Manual Transmission Unit Installation

Install the output shaft into 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.

HINT:

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

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.

NOTICE:

Install the bearing (with snap ring) to the counter gear's rear side.

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

HINT:

Hold the front side of the counter gear by hand.

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

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

Torque:

18 N*m{185 kgf*cm, 13 ft.*lbf}

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

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

Torque:

17 N*m{175 kgf*cm, 13 ft.*lbf}

Install a new E-ring and the shift fork to the shift arm.

Install the arm bracket with the shift arm to the intermediate plate.

Install the 2 bolts.

Torque:

18 N*m{185 kgf*cm, 13 ft.*lbf}

Install the lock ball.

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

Install the 5th gear to the counter gear.

Temporarily install the No. 3 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, press in the No. 5 gear spline piece with the No. 3 synchronizer ring slots aligned with the shifting keys.

Mount the intermediate plate to the vise.

Select a snap ring that will allow minimal axial play.

Standard clearance:

0.10 mm (0.0039 in.) or less

Standard counter gear rear shaft snap ring thickness:

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 in the snap ring to the counter gear.

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.100 to 0.300 mm (0.0039 to 0.0117 in.)

Maximum clearance:

0.300 mm (0.0117 in.)

Install the No. 2 shift fork shaft through the No. 2 gear shift fork, No. 1 gear shift fork and intermediate plate.

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

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

Torque:

20 N*m{204 kgf*cm, 14 ft.*lbf}

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

Coat the No. 1 interlock pin with MP grease.

Using a magnetic finger, install the No. 1 interlock pin to the intermediate plate.

Install the No. 1 shift fork shaft through the No. 2 gear shift fork and intermediate plate.

Install the No. 1 shift fork with the bolt.

Torque:

20 N*m{204 kgf*cm, 14 ft.*lbf}

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

Install the No. 3 head gear shift to the No. 3 shift fork shaft.

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

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

Coat the shift interlock pin with MP grease.

Using a magnetic finger, install the No. 3 shift interlock pin to the intermediate plate.

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

Coat the shift detent ball with MP grease.

Install the shift detent ball and the shift detent ball low side compression spring to the reverse shift fork.

Install the No. 3 shift fork shaft through the reverse shift arm.

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

Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the reverse shift head.

Coat the ball pin shift interlocks with MP grease.

Using a magnetic finger, install the ball pin shift interlocks to the intermediate plate.

Install the No. 4 shift fork shaft through the reverse shift fork, intermediate plate and reverse shift head.

Using a brass bar and hammer, tap in the shift fork shaft snap ring and 2 reverse shift head rings.

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

Torque:

20 N*m{204 kgf*cm, 14 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.

Torque:

19 N*m{190 kgf*cm, 14 ft.*lbf}

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

Coat the 3 spring seats with adhesive.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a T40 "TORX" socket, install the 3 spring seats to the intermediate plate.

Torque:

19 N*m{190 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 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 bearing retainer front.

SST

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

Standard depth:

12.5 to 13.5 m (0.492 to 0.531 in.)

Check that "FIPG" is imprinted on the bearing retainer front.

w/o Gasket:
Apply seal packing to the bearing retainer front as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

w/ Gasket:
Install a new gasket and the bearing retainer front to the transmission case.

w/o Gasket:
Install the bearing retainer front to the transmission case.

Apply adhesive to the bolt threads.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the 8 bolts.

Torque:

17 N*m{175 kgf*cm, 12 ft.*lbf}w/ Gasket

12 N*m{125 kgf*cm, 10 ft.*lbf}w/o Gasket

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

SST

09223-00010

Standard depth:

45 to 46 mm (1.772 to 1.811 in.)

NOTICE:

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

Lightly apply MP grease to the tip 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.

Torque:

19 N*m{190 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.

Torque:

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

Install the shift lever housing with the bolt.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

Coat the shift detent ball with MP grease, and install it and the compression spring to the extension housing.

Using a T40 "TORX" socket, install the spring seat to the extension housing.

Torque:

19 N*m{190 kgf*cm, 14 ft.*lbf}

Install the oil deflector and shift lever retainer to the transfer adaptor with the 4 bolts.

Torque:

18 N*m{185 kgf*cm, 13 ft.*lbf}

Install the 2 restrict pins to the transfer adaptor.

Torque:

28 N*m{290 kgf*cm, 21 ft.*lbf}

Install the clutch housing.

Apply adhesive to the bolt threads.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the 9 bolts.

Torque:

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

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

SST

09817-16011

Torque:

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

Install the release fork boot to the clutch housing.

Install the release fork support to the clutch housing.

Torque:

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

Coat the release bearing with Multemp 8158 grease or equivalent, and install it to the release fork with the clutch release bearing clip.

Grease:

Multemp 8158 Grease or equivalent

Install the release fork to the input shaft.

Apply molybdenum disulphide lithium base grease to the input shaft spline.

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

Torque:

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

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

Torque:

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