176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      • SST: 09950-60010 
        • 09951-00530
    2. Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with plate washer onto the transmission case.
      Fig 10: Installing Front Differential Case Rear Tapered Roller Bearing (Outer Race) Using SST
      GTY159171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09309-36010 
      • SST: 09950-60020 
        • 09951-00710
      • SST: 09950-70010 
        • 09951-07150

      HINT: 

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

  9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    Fig 11: Identifying Differential Case Assembly
    GTY165423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the differential case assembly with gear oil, and install it onto the front transaxle case.
    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.
      Fig 12: Measuring Preload Using SST & Torque Wrench
      GTY294322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-32011 
    4. Using SST and a torque wrench, measure the preload.
      Fig 13: Measuring Preload Using SST & Torque Wrench
      GTY294322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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)

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

      Plate washer thickness

      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 
    Fig 14: Installing Transmission Case Oil Seal With SST
    GTY159282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.)

    2. Coat the lip of the front transmission case oil seal with MP grease.
  11. INSTALL TRANSAXLE CASE OIL SEAL 
    Fig 15: Installing Transmission Case Oil Seal With SST
    GTY159283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.)

    2. Coat the lip of the transaxle case oil seal with MP grease.
  12. INSTALL TRANSMISSION MAGNET 
    Fig 16: Identifying Transmission Magnet
    GTY159490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Clean the transmission magnet and install it onto the front transaxle case.
  13. INSTALL BEARING LOCK PLATE 
    Fig 17: Identifying Bearing Lock Plate Bolt
    GTY159489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the bearing lock plate onto the front transaxle case with the bolt.

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

  14. INSTALL NO. 1 OIL RECEIVER PIPE 
    Fig 18: Identifying Oil Receiver Pipe No. 1 Bolt
    GTY159393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  15. INSTALL NO. 2 OIL RECEIVER PIPE 
    Fig 19: Identifying Oil Receiver Pipe No. 2 Bolt
    GTY165657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  16. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    Fig 20: Installing Reverse Restrict Pin Assembly
    GTY159218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the reverse restrict pin assembly onto the manual transmission case.
      NOTE:

      Set the reverse restrict pin assembly in the correct orientation.

    2. Using a pin punch (5 mm) and a hammer, install the slotted pin onto the reverse restrict pin assembly.
      Fig 21: Installing Slotted Pin
      GTY159219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Drive in depth

      15.5 to 16.5 mm (0.6102 to 0.6496 in.)

    3. Apply sealant to the reverse restrict pin plug.
      Fig 22: Installing Reverse Restrict Pin Plug Onto Manual Transmission Case
      GTY158805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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) 

  17. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    Fig 23: Identifying Manual Transaxle Case Receiver & Bolts
    GTY159488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  18. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    Fig 24: Identifying Differential Case Assembly
    GTY165423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.
  19. INSTALL INPUT SHAFT ASSEMBLY 
    Fig 25: Identifying Input Shaft Assembly
    GTY164235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.
  20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY 
    Fig 26: Aligning Mark On Reverse Idler Gear Shaft With Bolt Hole
    GTY165584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  21. INSTALL NO. 1 GEAR SHIFT FORK SHAFT 
    Fig 27: Identifying No. 1 Gear Shift Fork And No. 2 Gear Shift Fork
    GTY159220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the No. 1 gear shift fork and No. 2 gear shift fork with gear oil and install them.
    2. Coat the No. 1 gear shift fork shaft with gear oil and install it.
      Fig 28: Identifying No. 1 Gear Shift Fork Shaft
      GTY165215Courtesy 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
      GTY165710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT 
    Fig 30: Locating Shift Fork Balls
    GTY159229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    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: Identifying New Shift Fork Shaft Snap Rings
      GTY159221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the No. 3 gear shift fork shaft with gear oil and install it.
      Fig 32: Identifying Gear Shift Fork Shaft No. 3
      GTY159222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL NO. 2 GEAR SHIFT FORK SHAFT 
    Fig 33: Installing No. 2 Gear Shift Fork Shaft
    GTY158849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

    2. Coat the 2 shift lock bolts with sealant and install them onto the No. 2 gear shift fork and No. 1 shift head.
      Fig 34: Identifying Shift Lock Bolts
      GTY163753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY 
    Fig 35: Identifying Reverse Shift Arm Bracket Assembly Bolts
    GTY159207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  25. INSTALL MANUAL TRANSMISSION CASE 
    Fig 36: Identifying FIPG To Manual Transmission Case
    GTY165415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

    2. Install the 13 bolts onto the manual transmission side.
      Fig 37: Identifying Manual Transmission Side Bolts
      GTY166834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the 3 bolts onto the manual transaxle side.
      Fig 38: Identifying Transaxle Case Side Bolts
      GTY159205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  26. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    Fig 39: Identifying Reverse Idler Gear Shaft Bolt
    GTY159486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  27. INSTALL NO. 2 LOCK BALL ASSEMBLY 
    Fig 40: Identifying Lock Ball Assembly No. 1
    GTY166431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  28. INSTALL SHIFT DETENT BALL 
    Fig 41: Identifying Shift Detent Ball
    GTY164288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    2. Coat the 2 shift detent ball plugs with sealant and install them using a hexagon wrench.
      Fig 42: Identifying Shift Detent Ball Plugs
      GTY165097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

    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
      GTY162221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the shift detent ball plug with sealant and install it using a hexagon wrench.
      Fig 44: Identifying Shift Detent Ball Plug
      GTY159204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  29. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING 
    Fig 45: Removing/Installing Input Shaft Rear Bearing Hole Snap Ring
    GTY159202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, install a new input shaft rear bearing hole snap ring onto the input shaft.
  30. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING 
    Fig 46: Removing/Installing Output Shaft Rear Bearing Hole Snap Ring
    GTY159201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, install a new output shaft rear bearing hole snap ring onto the output shaft.
  31. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING 
    Fig 47: Installing Shift Fork Shaft Snap Ring
    GTY165702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring onto the No. 2 shift fork shaft.
  32. INSTALL BEARING RETAINER REAR 
    Fig 48: Identifying Bearing Retainer Rear
    GTY165952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  33. INSTALL 5TH DRIVEN GEAR 
    Fig 49: Installing 5th Driven Gear Onto Output Shaft Using SST
    GTY159086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, install the 5th driven gear onto the output shaft.
      • SST: 09309-12020 
  34. INSTALL 5TH GEAR NEEDLE ROLLER BEARING 
    Fig 50: Identifying 5th Gear Needle Roller Bearing
    GTY162217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.
  35. INSTALL 5TH GEAR 
    Fig 51: Identifying 5th Gear
    GTY165703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the 5th gear with gear oil and install it onto the input shaft.
  36. INSTALL NO. 3 SYNCHRONIZER RING 
    Fig 52: Identifying Synchronizer Ring No. 3
    GTY157681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.
  37. INSTALL NO. 3 TRANSMISSION CLUTCH HUB 
    Fig 53: Installing No. 3 Transmission Clutch Hub
    GTY159223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

    2. Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft.
      • SST: 09636-20010 
      Fig 54: Installing Transmission Clutch Hub No. 3 Onto Input Shaft
      GTY159224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    3. Select a clutch hub No. 3 shaft snap ring that will allow minimum axial play.
      Fig 55: Installing Snap Ring Onto Input Shaft
      GTY165637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Clearance

      0.1 mm or less

      Snap ring thickness

      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 
    Fig 56: Measuring 5th Gear Thrust Clearance
    GTY167003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  39. INSPECT 5TH GEAR RADIAL CLEARANCE 
    Fig 57: Measuring 5th Gear Radial Clearance
    GTY162215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance

      JTEKT 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

      JTEKT 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.

  40. INSTALL NO. 3 GEAR SHIFT FORK 
    Fig 58: Installing Gear Shift Fork No. 3
    GTY159225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

    2. Coat the gear shift fork lock bolt with sealant, and install it onto the No. 3 gear shift fork.
      Fig 59: Installing Gear Shift Fork Lock Bolt
      GTY165627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

  41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    Fig 60: Installing Manual Transmission Output Shaft Rear Set Nut
    GTY159226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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

    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.
      Fig 61: Staking Manual Transmission Output Shaft Rear Set Nut
      GTY159227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the 2 gears.
  42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    Fig 62: Applying FIPG To Manual Transaxle Case Cover Sub-Assembly
    GTY159243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

    2. Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.
      Fig 63: Identifying Manual Transmission Case Cover Sub-Assembly
      GTY159242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  43. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    Fig 64: Identifying Shift & Select Lever Shaft Assembly
    GTY164028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat the shift and select lever shaft assembly with gear oil, and install it onto the transmission case.
  44. INSTALL CONTROL SHAFT COVER OIL SEAL 
    Fig 65: Installing Control Shaft Cover Oil Seal
    GTY158804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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
      • SST: 09950-70010 
        • 09951-07150
    2. Coat the control shaft cover oil seal with MP grease.
  45. INSTALL CONTROL SHAFT COVER 
    Fig 66: Identifying Control Shaft Cover Bolts
    GTY166015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  46. INSTALL SHIFT GUIDE PIN 
    Fig 67: Identifying Shift Gate Pin & Washer
    GTY165134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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

  47. INSTALL NO. 1 LOCK BALL ASSEMBLY 
    Fig 68: Identifying No. 1 Lock Ball Assembly
    GTY158810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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

  48. INSTALL SHIFT LEVER DAMPER 
    Fig 69: Identifying Spring Washer And Nut
    GTY158811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER 
    Fig 70: Identifying Floor Shift Control Shift Lever Nut
    GTY158813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  50. INSTALL SELECTING BELL CRANK ASSEMBLY 
    Fig 71: Identifying Selecting Bell Crank Assembly
    GTY162538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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

      Torque: 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.

  51. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY 
    Fig 72: Removing/Installing Back-Up Light Switch
    GTY165698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

    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 
    Fig 73: Identifying Manual Transmission Filler Plug
    GTY159240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  54. INSTALL DRAIN PLUG SUB-ASSEMBLY 
    Fig 74: Identifying Drain Plug Sub-Assembly
    GTY159241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the drain plug onto the manual transmission case with a new gasket.

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

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