Section 3 (Manual Trans): Overhaul

WARNING: This page is about a different variant/trim than selected.

REMOVE MANUAL TRANSMISSION FILLER PLUG
1. Remove the manual transmission filler plug and gasket from the manual transmission case.
Fig 1: Removing Manual Transmission Filler Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRAIN (MTM) PLUG SUB-ASSY
1. Remove the drain (MTM) plug sub-assembly and gasket from the manual transmission case.
Fig 2: Removing Drain Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPEEDOMETER SENSOR (W/O ABS)
1. Remove the bolt and speedometer sensor from the transaxle case.
2. Remove the O-ring from the speedometer sensor.
REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY (W/O ABS)
1. Remove the clip and speedometer driven (MTM) gear sub-assembly from the speedometer sensor.
REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (W/ABS)
1. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
2. Remove the O-ring from the speedometer driven hole cover.
REMOVE CLUTCH RELEASE FORK SUB-ASSY
1. Remove the clutch release fork sub-assembly with clutch release bearing assembly from the transaxle case.
Fig 3: Removing Clutch Release Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE BEARING ASSY
1. Remove the clutch release bearing clip and clutch release bearing assembly from the clutch release fork sub-assembly.
Fig 4: Removing Clutch Release Bearing Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RELEASE FORK SUPPORT
1. Remove the clutch release fork support from the transaxle case.
Fig 5: Removing Release Fork Support
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE FORK BOOT
1. Remove the clutch release fork boot from the transaxle case.
Fig 6: Removing Clutch Release Fork Boot
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK UP LAMP SWITCH ASSY
1. Remove the back up lamp switch assembly and gasket from the manual transmission case.
Fig 7: Removing Back Up Lamp Switch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
1. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.
Fig 8: Removing Floor Shift Control Lever Housing Support Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SELECTING BELL CRANK ASSY
1. Remove the 2 bolts and selecting bellcrank assembly from the manual transmission case.
2. Remove the control shift lever bush.
Fig 9: Removing Control Shift Lever Bush
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX MANUAL TRANSAXLE ASSY
1. Using 2 wooden blocks, fix the manual transaxle assembly.
Fig 10: Using 2 Wooden Blocks, Fix Manual Transaxle Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCK BALL ASSY NO. 1
1. Remove the lock ball assembly No. 1 from the manual transmission case.
Fig 11: Removing Lock Ball Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT & SELECT LEVER SHAFT ASSY
1. Remove the 4 bolts, shift & select lever shaft assembly and gasket from the manual transmission case.
Fig 12: Removing Shift & Select Lever Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY
1. Remove the 9 bolts.
  
  Fig 13: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assembly to remove it from the manual transmission case.
  NOTE: Do not damage the manual transmission case.
Fig 14: Removing Manual Transmission Case Cover Sub Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
1. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
  
  Fig 15: Loosening Staked Part
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the gear to the double meshing.
3. Remove the manual transmission output shaft rear set nut.
4. Disengage the double mashing of the gear.
Fig 16: Removing Manual Transmission Output Shaft Rear Set Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK NO. 3
1. Remove the gear shift fork lock bolt from the gear shift fork No. 3.
  
  Fig 17: Removing Gear Shift Fork Lock Bolt From Gear Shift Fork No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the transmission hub sleeve No. 3 with gear shift fork No. 3 from the transmission clutch hub No. 3.
Fig 18: Removing Transmission Hub Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR THRUST CLEARANCE

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

5th gear thrust clearance:

THRUST CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
0.10-0.57 (0.0039-0.0224)	0.57 (0.0224)

Fig 19: Measuring 5th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR RADIAL CLEARANCE

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

5th gear radial clearance: mm (in.)

RADIAL CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
KOYO made: 0.015-0.058 (0.0006-0.0023)	KOYO made: 0.058 (0.0023)
NSK made: 0.015-0.056 (0.0006-0.0022)	NSK made: 0.056 (0.0022)

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

Fig 20: Measuring 5th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE TRANSMISSION CLUTCH HUB NO. 3
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
  
  Fig 21: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the transmission clutch hub No. 3, 5th gear and synchronizer ring No. 3 from the input shaft.
  
  Fig 22: Removing Transmission Clutch Hub No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010), 09950-60010 (09951-00200)
3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No. 3.
Fig 23: Identifying Synchromesh Shifting Keys
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH GEAR NEEDLE ROLLER BEARING
1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
Fig 24: Removing 5th Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH DRIVEN GEAR
1. Using SST, remove the 5th driven gear from the output shaft.
  SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190)
Fig 25: Removing 5th Driven Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RETAINER REAR (MTM)
1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.
Fig 26: Removing Bearing Retainer Rear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
Fig 27: Removing Output Shaft Rear Bearing Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
Fig 28: Removing Input Shaft Rear Bearing Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
Fig 29: Removing Reverse Idler Gear Shaft Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT FORK SHAFT SNAP RING
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 2.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
Fig 30: Removing Snap Ring gear Shift Fork Shaft No. 2.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT DETENT BALL
1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
  
  Fig 31: Removing Shift Detent Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the 2 seats, 2 springs and 2 shift detent balls from the manual transmission case.
  
  Fig 32: Removing Seats, Spring And Shift Detent Balls
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.
  
  Fig 33: Remove Shift Detent Ball Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a magnetic finger, remove the seat, spring and shift detent ball from the transaxle case.
Fig 34: Remove Seat, Spring And Shift Detent Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCK BALL ASSY NO. 1
1. Using a hexagon wench, remove the lock ball assembly No. 1 from the manual transmission case.
Fig 35: Removing Lock Ball Assembly No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE
1. Remove the 3 bolts from the transaxle case side.
  
  Fig 36: Locating 3 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the manual transmission case side.
  
  Fig 37: Removing 13 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, carefully tap the projection of the manual transmission case to remove it from the transaxle case.
  NOTE: Do not damage the manual transmission case and transaxle case.
Fig 38: Removing Manual Transmission Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SUB-ASSY
1. Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the transaxle case.
Fig 39: Removing Reverse Idler Gear Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE SHIFT ARM BRACKET ASSY
1. Remove the 2 bolts and reverse shift arm bracket assembly from the transaxle case.
Fig 40: Removing Reverse Shift Arm Bracket Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT NO. 2
1. Remove the 2 bolts from the gear shift fork No. 2 and gear shift head No. 1.
  
  Fig 41: Removing 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork shaft No. 2 and gear shift head No. 1 from the transaxle case.
Fig 42: Removing Gear Shift Fork Shaft And Gear Shift Head No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT SUB-ASSY NO. 1
1. Using 2 screwdrivers and a hammer, tap out the snap rings.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
  
  Fig 43: Removing Snap Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assembly No. 1 from the gear shift fork No. 1.
  
  Fig 44: Removing Gear Shift Fork Lock Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the gear shift fork No. 1.
Fig 45: Removing Gear Shift Fork No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT NO. 3
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 3.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
  
  Fig 46: Removing Snap Ring Gear Shift Fork Shaft No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift fork shaft No. 3 with reverse shift fork and gear shift fork No. 2 from the transaxle case.
  
  Fig 47: Removing Shift Fork Shaft No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
  
  Fig 48: Removing 2 Bolts From Reverse Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
5. Remove the reverse shift fork from the gear shift fork shaft No. 3.
Fig 49: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSY
1. Remove the input and output shaft assembly from the transaxle case.
Fig 50: Removing Input Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL CASE ASSY
1. Remove the differential case assembly from the transaxle case.
Fig 51: Removing Differential Case Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSAXLE CASE RECEIVER
1. Remove the bolt and manual transaxle case receiver from the transaxle case.
Fig 52: Removing Manual Transaxle Case Receiver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE RESTRICT PIN ASSY
1. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
  
  Fig 53: Removing Reverse Restrict Pin Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.
Fig 54: Removing Reverse Restrict Pin Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER PIPE NO. 1 (MTM)
1. Remove the bolt and oil receiver pipe No. 1 (MTM) from the manual transmission case.
  NOTE: Be careful not to damage the oil receiver pipe No. 1 (MTM).
Fig 55: Removing Oil Receiver Pipe No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER PIPE NO. 2 (MTM)
1. Remove the bolt and oil receiver pipe No. 2 (MTM) from the manual transmission case.
  NOTE: Be careful not to damage the oil receiver pipe No. 2 (MTM).
Fig 56: Removing Oil Receiver Pipe No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING LOCK PLATE
1. Remove the bolt and bearing lock plate from the transaxle case.
Fig 57: Removing Bearing Lock Plate Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the transaxle case.
Fig 58: Removing Transmission Magnet
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING
1. Using SST, remove the input shaft front bearing from the transaxle case.
  SST 09612-65014 (09612-01050, 09612-01060)
Fig 59: Removing Input Shaft Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
Fig 60: Removing Front Transaxle Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the output shaft front bearing from the transaxle case.
  SST 09308-00010
Fig 61: Removing Output Shaft Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT (MTM) COVER
1. Remove the output shaft (MTM) cover from the transaxle case.
Fig 62: Removing Output Shaft Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the FR differential case front tapered roller bearing (outer race) and shim from the transaxle case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 63: Removing FR Differential Case Front Tapered Roller Bearing And Shim
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove FR differential case front tapered roller bearing (inner race) from the front differential case.
  SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)
  
  NOTE: Be careful not to damage bearing.
Fig 64: Removing FR Differential Case Front Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, drive out the transaxle case oil seal from the transaxle case.
  SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
Fig 65: Removing Transaxle Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the FR differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 66: Removing FR Differential Case Rear Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.
  SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
  
  NOTE: Be careful not to damage bearing.
Fig 67: Removing FR Differential Case Rear Tapered Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.
  SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)
Fig 68: Removing Transmission Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYNCHRONIZER RING NO. 3
1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone, check that the ring locks.
  If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
  
  NOTE: Ensure the file lapping compound is completely washed off after rubbing.
3. Check again the breaking effect of the synchronizer ring.
  
  Fig 69: Inspecting Synchronizer Ring No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  Minimum clearance: 0.75 mm (0.0295 in.)
If the clearance is less than minimum, replace the synchronizer ring and gear cone by applying a small amount of the fine lapping compound on gear cone.

NOTE: Ensure the fine lapping compound is completely washed off after rubbing.

Fig 70: Measuring Clearance Between Synchronizer Ring Back And Spline End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSMISSION HUB SLEEVE NO. 3
1. Check the sliding condition between the transmission hub sleeve No. 3 and transmission clutch hub No. 3.
2. Check that spline gear's of the transmission hub sleeve No. 3 is not worn down.
  
  Fig 71: Inspecting Sliding Condition
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier calipers, inspect the transmission hub sleeve No. 3 and gear shift fork No. 3 as shown in the illustration.
  Standard clearance:
  
  0.3-0.5 mm (0.012-0.020 in.)
  
  If the clearance is out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3.
Fig 72: Inspecting Hub Sleeve And Gear Shift Luck
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR

Using a caliper gauge, inspect 5th gear as shown in the illustration.

5th gear inner diameter:

5TH GEAR INNER DIAMETER

Standard inner diameter: mm (in.)	Maximum inner diameter: mm (in.)
29.915-29.931 (1.1778-1.1783)	29.931 (1.1783)

If the inner diameter exceeds the maximum, replace the 5th gear.

Fig 73: Inspecting 5th Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT REVERSE IDLER GEAR SUB-ASSY

Using a caliper gauge, inspect the reverse idler gear sub-assembly as shown in the illustration.

Reverse idler gear sub-assembly inner diameter:

INNER DIAMETER

Standard inner diameter: mm (in.)	Maximum inner diameter: mm (in.)
18.040-18.058 (0.7102-0.7109)	18.058 (0.7109)

If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assembly.

Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.

Reverse idler gear shaft outer diameter:

OUTER DIAMETER

Standard inner diameter: mm (in.)	Minimum outer diameter: mm (in.)
17.966-17.984 (0.7073-0.7080)	17.966 (0.7073)

If the outer diameter is below the minimum, replace the reverse idler gear shaft.

Fig 74: Inspecting Reverse Idler Gear Sub Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OUTPUT SHAFT (MTM) COVER
1. Coat the output shaft (MTM) cover with MP grease, install it to the transaxle case.
  NOTE: Install the output shaft (MTM) cover projection into the case side hollow.
Fig 75: Installing Output Shaft Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT FRONT BEARING
1. Coat a new output shaft front bearing with gear oil, using SST and a press, install it to the transaxle case.
  SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)
  NOTE:
  - Be sure to install a new bearing in the correct direction, as shown in the illustration.
  - When replacing the output shaft front bearing, replace the output shaft front bearing inner race along with it.
Fig 76: Installing Output Shaft Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.
  SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
  
  Drive in depth: 15.6-16.0 mm (0.6142-0.6299 in.)
2. Coat the lip of the front transaxle case oil seal with MP grease.
Fig 77: Installing Front Transaxle Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT FRONT BEARING
1. Coat a new input shaft front bearing with MP grease, using SST and a press, install it to the transaxle case.
  SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
  
  Drive in depth: 0-0.3 mm (0-0.012 in.)
Fig 78: Installing Input Shaft Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install a new FR differential case front tapered roller bearing (inner race) to the front differential case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 79: Installing FR Differential Case Front Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new FR differential case front tapered roller bearing (outer race) with shim to the transaxle case.
  SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
Fig 80: Installing FR Differential Case Front Tapered Roller Bearing (Outer Race)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install a new FR differential case rear tapered roller bearing (inner race) to the front differential case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 81: Installing FR Differential Case Rear Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new FR differential case rear tapered roller bearing (outer race) with shim to the manual transmission case.
  SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)
  
  HINT:
  
  Use a shim of the same thickness with the removed one.
Fig 82: Installing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Coat the differential case assembly with gear oil, install it to the transaxle case.
Install the manual transmission case with 16 bolts.
Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf)

Fig 83: Installing Manual Transmission Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 09564-3201 1

Fig 84: Locating SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a torque wrench, measure the preload.

SST 09564-3201 1

Preload (at starting):

New bearing:

0.78-1.57 N.m (8-16 kgf.cm, 6.9-13.9 in.lbf)

If the preload is out of specification, select another shim.

Shim thickness:

SHIM 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)	-	-

Fig 85: Measuring Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

The preload will change by about 0.3-0.4 N.m (3-4 kgf.cm, 2.6-3.5 in.lbf) corresponding to a change of 0.05 mm (0.0020 in.) in shim thickness.

Remove the 16 bolts and manual transmission case from the transaxle case.
Remove the differential case assembly from the transaxle case.

INSTALL TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.
  SST 09316-60011 (09316-00011)
  
  Drive in depth: 9.9 +/- 0.3 mm (0.390 +/- 0.012 in.)
2. Coat the lip of the transmission case oil seal with MP grease.
Fig 86: Installing Transmission Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install a new transaxle case oil seal in the transaxle case.
  SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)
  
  Drive in depth: 1.9 +/- 0.3 mm (0.075 +/- 0.012 in.)
2. Coat the lip of the transaxle case oil seal with MP grease.
Fig 87: Installing Transaxle Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION MAGNET
1. Clean the transmission magnet, install it to the transaxle case.
Fig 88: Installing Transmission Magnet
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING LOCK PLATE
1. Install the bearing lock plate with the bolt.
  Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf)
Fig 89: Installing Bearing Lock Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL RECEIVER PIPE NO. 1 (MTM)
1. Install the oil receiver pipe No. 1 (MTM) with bolt to the manual transmission case.
  Torque: 17.2 N.m (175 kgf.cm, 13 ft.lbf)
NOTE:
- Prevent the oil receiver pipe No. 1 (MTM) from being deformed.
- Install the oil receiver pipe No. 1 (MTM) while placing it against the manual transmission case, as shown in the illustration.
Fig 90: Installing Oil Receiver Pipe No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL RECEIVER PIPE NO. 2 (MTM)
1. Install the oil receiver pipe No. 2 (MTM) with bolt to the manual transmission case.
  Torque: 17.2 N.m (175 kgf.cm, 13 ft.lbf)
NOTE:
- Prevent the oil receiver pipe No. 2 (MTM) from being deformed.
- Install the oil receiver pipe No. 2 (MTM) while placing it against the manual transmission case, as shown in the illustration.
Fig 91: Installing Oil Receiver Pipe No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE RESTRICT PIN ASSY
1. Install the reverse restrict pin assembly to the manual transmission case.
  NOTE: Do not set the reverse restrict pin assembly in incorrect orientation.
  
  Fig 92: Installing Reverse Restrict Pin Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (5 mm) and hammer, install the slotted pin to the reverse restrict pin assembly.
  Drive in depth (A):
  
  15.5-16.5 mm (0.6102-0.6496 in.)
3. Apply sealant to the reverse restrict pin plug.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Fig 93: Installing Slotted Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.
  Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf)
Fig 94: Installing Reverse Restrict Pin Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSAXLE CASE RECEIVER
1. Install the manual transaxle case receiver with the bolt to the transaxle case.
  Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf)
Fig 95: Installing Manual Transaxle Case Receiver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL CASE ASSY
1. Coat the differential case tapered roller bearing with gear oil, install the differential case assembly to the transaxle case.
Fig 96: Installing Differential Case Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT ASSY
1. Coat the sliding and rotating surface of the input and out put shafts with gear oil, install them to the transaxle case.
Fig 97: Installing Input Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SUB-ASSY
1. Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, install them as shown in the illustration.
  HINT:
  
  Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.
Fig 98: Installing Reverse Idler Gear Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GEAR SHIFT FORK SHAFT SUB-ASSY NO. 1
1. Coat the gear shift fork No. 1 and gear shift fork No. 2 with gear oil, install them.
  
  Fig 99: Locating Gear Shift Fork No. 1 And 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift fork shaft sub-assembly No. 1 with gear oil, install it.
3. Apply sealant to the shift fork lock bolt.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
4. Install the gear shift fork lock bolt.
  Torque: 15.7 N.m (160 kgf.cm, 12 ft.lbf)
  
  Fig 100: Installing Gear Shift Fork Lock Bolt.
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No. 1.
Fig 101: Installing Shaft Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GEAR SHIFT FORK SHAFT NO. 3
1. Coat the 2 balls with MP grease, install them to the reverse shift fork.
2. Install the reverse shift fork to the gear shift fork shaft No. 3.
  
  Fig 102: Installing Reverse Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft No. 3.
  
  Fig 103: Installing 2 Shift Fork Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the gear shift fork shaft No. 3 with gear oil, install it.
Fig 104: Identifying Gear Shift Fork Shaft No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GEAR SHIFT FORK SHAFT NO. 2
1. Coat the gear shift head No. 1 and gear shift fork shaft No. 2 with gear oil, install them.
  
  Fig 105: Installing Gear Shift Head No. 1 And Gear Shift Fork Shaft No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: To avoid the interference of the 2 shift fork balls, lift up the gear shift fork shaft No. 3 at the position shown in the illustration.
  
  Fig 106: Locating 2 Shift Fork Balls
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift lock bolts with sealant, install then to the gear shift fork No. 2 and gear shift head No. 1.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 15.7 N.m (160 kgf.cm, 12 ft.lbf)
Fig 107: Locating 2 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE SHIFT ARM BRACKET ASSY
1. Install the reverse shift arm bracket assembly with 2 bolts to the transaxle case.
  Torque: 17.2 N.m (175 kgf.cm, 13 ft.lbf)
Fig 108: Installing Reverse Shift Arm Bracket Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE
1. Apply FIPG to the manual transmission case, as shown in the illustration.
  FIPG:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
  
  NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
  
  Fig 109: Applying FIPG
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 13 bolts with sealant, install them to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf)
  
  Fig 110: Locating 13 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 3 bolts with sealant, install them to the transaxle case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf)
Fig 111: Locating 3 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SHAFT BOLT
1. Coat the reverse idler gear shaft bolt with sealant, install it with a new gasket.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf)
Fig 112: Installing Reverse Idler Gear Shaft Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LOCK BALL ASSY NO. 1
1. Coat the lock ball assembly No. 1 with sealant, install it with using a hexagon wrench.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)
Fig 113: Installing Lock Ball Assembly No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT DETENT BALL
1. Install the 2 shift detent balls, 2 springs with 2 seats to the manual transmission case.
  
  Fig 114: Installing Shift Detent Balls, Springs And Seats
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift detent ball plugs with sealant, install them with using a hexagon wrench.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
  
  Fig 115: Installing 2 Shift Detent Ball Plugs Using A Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the shift detent ball, spring and seat to the transaxle case.
  
  Fig 116: Installing Shift Detent Ball, Spring And Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the shift detent ball plug with sealant, install it with using a hexagon wrench.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
Fig 117: Installing 2 Shift Detent Ball Plug Using A Hexagon Wrench
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.
Fig 118: Installing Input Shaft Rear Bearing Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.
Fig 119: Installing Output Shaft Rear Bearing Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT FORK SHAFT SNAP RING
1. Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No. 2.
Fig 120: Installing Shift Fork Shaft Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING RETAINER REAR (MTM)
1. Coat the 5 bolts with sealant, install them and bearing retainer rear (MTM) to the manual transmission case.
  Torque: 27.4 N.m (279 kgf.cm, 20 ft.lbf)
Fig 121: Installing Bearing Retainer Rear
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 122: Installing 5th Driver Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR NEEDLE ROLLER BEARING
1. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, install them to the input shaft.
Fig 123: Installing 5th Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR
1. Coat the 5th gear with gear oil, install it to the input shaft.
Fig 124: Installing 5th Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO. 3
1. Coat the synchronizer ring No. 3 with gear oil, install it to the 5th gear.
Fig 125: Installing Synchronizer Ring No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO. 3

Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the transmission clutch hub No. 3.
HINT:

Do not set both openings of the shifting key springs in the same position.

Fig 126: Identifying 3 Synchromesh Shifting Keys
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a hammer, install the transmission clutch hub No. 3 to the input shaft.
SST 09636-20010

HINT:
- Before driving in the No. 3 clutch hub assembly, place the suitable sized wooden block on the rear side of the input shaft, as shown in the illustration.
- When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded, it might be damaged.
Fig 127: Installing Transmission Clutch Hub No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 3 below 0.1 mm (0.0039 in.).

Snap ring thickness:

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)	-	-

Using a brass bar and a hammer, install the snap ring to the input shaft.

Fig 128: Identifying Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR THRUST CLEARANCE

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

5th gear thrust clearance:

THRUST CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
0.10-0.57 (0.0039-0.0224)	0.57 (0.0224)

Fig 129: Measuring 5th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR RADIAL CLEARANCE

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

5th gear radial clearance:

RADIAL CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
KOYO made: 0.015-0.058 (0.0006-0.0023)	KOYO made: 0.058 (0.0023)
NSK made: 0.015-0.056 (0.0006-0.0022)	NSK made: 0.056 (0.0022)

If the clearance exceed the maximum value, replace the gear, needle roller bearing or shaft.

Fig 130: 5th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL GEAR SHIFT FORK NO. 3
1. Coat the transmission clutch hub sleeve No. 3 with gear oil, install it and gear shift fork No. 3 to the transmission clutch hub No. 3.
  HINT:
  
  Do not set the transmission clutch hub No. 3 in incorrect orientation.
  
  Fig 131: Installing Gear Shift Fork No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift lock fork ball with sealant, install it to the gear shift fork No. 3.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 15.7 N.m (160 kgf.cm, 12 ft.lbf)
Fig 132: Tightening Bolt With A Torque Wrench
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
1. Engage the gear double meshing.
2. Install a new manual transmission output shaft rear set nut.
  Torque: 117.6 N.m (1,200 kgf.cm, 87 ft.lbf)
  
  Fig 133: Installing Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
4. Disengage the gear double meshing.
Fig 134: Staking Manual Transmission Output Shaft Rear Set Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY
1. Apply FIPG to the manual transmission case cover sub-assembly as shown in the illustration.
  FIPG:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
  
  NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
  
  Fig 135: Applying FIPG
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the manual transmission case cover sub-assembly with the 9 bolts to the manual transmission case.
  Torque: 18.1 N.m (185 kgf.cm, 14 ft.lbf)
Fig 136: Installing Manual Transmission Case Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT & SELECT LEVER SHAFT ASSY
1. Coat the 4 bolts with sealant, install them, new gasket and shift & select lever shaft assembly to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 19.6 N.m (200 kgf.cm, 14 ft.lbf)
  
  NOTE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
Fig 137: Installing Shift & Select Lever Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LOCK BALL ASSY NO. 1
1. Coat the lock ball assembly No. 1 with sealant, install it to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29.4 N.m (300 kgf.cm, 22 ft.lbf)
Fig 138: Installing Lock Ball Any No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SELECTING BELL CRANK ASSY
1. Install the selecting bellcrank assembly with control shift lever bush with the 2 bolts to the manual transmission case.
  Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
  
  NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).
Fig 139: Installing Selecting Bell Crank Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
1. Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case.
  Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf)
Fig 140: Installing Floor Shift Control Lever Housing Support Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK UP LAMP SWITCH ASSY
1. Using SST, install the backup lamp switch assembly with a new gasket to the manual transmission case.
  Torque: 40.2 N.m (410 kgf.cm, 30 ft.lbf)
  
  SST 09817-16011
Fig 141: Installing Back Up Lamp Switch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (W/ABS)
1. Install a new O-ring to the speedometer driver hole cover sub-assembly.
2. Install the speedometer driver hole cover sub-assembly with the bolt.
  Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf)
INSTALL SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY (W/O ABS)
1. Install the speedometer driven (MTM) gear sub-assembly with clip to the speedometer sensor.
INSTALL SPEEDOMETER SENSOR (W/O ABS)
1. Install a new O-ring to the speedometer sensor.
2. Install the speedometer sensor with the bolt.
  Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf)
INSTALL RELEASE FORK SUPPORT
1. Install the release fork support to the transaxle case.
  Torque: 36.8 N.m (375 kgf.cm, 25 ft.lbf)
Fig 142: Installing Release Fork Support
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK BOOT
1. Install the clutch release fork boot to the transaxle case.
Fig 143: Installing Clutch Release Fork Boot
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE BEARING ASSY
1. Coat the clutch release bearing assembly with the release hub grease, install it to the clutch release fork sub-assembly.
  Sealant:
  
  Part No. 08887-01806, RELEASE HUB GREASE or equivalent
Fig 144: Installing Clutch Release Bearing Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK SUB-ASSY
1. Install the clutch release fork sub-assembly to the input shaft.
2. Apply clutch spline grease to spline of the input shaft.
  Sealant:
  
  Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent
Fig 145: Installing Clutch Release Fork Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN (MTM) PLUG SUB-ASSY
1. Install a new gasket with the drain (MTM) plug sub-assembly.
  Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)
Fig 146: Installing Drain Plug Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION FILLER PLUG
1. Install a new gasket with the manual transmission filler plug.
  Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)
Fig 147: Installing Manual Transmission Filler Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 4th gear thrust clearance.

4th gear thrust clearance:

THRUST CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
0.10-0.55 (0.0039-0.0217)	0.55 (0.0217)

Fig 1: Measuring 4th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD GEAR THRUST CLEARANCE

Using a dial indicator, measure the 3rd gear thrust clearance.

3rd gear thrust clearance:

THRUST CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
0.10-0.35 (0.0039-0.0138)	0.35 (0.0138)

Fig 2: Measuring 3rd Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 4th gear radial clearance.

4th gear radial clearance:

RADIAL CLEARANCE

	Standard clearance: mm (in.)	Maximum clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)	0.058 (0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)	0.056 (0.0022)

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

Fig 3: Measuring 4th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD GEAR RADIAL CLEARANCE

Fig 4: Measuring 3rd Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dial indicator, measure the 3rd gear radial clearance.

3rd gear radial clearance:

RADIAL CLEARANCE

	Standard clearance: mm (in.)	Maximum clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)	0.058 (0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)	0.0056 (0.0022)

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

REMOVE 4TH GEAR
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
  
  Fig 5: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the input shaft radial ball bearing rear and 4th gear from the input shaft.
  SST 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft assembly by hand so that it will not be dropped off.
Fig 6: Removing 4th Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR NEEDLE ROLLER BEARING
1. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
Fig 7: Removing 4th Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 4TH GEAR SYNCHRONIZER RING

Fig 8: Removing 4th Gear Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the 4th gear synchronizer ring from the transmission clutch hub No. 2.
REMOVE 3RD GEAR
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
  
  Fig 9: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the transmission clutch hub No. 2 and 3rd gear from the input shaft.
  SST 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft by hand so that it will not be dropped off.
Fig 10: Removing 3rd Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR SYNCHRONIZER RING
1. Remove the 3rd gear synchronizer ring from the 3rd gear.
Fig 11: Removing 3rd Gear Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 3RD GEAR NEEDLE ROLLER BEARING
1. Remove the 3rd gear needle roller bearing from the input shaft.
Fig 12: Removing 3rd Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION HUB SLEEVE NO. 2
1. Remove the transmission hub sleeve No. 2, 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No. 2.
  HINT:
  
  Using a waste to prevent the shifting key and shifting key spring from being scattered.
Fig 13: Removing Transmission Hub Sleeve No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INPUT SHAFT

Using a dial indicator, check the shaft runout.
Maximum runout: 0.015 mm (0.0006 in.)

If the runout exceeds the maximum, replace the input shaft.

Fig 14: Measuring Input Shaft Runout
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a micrometer, measure the outer diameter of the input shaft journal surface.

Input shaft outer diameter:

OUTER DIAMETER

Part	Standard outer diameter: mm (in.)	Minimum outer diameter: mm (in.)
A	24.885-24.900 (0.9797-0.9803)	24.885 (0.9797)
B	28.985-29.000 (1.1411-1.1417)	28.985 (1.1411)
C	30.985-31.000 (1.2198-1.2204)	30.985 (1.2198)
D	24.985-25.000 (0.9836-0.9842)	24.985 (0.9836)

If the outer diameter is below the minimum, replace the input shaft.

Fig 15: Measuring Outer Diameter Of Input Shaft Journal Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
  Standard inside diameter:
  
  34.015-34.031 mm (1.3391-1.3398 in.)
  
  Maximum inside diameter:
  
  34.031 mm (1.3398 in.)
  
  If the inside diameter exceeds the maximum, replace the 4th gear.
Fig 16: Measuring Inside Diameter Of 4th Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR
1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
  Standard inside diameter:
  
  36.015-36.031 mm (1.4179-1.4185 in.)
  
  Maximum inside diameter:
  
  36.031 mm (1.4185 in.)
  
  If the inside diameter exceeds the maximum, replace the 3rd gear.
Fig 17: Measuring Inside Diameter Of 3rd Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR SYNCHRONIZER RING
1. Check for wear or damage.
2. Check the braking effect of the 3rd gear synchronizer ring. Turn the 3rd gear synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
  If the braking effect is insufficient, apply a small amount of the fine lapping compound between 3rd gear synchronizer ring and 3rd gear cone. Lightly rub the 3rd gear synchronizer ring and 3rd gear cone together.
  
  NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
3. Check again the braking effect of the synchronizer ring.
  
  Fig 18: Inspecting 3rd Gear Synchronizer Ring Wear Or Damage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a feeler gauge, measure the clearance between 3rd gear synchronizer ring back and 3rd gear spline end.
  Minimum clearance:
  
  0.65 mm (0.0256 in.)
  
  If the clearance below than the minimum, replace the 3rd gear synchronizer ring, and apply small amount of the fine lapping compound on gear cone.
  
  NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
Fig 19: Inspecting 3rd Gear Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR SYNCHRONIZER RING
1. Check for wear or damage.
2. Check the braking effect of the 4th gear synchronizer ring. Turn the 4th gear synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
  If the braking effect is insufficient, apply a small amount of the fine lapping compound between 4th gear synchronizer ring and 4th gear cone. Lightly rub the 4th gear synchronizer ring and 4th gear cone.
  
  NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
  
  Fig 20: Inspecting 4th Gear Synchronizer Ring Wear Or Damage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a feeler gauge, measure the clearance between 4th gear synchronizer ring back and 4th gear spline end.
  Minimum clearance: 0.75 mm (0.0295 in.)
  
  If the clearance below than the minimum, replace the 4th gear synchronizer ring, and apply small amount of the fine lapping compound on gear cone.
  
  NOTE: Ensure the fine lapping compound is completely washed off after rubbing.
Fig 21: Inspecting 4th Gear Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSMISSION HUB SLEEVE NO. 2
1. Check the sliding condition between the transmission hub sleeve No. 2 and transmission clutch hub No. 2.
2. Check that the spline gear's edges of the transmission hub sleeve No. 2 is not worn down.
  
  Fig 22: Inspecting Sliding Condition
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier caliper, inspect the transmission hub sleeve No. 2 and gear shift fork No. 2 as shown in the illustration.
  Standard clearance:
  
  0.15-0.35 mm (0.0059-0.0137 in.)
  
  If the clearance is out of specification, replace the transmission hub sleeve No. 2 and gear shift fork No. 2.
Fig 23: Inspecting Transmission Hub Sleeve No. 2 And Gear Shift Fork No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION HUB SLEEVE NO. 2
1. Coat the transmission hub sleeve No. 2 with gear oil, install it to the transmission clutch hub No. 2.
  NOTE: Do not set the transmission clutch hub sleeve No. 2 and the transmission clutch hub No. 2 in incorrect orientation.
  
  Fig 24: Installing Transmission Hub Sleeve No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 synchromesh key springs with 3 synchromesh shifting keys to the transmission clutch hub No. 2.
  HINT:
  
  Do not set the both openings of the shifting key springs in the same position.
INSTALL 3RD GEAR NEEDLE ROLLER BEARING
1. Coat the 3rd gear needle roller bearing with gear oil, install it to the input shaft.
Fig 25: Installing 3rd Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR
1. Coat the 3rd gear with gear oil, install it to the input shaft.
Fig 26: Installing 3rd Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD GEAR SYNCHRONIZER RING
1. Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.
Fig 27: Installing 3rd Gear Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO. 2

Using SST and a press, install the transmission clutch hub No. 2 to the input shaft.
SST 09316-60011 (09316-00021)

Fig 28: Installing Transmission Clutch Hub No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 2 below 0.1 mm (0.0039 in.).

Snap ring thickness:

SNAP RING THICKNESS

Mark	Thickness: mm (in.)	Mark	Thickness: mm (in.)
0	2.30 (0.0906)	3	2.48 (0.0976)
1	2.36 (0.0929)	4	2.54(0.1000)
2	2.42 (0.0953)	5	2.60(0.1024)

Using a brass bar and a hammer, tap in the snap ring.
NOTE: Take care not to damage the journal surface of the input shaft.

Fig 29: Identifying Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 4TH GEAR SYNCHRONIZER RING
1. Coat the 4th gear synchronizer ring with gear oil, install it to the transmission clutch hub No. 2.
Fig 30: Installing 4th Gear Synchronizer Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR NEEDLE ROLLER BEARING
1. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil, install them to the input shaft.
Fig 31: Installing 4th Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH GEAR
1. Coat the 4th gear with gear oil, install it to the input shaft.
Fig 32: Installing 4th Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

Using SST and a press, install the input shaft rear radial ball bearing to the input shaft.
SST 09636-20010

Fig 33: Installing Input Shaft Rear Radial Ball Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring from the table below that will make the thrust clearance of the input shaft rear radial ball bearing below 0.1 mm (0.0039 in.).

Snap ring thickness:

SNAP RING THICKNESS

Mark	Thickness: mm (in.)	Mark	Thickness: mm (in.)
0	2.29(0.0901)	3	2.47 (0.0972)
1	2.35 (0.0925)	4	2.53 (0.0996)
2	2.41 (0.0948)	5	2.59(0.1019)

Using a brass bar and a hammer, tap in the snap ring.
NOTE: Take care not to damage the journal surface of the snap ring.

Fig 34: Identifying Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 3RD GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 3rd gear radial clearance.

3rd gear radial clearance:

RADIAL CLEARANCE

	Standard clearance: mm (in.)	Maximum clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)	0.058 (0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)	0.0056 (0.0022)

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

Fig 35: Measuring 3rd Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR RADIAL CLEARANCE

Fig 36: Measuring 4th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a dial indicator, measure the 4th gear radial clearance.

4th gear radial clearance:

RADIAL CLEARANCE

	Standard clearance: mm (in.)	Maximum clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)	0.058 (0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)	0.056 (0.0022)

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

INSPECT 3RD GEAR THRUST CLEARANCE

Using a dial indicator, measure the 3rd gear thrust clearance.

3rd gear thrust clearance:

THRUST CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
0.10-0.35 (0.0039-0.0138)	0.35 (0.0138)

Fig 37: Measuring 3rd Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 4TH GEAR THRUST CLEARANCE

Using a feeler gauge, measure the 4th gear thrust clearance.

4th gear thrust clearance:

THRUST CLEARANCE

Standard clearance: mm (in.)	Maximum clearance: mm (in.)
0.10-0.55 (0.0039-0.0217)	0.55 (0.0217)

Fig 38: Measuring 4th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 1ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.
  Standard clearance:
  
  0.10-0.40 mm (0.0039-0.0157 in.)
Fig 1: Measuring 1st Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 2nd gear thrust clearance.
  Standard clearance:
  
  0.10-0.45 mm (0.0039-0.0177 in.)
Fig 2: Measuring 2nd Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 1ST GEAR RADIAL CLEARANCE

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

Standard clearance:

STANDARD CLEARANCE

Bearing	Clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)

If the clearance is out of specification, replace the 1st gear needle roller bearing.

Fig 3: Measuring 1st Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 2nd gear radial clearance.

Standard clearance:

STANDARD CLEARANCE

Bearing	Clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)

If the clearance is out of specification, replace the 2nd gear needle roller bearing.

Fig 4: Measuring 2nd Gear Radial Clearance

REMOVE 4TH DRIVEN GEAR

Fig 5: Removing 4th Driven Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a press, remove the output shaft rear bearing with 4th driven gear from the output shaft.
  SST 09950-00020
REMOVE OUTPUT GEAR SPACER
1. Remove the output gear spacer from the output shaft.
Fig 6: Removing Output Gear Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2ND GEAR
1. Using SST and a press, remove the 3rd driven gear with 2nd gear from the output shaft.
  SST 09950-00020
Fig 7: Removing 2nd Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2ND GEAR NEEDLE ROLLER BEARING
1. Remove the 2nd gear needle roller bearing from the output shaft.
Fig 8: Removing 2nd Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SYNCHRONIZER RING SET NO. 2
1. Remove the synchronizer ring set No. 2 from the output shaft.
Fig 9: Removing Synchronizer Ring Set No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Using a waste to prevent the snap ring from being scattered.
  
  Fig 10: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the transmission clutch hub No. 1 with 1st gear from the output shaft.
  SST 09950-00020
  NOTE:
  - Do not tighten SST excessively.
  - Support the input shaft by hand so that it will not be dropped off.
Fig 11: Removing 1st Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SYNCHRONIZER RING NO. 1
1. Remove the synchronizer ring No. 1 from the 1st gear.
Fig 12: Removing Synchronizer Ring No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR NEEDLE ROLLER BEARING
1. Remove the 1st gear needle roller bearing from the output shaft.
Fig 13: Removing 1st Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR THRUST WASHER
1. Remove the 1st gear thrust washer from the output shaft.
Fig 14: Removing 1st Gear Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
1. Remove the 1st gear thrust washer pin or ball from the output shaft.
Fig 15: Removing 1st Gear Thrust Washer Pin Or Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE GEAR
1. Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear.
  NOTE: Using a waste to prevent the synchromesh shifting key and spring from being scattered.
Fig 16: Removing Reverse Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OUTPUT SHAFT
1. Using a dial indicator and 2 V-blocks, measure the shaft runout.
  Maximum runout: 0.015 mm (0.0006 in.)
  
  If the runout exceeds the maximum, replace the output shaft.
  
  Fig 17: Measuring Output Shaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the outer diameter of the output shaft journal surface.
  Outer diameter:
  
  Part A: 31.985 mm (1.2592 in.)
  
  Part B: 37.985 mm (1.4955 in)
  
  Part C: 32.985 mm (1.2986 in)
  
  If the outer diameter is below the minimum, replace the output shaft.
Fig 18: Measuring Outer Diameter Of Output Shaft Journal Surface
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Inside diameter:

INSIDE DIAMETER

New gear: mm (in.)	Maximum inside diameter: mm (in.)
38.015-38.031 (1.4967-1.4973)	38.031 (1.4973)

If the inside diameter exceeds the maximum, replace the 2nd gear.

Fig 19: Measuring Inside Diameter Of 2nd Gear

INSPECT 1ST GEAR

Using a cylinder gauge, measure the inside diameter of the 1st gear.

Inside diameter:

INSIDE DIAMETER

New gear: mm (in.)	Maximum inside diameter: mm (in.)
44.015-44.031 (1.7329-1.7335)	44.031 (1.7335)

If the inside diameter exceeds the maximum, replace the 1st gear.

Fig 20: Measuring Inside Diameter Of 1st Gear

INSPECT 1ST GEAR THRUST WASHER

Using a micrometer, measure the thickness of 1st gear thrust washer.

Thickness:

THRUST WASHER THICKNESS

New thrust washer: mm (in.)	Minimum thickness: mm (in.)
5.975-6.025 (0.2352-0.2372)	5.9755 (0.2352)

If the thickness is below the minimum, replace the 1st gear thrust washer.

Fig 21: Measuring Thickness Of 1st Gear Thrust Washer

INSPECT SYNCHRONIZER RING SET NO. 2
1. Coat the 2nd gear cone with gear oil.
  Check the braking effect of the synchronizer ring set No. 2.
  
  Fig 22: Inspecting Braking Effect
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  Standard clearance: 0.7-1.3 mm (0.0276-0.0512 in.)
  
  If the clearance is out of specification, replace the synchronizer ring set No. 2.
Fig 23: Inspecting Synchronizer Ring Set No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SYNCHRONIZER RING NO. 1
1. Coat the 1st gear cone with gear oil.
  Check the braking effect of the synchronizer ring No. 1.
  
  Fig 24: Inspecting Braking Effect
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
  Standard clearance: 0.75-1.65 mm (0.0295-0.065 in.)
  
  If the clearance is out of specification, replace the synchronizer ring No. 1.
Fig 25: Inspecting Synchronizer Ring No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE GEAR
1. Using a vernier caliper gauge, measure the clearance between reverse gear and shift fork.
  Standard clearance:
  
  0.15-0.35 mm (0.0059-0.0138 in.)
  
  If the clearance is out of specification, replace the reverse gear and reverse shift fork.
Fig 26: Measuring Clearance Between Reverse Gear And Shift Fork
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT TRANSMISSION CLUTCH HUB NO. 1
1. Check that the transmission clutch hub No. 1 and reverse gear sub-assembly slides smoothly.
2. Check that the spline gear's edges of the reverse gear sub-assembly is not worn down.
Fig 27: Inspecting Spline Gear's Edges
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE GEAR
1. Coat the reverse gear with gear oil, install it to the transmission clutch hub No. 1.
  NOTE: Be sure to set the reverse gear and transmission clutch hub No. 1 in incorrect orientation.
2. Using a screwdriver, install the 3 synchromesh shifting key springs and 3 synchromesh shifting keys.
Fig 28: Installing Reverse Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OUTPUT SHAFT FRONT BEARING

Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.
SST 09223-50010

Fig 29: Installing Output Shaft Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring from the table below that will make the thrust clearance of the output shaft front bearing (inner race) below 0.1 mm (0.0039 in.).

Snap ring thickness:

SNAP RING THICKNESS

Part No.	Thickness: mm (in.)	Mark
90520-30032	1.85-1.90 (0.0728-0.0748)	7
90520-30033	1.90-1.95 (0.0748-0.0768)	8
90520-30002	1.95-2.00 (0.0768-0.0787)	1
90520-30003	2.00-2.05 (0.0787-0.0807)	2
90520-30004	2.05-2.10 (0.0807-0.0827)	3
90520-30005	2.10-2.15 (0.0827-0.0846)	4
90520-30006	2.15-2.20 (0.0846-0.0866)	5
90520-30007	2.20-2.25 (0.0866-0.0886)	6

Using a brass bar and a hammer, tap in the snap ring.
NOTE: Take care not to damage the journal surface of the output shaft.

Fig 30: Identifying Snap Ring

INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
1. Coat the 1st gear thrust washer pin or ball with MP grease, install it to the output shaft.
Fig 31: Installing 1st Gear Thrust Washer Pin Or Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR THRUST WASHER
1. Coat the 1st gear thrust washer with gear oil, install it to the output shaft.
Fig 32: Installing 1st Gear Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
1. Coat the 1st gear needle roller bearing with gear oil, install it to the output shaft.
Fig 33: Installing 1st Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST GEAR
1. Coat the 1st gear with gear oil, install it to the output shaft.
Fig 34: Installing 1st Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO. 1
1. Coat the synchronizer ring No. 1 with gear oil, install it to the 1st gear.
Fig 35: Installing Synchronizer Ring No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO. 1

Using SST and a press, install the transmission clutch hub No. 1 to the output shaft.
SST 09316-60011 (09316-00031)

NOTE: The 1st gear can be turned.

Fig 36: Installing Transmission Clutch Hub No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 1 below 0.1 mm (0.0039 in.).

Snap ring thickness:

SNAP RING THICKNESS

Part No.	Thickness: mm (in.)	Mark
90520-29018	2.50 (0.0984)	A
90520-29019	2.56 (0.1008)	B
90520-29020	2.62 (0.1031)	C
90520-29021	2.68 (0.1055)	D
90520-29022	2.74 (0.1079)	E
90520-29023	2.80 (0.1102)	F

Using a brass bar and a hammer, install the snap ring to the output shaft.
NOTE: Take care not to damage the journal surface of the output shaft.

Fig 37: Identifying Snap Ring

INSTALL 2ND GEAR NEEDLE ROLLER BEARING
1. Coat the 2nd gear needle roller bearing with gear oil, install it to the output shaft.
Fig 38: Installing 2nd Gear Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING SET NO. 2
1. Coat the synchronizer ring set No. 2 with gear oil, install it to the 2nd gear.
Fig 39: Installing Synchronizer Ring Set No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND GEAR
1. Coat the 2nd gear with gear oil, install it to the output shaft.
  NOTE: Fit the synchronizer inner ring claws into the slots in the transmission clutch hub No. 1.
Fig 40: Installing 2nd Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 3RD DRIVEN GEAR
1. Using SST and a press, install the 3rd driven gear to the output shaft.
  SST 09309-36100 (09309-03610), 09608-00071, 09950-60010 (09951-00450)
Fig 41: Installing 3rd Driven Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT GEAR SPACER
1. Install the output gear spacer to the output shaft.
Fig 42: Installing Output Gear Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 4TH DRIVEN GEAR
1. Using SST and a press, install 4th driven gear to the output shaft.
  SST 09612-22011
Fig 43: Installing 4th Driven Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING
1. Using SST and a press, install output shaft rear bearing to the output shaft.
  SST 09612-22011
Fig 44: Installing Output Shaft Rear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 2ND GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 2nd gear radial clearance.

Standard clearance:

STANDARD CLEARANCE

Bearing	Clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)

If the clearance is out of specification, replace the 2nd gear needle roller bearing.

Fig 45: Measuring 2nd Gear Radial Clearance

INSPECT 1ST GEAR RADIAL CLEARANCE

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

Standard clearance:

STANDARD CLEARANCE

Bearing	Clearance: mm (in.)
KOYO made	0.015-0.058 (0.0006-0.0023)
NSK made	0.015-0.056 (0.0006-0.0022)

If the clearance is out of specification, replace the 1st gear needle roller bearing.

Fig 46: Measuring 1st Gear Radial Clearance

INSPECT 2ND GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 2nd gear thrust clearance.
  Standard clearance:
  
  0.10-0.45 mm (0.0039-0.0177 in.)
Fig 47: Measuring 2nd Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1 ST GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the 1st gear thrust clearance.
  Standard clearance:
  
  0.10-0.40 mm (0.0039-0.0157 in.)
Fig 48: Measuring 1st Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE SPEEDOMETER DRIVE (MTM) GEAR
1. Remove the speedometer drive (MTM) gear from the front differential case.
Fig 1: Removing Speedometer Drive Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL RING GEAR
1. Place match marks on the front differential ring gear and front differential case.
  
  Fig 2: Locating Match Marks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 8 bolts. Using a hammer, remove the front differential ring gear.
Fig 3: Removing Front Differential Ring Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
1. Fixing the front differential pinion from the front differential case side. Using a dial indicator, measure the backlash of the front differential side gear.
  Standard backlash:
  
  0.05-0.20 mm (0.0020 - 0.0079 in.)
  
  If the backlash is not within the specification, install the connect side gear thrust washers.
Fig 4: Measuring Backlash Of Front Differential Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a chisel and a hammer, loosen the staked part of the front differential case.
  
  Fig 5: Locating Staked Part Of Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (+/- 3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
Fig 6: Removing Front Differential Pinion Shaft Straight Pin
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL PINION SHAFT NO. 1
1. Remove the front differential pinion shaft No. 1 from the front differential case.
Fig 7: Removing Front Differential Pinion Shaft No. 1
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL SIDE GEAR
1. Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gear thrust washers and 2 front differential side gears from the front differential case.
  HINT:
  
  Turning the front differential pinion, remove the 2 pinions and side gear.
Fig 8: Removing Front Differential Side Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER
1. Using a micrometer, measure the thickness of the front differential pinion thrust washer.
  Minimum thickness: 0.92 mm (0.0362 in.)
  
  If the clearance is below the minimum, replace the front differential pinion thrust washer.
Fig 9: Measuring Thickness Of Front Differential Pinion Thrust Washer
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INSPECT FRONT DIFFERENTIAL PINION SHAFT NO. 1
1. Using a micrometer, measure the outer diameter of the front differential pinion shaft No. 1.
  Minimum outer diameter: 16.982 mm (0.6686 in.)
  
  If the outer diameter is less than the minimum, replace the front differential pinion shaft No. 1.
Fig 10: Measuring Outer Diameter Of Pinion Shaft No. 1
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INSTALL FRONT DIFFERENTIAL SIDE GEAR
1. Coat the sliding and rotating surface of the 2 front differential side gears with MP grease.
2. Install the 2 front differential side gear thrust washers to the 2 front differential side gear.
  HINT:
  
  Install the front differential side gear thrust washer that has the same thickness as the removed one.
3. Install the 2 front differential side gears, 2 front differential pinions and 2 front differential side gear thrust washers to the front differential case.
  HINT:
  
  Turning the front differential pinion, install the 2 front differential pinions with front differential case.
Fig 11: Installing Front Differential Side Gear
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INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1
1. Coat the rotating surface of the front differential pinion shaft No. 1 with gear oil.
2. Install the front differential pinion shaft No. 1 to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
Fig 12: Installing Front Differential Pinion Shaft No. 1
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ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH

Fixing the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Standard backlash:

0.05-0.20 mm (0.0020-0.0079 in.)

If the backlash is out of specification, replace the side gear thrust washer.

Thrust washer thickness:

THRUST WASHER THICKNESS

Part No.	Thickness: mm (in.)
41361-22140	0.95 (0.0374)
41361-22020	1.00 (0.0394)
41361-22150	1.05 (0.0413)
41361-22030	1.10 (0.0433)
41361-22160	1.15 (0.0453)
41361-22040	1.20 (0.0472)

Fig 13: Adjusting Front Differential Side Gear Backlash

HINT:

Because the thrust washer does not have any identification mark, measure the front thickness with a micrometer to select a proper thrust washer.
Select washers that has the same thickness as both the right and left.

INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN
1. Using a pin punch (3 mm) and a hammer, install the front differential pinion shaft straight pin to the front differential case.
  
  Fig 14: Installing Front Differential Pinion Shaft Straight Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a chisel and a hammer, stake the front case hole.
Fig 15: Staking Front Case Hole
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INSTALL FRONT DIFFERENTIAL RING GEAR
1. Using a heater, heat the front differential ring gear to 90-110°C (194.0-230.0°F)
2. Clean the contact surface of the front differential case.
  
  Fig 16: Heading Differential Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the both match marks, quickly install the 8 bolts with the front differential ring gear to the front differential case.
  Torque: 77.4 N.m (789 kgf.cm, 57 ft.lbf)
Fig 17: Aligning Both Match Marks
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INSTALL SPEEDOMETER DRIVE (MTM) GEAR
1. Install the speedometer drive (MTM) gear to the front differential case.
Fig 18: Installing Speedometer Drive Gear
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REMOVE CONTROL SHIFT LEVER BUSH
1. Remove the control shift lever bush from the selecting bell-crank assembly.
Fig 1: Removing Control Shift Lever Bush
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REMOVE SELECTING BELLCRANK DUST COVER NO. 1
1. Remove the selecting bellcrank dust cover No. 1 from the selecting bellcrank assembly.
Fig 2: Removing Selecting Bell Crank Dust Cover No. 1
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REMOVE SELECTING BELL CRANK NO. 2
1. Remove the nut, spring washer and selecting bellcrank No. 2 plate washer.
2. Remove the selecting bellcrank No. 2 from the selecting bell-crank support.
Fig 3: Removing Nut
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REMOVE SELECTING BELLCRANK DUST COVER NO. 2
1. Remove the selecting bellcrank dust cover No. 2 from the selecting bellcrank No. 2.
Fig 4: Removing Selecting Bellcrank Dust Cover No. 2
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REMOVE SELECTING BELLCRANK NO. 2 BUSH
1. Remove the 2 selecting bellcrank No. 2 bushes from the selecting bellcrank No. 2.
Fig 5: Removing Selecting Bellcrank No. 2 Bush
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REMOVE SELECT SPRING SEAT NO. 2
1. Using a screwdriver, remove the E-ring, select spring seat No. 2 and select return spring No. 2 from the shift & select lever shaft.
Fig 6: Removing Select Spring Seat No. 2
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REMOVE SHIFT LEVER INNER NO. 2
1. Using a pin punch (5 mm) and a hammer, remove the slotted pin and shift lever inner No. 2 from the shift & select lever shaft.
  HINT:
  
  Make sure the orientation of the shift lever inner No. 2.
Fig 7: Removing Slotted Pin And Shift Lever Inner No. 2
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REMOVE SHIFT LEVER INNER NO. 1
1. Using a pin punch (5 mm) and a hammer, remove the slotted pin, shift lever inner No. 1 and shift inter lock plate from the shift & select lever shaft.
  HINT:
  
  Make sure the orientation of the shift lever inner No. 1.
Fig 8: Removing Slotted Pin
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REMOVE SELECT INNER LEVER
1. Using a pin punch (5 mm) and a hammer, remove the slotted pin, select inner lever, select return spring No. 1 and select return spring seat No. 1.
  HINT:
  
  Make sure the orientation of the select inner lever.
Fig 9: Removing Select Inner Lever
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REMOVE CONTROL SHAFT COVER
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
2. Remove the control shaft cover and shift & select lever shaft dust boot.
Fig 10: Removing Control Shaft Cover
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REMOVE CONTROL SHAFT COVER OIL SEAL
1. Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.
Fig 11: Removing Control Shaft Cover Oil Seal
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INSTALL CONTROL SHAFT COVER OIL SEAL
1. Using SST and a hammer, install a new control shaft cover oil seal to the control shaft cover.
  SST 09950-60010 (09951-00220), 09950-70010 (09951-07100)
  
  Drive in depth: 0.7 +/- 0.5 mm (0.0276 +/- 0.0197 in.)
2. Coat the lip of control shaft cover oil seal with MP grease.
Fig 12: Installing Control Shaft Cover Oil Seal
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INSTALL CONTROL SHAFT COVER
1. Coat the shift & select lever shaft boot with MP grease, install it to the control shaft cover.
2. Install the control shaft cover to the shift & select lever.
  HINT:
  
  Install the dust boot with the projection up and the hole side down.
3. Coat the shift & select lever shaft with MP grease.
  
  Fig 13: Installing Control Shaft Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a brass bar and a hammer, tap in the snap ring to the shift & select lever shaft.
Fig 14: Identifying Snap Ring
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INSTALL SELECT INNER LEVER
1. Coat the select spring seat No. 1 with MP grease, install it to the shift & select lever shaft.
2. Install the select return spring and select inner lever to the shift & select lever shaft.
3. Using a pin punch (5 mm) and a hammer, install the slotted pin to the select lever inner lever.
  Drive in depth: 3.0- 4.0 mm (0.1181-0.1575 in.)
Fig 15: Installing Select Inner Lever
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INSTALL SHIFT LEVER INNER NO. 1
1. Coat the shift interlock plate and shift lever inner No. 1 with MP grease.
2. Install the shift interlock plate with shift lever inner No. 1 to the shift & select lever shaft.
3. Using a pin punch (5 mm) and a hammer, install the slotted pin to the shift lever inner No. 1.
  Drive in depth: 0 +/- 0.5 mm (0 +/- 0.0197 in.)
Fig 16: Installing Shift Lever Inner No. 1
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INSTALL SHIFT LEVER INNER NO. 2
1. Install the shift lever inner No. 2 to the shift & select lever shaft.
2. Using a pin punch (5 mm) and a hammer, install the slotted pin to the shift lever inner No. 2.
  Drive in depth: 0 +/- 0.5 mm (0 +/- 0.0197 in.)
Fig 17: Installing Shift Lever Inner No. 2
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INSTALL SELECT SPRING SEAT NO. 2
1. Coat the select spring seat No. 2 with MP grease, install it with select return spring to the shift & select lever shaft.
2. Using pliers, install the E-ring to the shift & select lever shaft.
Fig 18: Installing Select Spring Seat No. 2
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INSTALL SELECTING BELLCRANK NO. 2 BUSH
1. Coat the selecting bellcrank No. 2 bushes with MP grease, install them to the selecting bellcrank.
Fig 19: Installing Selecting Bellcrank No. 2 Bush
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INSTALL SELECTING BELLCRANK DUST COVER NO. 2
1. Coat the selecting bellcrank dust cover No. 2 with MP grease, install it to the selecting bellcrank No. 2.
Fig 20: Installing Selecting Bellcrank Dust Cover No. 2
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INSTALL SELECTING BELL CRANK NO. 2
1. Install the selecting bellcrank No. 2, selecting bellcrank No. 2 plate washer and spring washer with nut.
  Torque: 11.8 N.m (120 kgf.cm, 9 ft.lbf)
Fig 21: Installing Selecting Bellcrank No. 2
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INSTALL SELECTING BELLCRANK DUST COVER NO. 1
1. Install the selecting bellcrank dust cover No. 1 to the selecting bellcrank assembly.
Fig 22: Installing Selecting Bellcrank Dust Cover No. 1
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INSTALL CONTROL SHIFT LEVER BUSH
1. Coat the control shift lever bush with MP grease, install it to the selecting bellcrank assembly.
Fig 23: Installing Control Shift Lever Bush
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