Manual Transmission Unit (For 1Gd-Ftv) Reassembly

Install the No. 1 release arm and shift arm pivot to the shift interlock bracket.

Install a new E-ring to the shift arm pivot.

Install the compression spring and shift detent ball to the shift interlock bracket.

Install the No. 4 gear shift fork shaft.

Install the No. 4 gear shift fork to the No. 4 gear shift fork shaft.

Using 5 mm a pin punch and hammer, tap a new slotted spring pin into the No. 4 gear shift fork and No. 4 gear shift fork shaft.

Standard depth:

0 to 0.5 mm (0 to 0.0196 in.)

Install the No. 1 gear shift fork and No. 2 gear shift head to the No. 4 gear shift fork shaft.

Using a 5 mm pin punch and hammer, tap a new slotted spring pin into the No. 2 gear shift head and No. 4 gear shift fork shaft.

Standard depth:

0 to 0.5 mm (0 to 0.0196 in.)

Install the compression spring and shift detent ball to the shift interlock bracket.

Install the No. 1 gear shift fork shaft to the shift interlock bracket.

Install the No. 1 gear shift head to the No. 1 gear shift fork shaft.

Using a 5 mm pin punch and hammer, tap a new slotted spring pin into the No. 1 gear shift head and No. 1 gear shift fork shaft.

Standard depth:

0 to 0.5 mm (0 to 0.0196 in.)

Install the compression spring and shift detent ball to the shift interlock bracket.

Install the No. 2 gear shift fork shaft to the shift interlock bracket.

Install the No. 2 gear shift fork with a new bolt.

Torque:

20 N*m{199 kgf*cm, 14 ft.*lbf}

Install the compression spring and shift detent ball to the shift interlock bracket.

Install the No. 3 gear shift fork shaft to the shift interlock bracket.

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

Torque:

20 N*m{199 kgf*cm, 14 ft.*lbf}

Using SST, install the transmission case needle bearing into the front transmission case so that dimension A in the illustration is as specified.

SST

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

Dimension A:

0.50 to 1.50 mm (0.0197 to 0.0590 in.)

Using SST and a hammer, tap a new transmission case oil seal into the front transmission case so that dimension A in the illustration is as specified.

SST

09950-70010(09951-07100)
09950-60010(09951-00470)

Dimension A:

60.0 to 60.8 mm (2.363 to 2.393 in.)

Apply gear oil to the lip of the transmission case oil seal.

Using snap ring pliers, install the 2 front bearing shaft snap rings.

Install the No. 3 oil receiver pipe to the front transmission case.

HINT:

Align the protrusion of the No. 3 oil receiver pipe with the cutout of the front transmission case and install the No. 3 oil receiver pipe to the front transmission case.

Apply gear oil to all sliding and rotating parts.

Temporarily install the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks, gear shift fork shafts, and tie them with a piece of rope or string.

Using a snap ring expander, expand the 2 snap rings and install the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks, gear shift fork shafts.

HINT:

Make sure that the snap ring fits into the grooves of the input shaft and front bearing of the counter gear shaft.

Untie the output shaft assembly, input shaft assembly, counter gear assembly shift interlock bracket, gear shift forks, gear shift fork shafts.

Using a 27 mm hexagon wrench, install a new manual transmission case plug to the front transmission case.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Install the shift interlock bracket with the 4 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Install the reverse idler gear, reverse idler gear bearing and reverse idler gear shaft.

HINT:

Make sure that the reverse idler gear faces the correct direction as shown in the illustration.

NOTICE:

Make sure that the hole in the reverse idler gear shaft is in the position shown in the illustration.

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

SST

09817-16011

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

Install the compression spring and lock ball pin to the shift and select lever.

Install the shift and select lever, shift and select cam and shift interlock plate to the shift and select lever shaft.

Using a 5 mm pin punch and hammer, tap in a new slotted pin to the shift and select lever shaft.

Standard depth:

1.0 to 2.0 mm (0.0394 to 0.0787 in.)

Install a new bolt to the shift and select lever.

Torque:

47 N*m{479 kgf*cm, 35 ft.*lbf}

Install a new E-ring to the lever shaft.

Align the groove of the shift and select cam with the reverse idler shaft and the claw with the groove of the control assembly, and then install the shift and select lever shaft.

Install the No. 2 oil receiver pipe to the transmission middle case.

Install a new gasket and the drain plug sub-assembly to the transmission middle case.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

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

Seal Packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

Install the transmission middle case with the 11 bolts.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Bolt length:

for bolt A: 40 mm (1.57 in.)

for bolt B: 80 mm (3.15 in.)

Install a new gasket and the reverse idler gear shaft bolt to the reverse idler gear shaft.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Install the transmission oil separator with the 2 bolts.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Using SST, install the transfer adapter needle roller bearing to the transfer adapter.

SST

09950-60010(09951-00220)
09950-70010(09951-07150)

Coat a new counter gear rear radial ball bearing with gear oil, and then using SST and a press, install it to the transfer adapter.

SST

09950-70010(09951-07360)
09950-60010(09951-00650)

Install the bearing lock plate with the bolt.

Torque:

11 N*m{115 kgf*cm, 8 ft.*lbf}

Using SST and a press, press in 2 new rear output shaft bearings (outer race) to the transfer adapter.

SST

09950-70010(09951-07100,09951-07360)
09950-60020(09951-00790)

Using a 14 mm hexagon socket wrench, install a new transfer adapter case plug to the transfer adapter.

Torque:

35 N*m{357 kgf*cm, 26 ft.*lbf}

Install the oil separator packing seal to the transfer adapter.

HINT:

Insert the protruding part of the oil separator packing seal into the groove of the transfer adapter.

Install the No. 1 oil receiver pipe to the transfer adapter.

Install 2 new gaskets and the 2 manual transmission filler plugs to the transfer adapter.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

Install the transfer adapter and 2 brackets to the transmission middle case with the 10 bolts.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Install the ball and compression spring to the transfer adapter.

Using a 10 mm socket hexagon wrench, install a new shift detent ball plug to the transfer adapter.

Torque:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Using a belt and wooden block, securely fasten the transmission to the workbench.

Install a new output shaft spacer and a new rear output shaft bearing (inner race).

Temporarily install a new manual transmission output shaft rear set nut by hand.

HINT:

Fit the spacer and rear output shaft bearing securely.

Move the shift and select lever shaft to N.

Using SST, rotate the output shaft 15 times at a speed of 100 rpm or less in order to settle the bearing.

Using SST and a torque wrench, measure the output shaft preload.*1

SST

09326-35010(09326-03010,09326-03020)

Engage 5th gear, and then secure the input shaft using SST.

SST

09322-35010(09322-03010,09322-03020,09322-03030,90105-12087,90170-12030)

HINT:

1. Install SST securely so that (A) is in-line with the input shaft.
   
2. Make sure that (A) moves back and forth by hand after installing SST.
   

Using SST and a torque wrench, tighten the nut.

Torque:

580 N*m{5914 kgf*cm, 428 ft.*lbf}

Move the shift and select lever shaft to N.

Using SST, rotate the output shaft 15 times at a speed of 100 rpm or less in order to settle the bearing.

Using SST and a torque wrench, measure the output shaft preload.*2

SST

09326-35010(09326-03010,09326-03020)

Adjust the preload so that the difference between *1 and *2 is within the specified range.

Standard Preload (at starting):

*2 - *1 = 0.45 to 1.05 N*m (4.59 to 10.7 kgf*cm, 3.99 to 9.29 in.*lbf)

1. If the preload is more than the standard, replace the output shaft spacer.
   

Using a chisel and hammer, caulk the manual transmission output shaft rear set nut.

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

Install the manual transmission case cover with 4 new bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Install the shift lever housing with a new bolt.

Torque:

47 N*m{479 kgf*cm, 35 ft.*lbf}

Apply seal packing to the floor shift control shift lever retainer sub-assembly as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

Parts must be assembled within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

Install the floor shift control shift lever retainer sub-assembly with the 4 bolts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the clutch release fork support boot to the front transmission case.

Install the release fork support to the manual transmission unit.

Torque:

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.

NOTICE:

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