Coat the needle roller bearing with gear oil and install it to the output shaft.

Coat the 3rd gear with gear oil and install it to the output shaft.

Coat the No. 1 synchronizer ring with gear oil and install it to the 3rd gear.

Coat the hub sleeve with gear oil and install it to the clutch hub.

Text in Illustration

Front

• ПРИМЕЧАНИЕ:

• Be sure to install the hub sleeve to the clutch hub in the correct direction.

Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

• ПРИМЕЧАНИЕ:

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

Using SST and a press, install the No. 2 clutch hub to the output shaft.

• SST
• 09316-60011(09316-00021)

Select a clutch hub shaft snap ring that will allow minimal axial play.

• Standard clearance:
• 0.10 mm (0.00394 in.) or less

• Standard Clutch Hub Shaft Snap Ring:

• Mark	Thickness
  C-1	1.75 to 1.80 mm (0.0689 to 0.0709 in.)
  D	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
  D-1	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
  E	1.90 to 1.95 mm (0.0748 to 0.0768 in.)
  E-1	1.95 to 2.00 mm (0.0768 to 0.0787 in.)
  F	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
  F-1	2.05 to 2.10 mm (0.0807 to 0.0827 in.)

Using a snap ring expander, install the snap ring.

Using a feeler gauge, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Coat the needle roller bearing with gear oil and install it to the output shaft.

Coat the 2nd gear with gear oil and install it to the output shaft.

Coat the No. 2 synchronizer ring with gear oil and install it to the 2nd gear.

Coat the reverse gear with gear oil and install it to the clutch hub.

Text in Illustration

Front

• ПРИМЕЧАНИЕ:

• Be sure to install the reverse gear to the clutch hub in the correct direction.

Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

• ПРИМЕЧАНИЕ:

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

Using SST and a press, install the clutch hub to the output shaft.

• SST
• 09316-60011

Coat the synchronizer ring with gear oil and install it to the No. 1 clutch hub.

Coat the lock ball with gear oil and install it to the output shaft.

Coat the needle roller bearing with gear oil.

Install the inner race and needle roller bearing to the 1st gear.

Coat the 1st gear with gear oil and install it to the output shaft.

Using SST and a press, install the center bearing to the output shaft.

• SST
• 09316-60011(09316-00021)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using SST and a press, install the 5th gear to the output shaft.

• SST
• 09316-60011(09316-00021)

Select a snap ring that will allow minimal axial play.

• Standard clearance:
• 0.10 mm (0.00394 in.) or less

• Standard Output Shaft Bearing Shaft Snap Ring:

• Mark	Thickness
  A	2.67 to 2.72 mm (0.1052 to 0.1070 in.)
  B	2.73 to 2.78 mm (0.1075 to 0.1094 in.)
  C	2.79 to 2.84 mm (0.1099 to 0.1118 in.)
  D	2.85 to 2.90 mm (0.1123 to 0.1141 in.)
  E	2.91 to 2.96 mm (0.1146 to 0.1165 in.)
  F	2.97 to 3.02 mm (0.1170 to 0.1188 in.)
  G	3.03 to 3.08 mm (0.1193 to 0.1212 in.)
  H	3.09 to 3.14 mm (0.1217 to 0.1236 in.)
  J	3.15 to 3.20 mm (0.1241 to 0.1259 in.)
  K	3.21 to 3.26 mm (0.1264 to 0.1283 in.)
  L	3.27 to 3.32 mm (0.1288 to 0.1307 in.)

Using a brass bar and hammer, tap on the snap ring.

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.30 mm (0.00394 to 0.0118 in.)

Using a feeler gauge, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.009 to 0.056 mm (0.000355 to 0.00220 in.)

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

• Standard Journal diameter:

• Item	Specified Condition
  Journal A	34.984 to 35.000 mm (1.3774 to 1.3779 in.)
  Journal B	37.984 to 38.000 mm (1.4955 to 1.4960 in.)
  Journal C	30.384 to 30.400 mm (1.1963 to 1.1968 in.)

Using a micrometer, measure the flange thickness.

• Standard thickness:
• 4.80 to 5.20 mm (0.189 to 0.204 in.)

• Minimum thickness:
• 4.80 mm (0.189 in.)

Using a micrometer, measure the inner race thickness.

• Standard thickness:
• 3.995 to 4.195 mm (0.158 to 0.165 in.)

• Minimum thickness:
• 3.995 mm (0.158 in.)

Using a micrometer, measure the outside diameter of the inner race.

• Standard outside diameter:
• 38.985 to 39.000 mm (1.5349 to 1.5354 in.)

• Minimum outside diameter:
• 38.985 mm (1.5349 in.)

Coat the 1st gear cone with gear oil.

Check the braking effect of the No. 1 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 1st gear spline end.

• Standard clearance:
• 1.00 to 2.00 mm (0.0394 to 0.0787 in.)

Coat the 2nd gear cone with gear oil.

Check the braking effect of the No. 1 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 2nd gear spline end.

• Standard clearance:
• 1.00 to 2.00 mm (0.0394 to 0.0787 in.)

Coat the 3rd gear cone with gear oil.

Check the braking effect of the No. 2 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 2 synchronizer ring back and 3rd gear spline end.

• Standard clearance:
• 1.0 to 2.0 mm (0.0394 to 0.0787 in.)

Using a vernier caliper, measure the clearance between the reverse gear and No. 1 gear shift fork.

• Standard clearance:
• 0.15 to 0.35 mm (0.00591 to 0.0137 in.)

• Maximum clearance:
• 0.35 mm (0.0137 in.)

Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.

Check that the splines of the reverse gear are not worn down.

Using a vernier caliper, measure the No. 2 hub sleeve and No. 2 gear shift fork as shown in the illustration.

• Standard clearance:
• 0.15 to 0.35 mm (0.00591 to 0.0137 in.)

Check the sliding condition between the No. 2 hub sleeve and No. 2 clutch hub.

Check that the splines of the No. 2 transmission hub sleeve are not worn down.

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

• Standard inside diameter:
• 44.015 to 44.040 mm (1.7329 to 1.7338 in.)

• Maximum inside diameter:
• 44.040 mm (1.7338 in.)

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

• Standard inside diameter:
• 44.015 to 44.040 mm (1.7329 to 1.7338 in.)

• Maximum inside diameter:
• 44.040 mm (1.7338 in.)

Using a cylinder gauge, measure the inside diameter of the 3rd gear.

• Standard inside diameter:
• 44.015 to 44.040 mm (1.7329 to 1.7338 in.)

• Maximum inside diameter:
• 44.040 mm (1.7338 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.30 mm (0.00394 to 0.0118 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a feeler gauge, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.009 to 0.056 mm (0.000355 to 0.00220 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using 2 screwdrivers and a hammer, tap off the snap ring from the output shaft.

Using SST and a press, remove the 5th gear, center bearing, 1st gear bearing inner race, 1st gear and 1st gear needle roller bearing from the output shaft.

• SST
• 09527-10011

Remove the No. 1 synchronizer ring from the No. 1 clutch hub.

Using a magnet hand, remove the lock ball.

Using SST and a press, remove the reverse gear, No. 1 transmission clutch hub, No. 1 synchronizer ring and 2nd gear.

• SST
• 09950-00020

Remove the No. 2 synchronizer ring from the 2nd gear.

Remove the needle roller bearing from the output shaft.

Remove the 2 synchromesh shifting key springs.

Remove the reverse gear and 3 synchromesh shifting keys from the transmission clutch hub.

Using a snap ring expander, remove the snap ring from the output shaft.

Using a press, remove the No. 2 transmission clutch hub and 3rd gear.

Remove the No. 1 synchronizer ring from the 3rd gear.

Remove the needle roller bearing from the output shaft.

Remove the 2 synchromesh shifting key springs.

Remove the transmission hub sleeve and 3 synchromesh shifting keys from the transmission clutch hub.

Using SST and a press, install a new front bearing.

• SST
• 09950-60010(09951-00400)
  09950-70010(09951-07100)

Select a snap ring that will allow minimal axial play.

• Standard clearance:
• 0.10 mm (0.0039 in.) or less

• Standard Front Bearing Shaft Snap Ring:

• Mark	Thickness
  0	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
  1	2.10 to 2.15 mm (0.0827 to 0.0847 in.)
  2	2.15 to 2.20 mm (0.0847 to 0.0866 in.)
  3	2.20 to 2.25 mm (0.0866 to 0.0886 in.)
  4	2.25 to 2.30 mm (0.0886 to 0.0906 in.)
  5	2.30 to 2.35 mm (0.0906 to 0.0925 in.)

Using a snap ring expander, install the snap ring.

Coat the 13 input shaft bearings with MP grease and install them to the input shaft.

Coat the No. 2 synchronizer ring with gear oil and install it to the input shaft.

Coat the input shaft cone with gear oil.

Check the braking effect of the No. 2 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 2 synchronizer ring back and input shaft spline end.

• Standard clearance:
• 1.00 to 2.00 mm (0.0394 to 0.0787 in.)

Remove the synchronizer ring.

Remove the 13 input shaft bearings.

Using a snap ring expander, remove the snap ring.

Using SST and a press, remove the front bearing.

• SST
• 09950-00020

Install the output shaft to the intermediate plate by pushing on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.

Using a snap ring expander, install the snap ring to the center bearing.

• УКАЗАНИЕ:

• Make sure the shaft snap ring is flush with the intermediate plate surface.

Coat the input shaft and No. 2 synchronizer ring with gear oil, and install them to the output shaft.

Coat the input shaft and No. 2 synchronizer ring with gear oil.

Temporarily install the counter gear, input shaft and a new center bearing to the intermediate plate.

• ПРИМЕЧАНИЕ:

• Install the bearing (with snap ring) to the rear side of the counter gear.

Using a plastic-faced hammer, install the center bearing to the intermediate plate by tapping the outer race to the counter gear center bearing.

• УКАЗАНИЕ:

• Hold the front side of the counter gear by hand.

Using a snap ring expander, install the counter shaft center bearing snap ring to the counter shaft center bearing.

Using a T40 "TORX" socket, install the output shaft rear bearing retainer to the intermediate plate with the 4 screws.

• Момент затяжки:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Install the reverse idler gear shaft and reverse idler gear to the intermediate plate.

Install the reverse idler gear shaft stopper to the intermediate plate with the bolt.

• Момент затяжки:
• 17 N*m{ 173 kgf*cm, 13 ft.*lbf}

Install the reverse shift arm bracket to the intermediate plate with the 2 bolts.

• Момент затяжки:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Install the lock ball.

Install the 5th gear thrust washer.

Coat the counter shaft 5th gear with gear oil.

Install the counter 5th gear, counter shaft 5th gear bearing, 3 synchromesh shifting keys, 2 synchromesh shifting key springs and No. 3 transmission hub sleeve.

• УКАЗАНИЕ:

• Be sure to set the No. 3 transmission hub sleeve and 3 synchromesh shifting keys to the counter shaft 5th gear incorrect direction.

Text in Illustration

Front

Install the counter 5th gear bearing to the 5th gear.

Install the counter shaft 5th gear to the counter gear.

Temporarily install the No. 1 synchronizer ring on the No. 5 gear spline piece.

Remove the intermediate plate from the vise.

Stand the transmission as shown in the illustration.

Using a press and 22 mm socket wrench, install the No. 5 gear spline piece with the No. 1 synchronizer ring slots aligned with the shifting keys.

Fix the intermediate plate in a vise between aluminum plates.

Select a snap ring that will allow minimal axial play.

• Standard clearance:
• 0.10 mm (0.00394 in.) or less

• Standard Counter Gear Rear Shaft Snap Ring:

• Mark	Thickness
  A	2.80 to 2.85 mm (0.110 to 0.112 in.)
  B	2.85 to 2.90 mm (0.112 to 0.114 in.)
  C	2.90 to 2.95 mm (0.114 to 0.116 in.)
  D	2.95 to 3.00 mm (0.116 to 0.118 in.)
  E	3.00 to 3.05 mm (0.118 to 0.120 in.)
  F	3.05 to 3.10 mm (0.120 to 0.122 in.)
  G	3.10 to 3.15 mm (0.122 to 0.124 in.)

Using a brass bar and hammer, tap the snap ring to the counter gear.

Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

• Standard clearance:
• 0.10 to 0.30 mm (0.00394 to 0.0118 in.)

Install the No. 2 gear shift fork and No. 1 gear shift fork.

Pass the No. 2 gear shift fork shaft through the intermediate plate, No. 2 gear shift fork and No. 1 gear shift fork to install it.

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

Install the bolt to the No. 2 gear shift fork.

• Момент затяжки:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Coat the No. 2 shift interlock pin with MP grease and install it to the No. 1 gear shift fork shaft.

Coat the No. 1 shift interlock pin with MP grease.

Using a magnet hand, install the No. 1 shift interlock pin to the intermediate plate.

Pass the No. 1 gear shift fork shaft through the intermediate plate and No. 2 gear shift fork to install it.

Install the bolt to the No. 1 shift fork.

• Момент затяжки:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Using pliers, install the shaft snap ring to the No. 1 gear shift fork shaft.

Install the shift arm shoe E-ring and the shift arm shoe to the reverse shift arm.

Install the reverse shift arm E-ring and reverse shift fork to the reverse shift arm.

Install the reverse shift arm to the reverse shift arm bracket.

Coat the No. 2 shift interlock pin with MP grease, and install it to the No. 3 gear shift fork shaft.

Coat the No. 3 shift interlock pin with MP grease.

Using a magnet hand, install the No. 3 shift interlock pin to the intermediate plate.

Install the No. 3 gear shift fork shaft through the reverse shift fork and intermediate plate.

Install the reverse shift head ring to the reverse shift fork shaft.

Using a 5 mm pin punch and a hammer, tap in the slotted spring pin to the No. 3 shift fork shaft.

Install the No. 5 gear shift fork shaft and reverse shift head.

Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the No. 3 shift fork shaft.

Coat the 2 shift detent balls with MP grease.

Using a magnet hand, install the 2 shift detent balls to the intermediate plate.

Pass the No. 4 gear shift fork shaft through the reverse shift fork, intermediate plate and reverse shift head to install it.

Install a new No. 3 gear shift fork with the bolt.

• Момент затяжки:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Coat the No. 2 detent ball with MP grease.

Install the No. 2 detent ball and compression spring to the intermediate plate.

Coat the spring seat with adhesive.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a T40 "TORX" socket, install the spring seat to the intermediate plate.

• Момент затяжки:
• 19 N*m{ 194 kgf*cm, 14 ft.*lbf}

Coat the 3 shift detent balls with MP grease, and then install them and the 3 compression springs to the intermediate plate.

Coat the spring seat and 2 ball plugs with adhesive.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a T40 "TORX" socket, install the spring seat and 2 ball plugs to the intermediate plate.

• Момент затяжки:
• 19 N*m{ 194 kgf*cm, 14 ft.*lbf}

Apply seal packing to the transmission case as shown in the illustration.

• Seal packing:
• Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Stand the intermediate plate as shown in the illustration.

Using a plastic-faced hammer, install the transmission case to the intermediate plate as shown in the illustration.

Using a snap ring expander, install the snap ring to the counter gear front bearing.

Using a snap ring expander, install the snap ring to the input shaft front bearing.

Using SST, press in a new oil seal to the front bearing retainer.

• SST
• 09950-60010(09951-00440,09952-06010)

• Standard depth:
• 12.2 to 13.2 m (0.480 to 0.519 in.)

• ПРИМЕЧАНИЕ:

• Do not damage the oil seal lip.

Apply a light coat of MP grease to the lip of the oil seal.

Install a new gasket and the front bearing retainer to the transmission case.

Install the 8 bolts.

• Момент затяжки:
• 17 N*m{ 173 kgf*cm, 13 ft.*lbf}

Using SST, tap in a new oil seal to the transfer adaptor.

• SST
• 09223-00010

• Standard depth:
• 45 to 46 mm (1.78 to 1.81 in.)

• ПРИМЕЧАНИЕ:

• Be careful not to damage the lip of the oil seal.

Apply a light coat of MP grease to the lip of the oil seal.

Install the restrict pin to the transfer adaptor.

Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the transfer adaptor.

Using a T40 "TORX" socket, install the plug to the transfer adaptor.

• Момент затяжки:
• 19 N*m{ 194 kgf*cm, 14 ft.*lbf}

Install the shift and select lever and shift lever housing to the transfer adaptor.

Install the oil receiver pipe to the transfer adaptor.

Install the magnet to the transfer adaptor.

Apply seal packing to the transfer adaptor as shown in the illustration.

• Seal packing:
• Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Install the transfer adaptor to the manual transmission case with the 8 bolts.

• Момент затяжки:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

• УКАЗАНИЕ:

• Each bolt length is indicated below.

• 80 mm (3.15 in.) for bolt A

• 130 mm (5.12 in.) for bolt B

Install the bolt to the shift lever housing.

• Момент затяжки:
• 33 N*m{ 340 kgf*cm, 25 ft.*lbf}

Coat the shift detent ball with MP grease, and then install it and the compression spring to the transfer adapter.

Using a T40 "TORX" socket, install the spring seat to the transfer adapter.

• Момент затяжки:
• 19 N*m{ 194 kgf*cm, 14 ft.*lbf}

Install a new gasket to the transfer adapter.

Install the shift lever retainer with the 4 bolts.

• Момент затяжки:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Install the 2 restrict pins to the transfer adaptor.

• Момент затяжки:
• 28 N*m{ 286 kgf*cm, 21 ft.*lbf}

Install the front transmission case.

Apply adhesive to the bolt threads.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the 9 bolts.

• Момент затяжки:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Using SST, install a new gasket and the back-up light switch to the manual transmission case.

• SST
• 09817-16011

• Момент затяжки:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Install the release fork boot to the front transmission case.

Install the release fork support to the front transmission case.

• Момент затяжки:
• 39 N*m{ 400 kgf*cm, 29 ft.*lbf}

Apply release hub grease to the clutch release bearing, and then install it to the clutch release fork with the clip.

• Grease:
• Toyota Genuine Release Hub Grease or equivalent

Install the clutch release fork.

• ПРИМЕЧАНИЕ:

• After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

Apply clutch spline grease to the spline of the input shaft.

• Grease:
• Toyota Genuine Clutch Spline Grease or equivalent

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

• Момент затяжки:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Install a new gasket and the filler plug to the transmission case.

• Момент затяжки:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}