Manual Transmission Unit Installation

Apply gear oil to the sliding part of the output shaft.

Using a plastic-faced hammer, install the output shaft by tapping the intermediate plate.

Using a snap ring expander, install the shaft snap ring to the output shaft.

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

NOTICE:

1. Install the No. 2 synchronizer ring so that its groove fits into the No. 2 synchromesh shifting key.
   
2. Check that the input shaft rotates slightly.
   

Temporarily install the counter gear to the intermediate plate.

Using SST and a hammer, tap in a new center bearing to the intermediate plate.

SST

09316-60011(09316-00011)

HINT:

Install the bearing while tapping the tip of the counter gear with a plastic-faced hammer so that the counter gear does not hit the side wall of the output shaft gear by being pushed forward.

Apply gear oil to each sliding part of the reverse idler gear and reverse idler gear shaft, and install the reverse idler gear and the reverse idler shaft to the intermediate plate.

NOTICE:

Face the groove side of the reverse idler shaft to the rear side, and install it from the rear side.

Insert the protrusion of the bearing retainer into the groove of the reverse idler gear shaft. Then install the bearing retainer with the 4 bolts.

Torque:

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

Apply MP grease to the washer pin, and install it to the counter gear.

Apply gear oil to the thrust washer, and install it to the counter gear.

NOTICE:

Install the thrust washer so that its chamfer side faces to the front side.

Apply gear oil to the sliding part of the No. 3 transmission hub sleeve, and install it to the counter 5th gear.

NOTICE:

Be sure of the direction of the No. 3 transmission hub sleeve and counter 5th gear.

Install the No. 3 transmission hub sleeve.

1. for Type A:
   Install the 2 No. 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the counter 5th gear.
   





2. for Type B:
   Install the 2 No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring to the counter 5th gear as shown in the illustration.
   

   HINT:

   When installing the synchromesh shifting key spring, make sure the protrusion fits into the cutout.

Using a snap ring expander, install the snap ring to the counter 5th gear.

Apply gear oil to the bearing and install it to the counter 5th gear.

Apply gear oil to the 5th gear and No. 3 transmission hub sleeve, and install it to the counter gear.

Apply gear oil to the No. 3 synchronizer ring, and install it to the counter gear.

NOTICE:

Install the No. 3 synchronizer ring so that its groove fits into the No. 3 synchromesh shifting key.

Using SST and a press, press in the gear spline piece to the counter gear.

SST

09316-60011(09316-00011)

NOTICE:

Check that the gear rotates freely.

Select a snap ring so that the thrust gap between the No. 5 gear spline piece and snap ring is within the specification.

Standard clearance:

0.10 mm (0.0039 in.) or less

Standard snap ring thickness:

Mark	Thickness
A	2.80 to 2.85 mm (0.1102 to 0.1122 in.)
B	2.85 to 2.90 mm (0.1122 to 0.1141 in.)
C	2.90 to 2.95 mm (0.1141 to 0.1160 in.)
D	2.95 to 3.00 mm (0.1160 to 0.1181 in.)
E	3.00 to 3.05 mm (0.1181 to 0.1200 in.)
F	3.05 to 3.10 mm (0.1200 to 0.1220 in.)
G	3.10 to 3.15 mm (0.1220 to 0.1240 in.)

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

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

Using a dial indicator, check the gear radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Using SST and a press, press in the spacer and a new rear bearing to the output shaft.

SST

09309-35010

Select a shaft snap ring so that the thrust gap between the output shaft bearing shaft and snap ring is within the specification.

Standard clearance:

0.10 mm (0.0039 in.) or less

Standard snap ring thickness:

Mark	Thickness	Mark	Thickness
A	2.65 to 2.70 mm (0.1043 to 0.1063 in.)	K	3.10 to 3.15 mm (0.1220 to 0.1240 in.)
B	2.70 to 2.75 mm (0.1063 to 0.1083 in.)	L	3.15 to 3.20 mm (0.1240 to 0.1260 in.)
C	2.75 to 2.80 mm (0.1083 to 0.1102 in.)	M	3.20 to 3.25 mm (0.1260 to 0.1280 in.)
D	2.80 to 2.85 mm (0.1102 to 0.1122 in.)	N	3.25 to 3.30 mm (0.1280 to 0.1299 in.)
E	2.85 to 2.90 mm (0.1122 to 0.1141 in.)	P	3.30 to 3.35 mm (0.1299 to 0.1319 in.)
F	2.90 to 2.95 mm (0.1141 to 0.1160 in.)	Q	3.35 to 3.40 mm (0.1319 to 0.1339 in.)
G	2.95 to 3.00 mm (0.1160 to 0.1181 in.)	R	3.40 to 3.45 mm (0.1339 to 0.1358 in.)
H	3.00 to 3.05 mm (0.1181 to 0.1200 in.)	S	3.45 to 3.50 mm (0.1358 to 0.1378 in.)
J	3.05 to 3.10 mm (0.1200 to 0.1220 in.)	-	-

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

Using snap ring pliers, install the snap ring.

Install the ball and drive gear.

Using snap ring pliers, install the snap ring.

Install the arm bracket on the intermediate plate with the 2 bolts.

Torque:

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

Install the shift arm to the shift fork. Using a screwdriver and hammer, tap in a new E-ring.

Install the tip of the reverse shift arm to the reverse idler gear. Align the cut end of the reverse shift arm with the reverse shift arm bracket pin, and install them.

Install the compression spring and reverse shift fork ball to the reverse shift fork.

Apply gear oil to the sliding part of the No. 4 shift fork shaft.

Using a screwdriver, install the No. 3 shift fork shaft by pushing the reverse shift fork ball lightly.

Using a brass bar and hammer, tap in the snap ring to the No. 4 shift fork shaft.

Install the reverse shift fork ball to the reverse shift fork.

Install the No. 1 shift interlock roller to the intermediate plate.

Install the No. 3 shift fork to the No. 3 transmission hub sleeve and No. 3 shift fork shaft to the intermediate plate from the front side.

Using a brass bar and hammer, tap in the snap ring to the shift fork shaft.

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

Install the No. 1 shift interlock roller to the intermediate plate.

Install the No. 1 shift fork to the reverse gear.

Install the No. 1 shift fork shaft to the intermediate plate from the rear side.

Install the shift fork set bolt to the No. 1 shift fork.

Torque:

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

Using a brass bar and hammer, tap in the shift fork shaft snap ring to the No. 1 shift fork shaft.

Install the shift interlock pin and No. 1 shift interlock roller to the intermediate plate.

Install the No. 2 shift fork to the No. 2 transmission hub sleeve.

Apply gear oil to the No. 2 shift fork, and install it to the intermediate plate from the rear side.

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

Torque:

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

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

Install the 2 compression springs and 2 shift detent balls to the intermediate plate.

Using a T40 ''torx'' socket, install the 3 spring seats to the intermediate plate.

Torque:

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

Install the detent ball and low side compression spring to the intermediate plate.

Using a T40 ''torx'' socket, install the spring seat to the intermediate plate.

Torque:

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

Clean the transmission magnet, and install it to the intermediate plate.

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Using a plastic-faced hammer, tap the transmission case to attach it to the intermediate plate.

Using a snap ring expander, install the snap ring to the transmission case.

Using a snap ring expander, install the snap ring to the transmission case.

Using SST and a hammer, tap in a new oil seal to the front bearing retainer.

SST

09950-60010(09951-00300,09951-00520,09952-06010)
09950-70010(09951-07100)

Standard oil seal depth:

11.20 to 12.20 mm (0.4409 to 0.4803 in.)

Lightly apply MP grease to the lip of the oil seal.

Apply seal packing to the bearing retainer as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Install the bearing retainer front to the transmission case with the 8 bolts.

Torque:

16.5 N*m{170 kgf*cm, 12 ft.*lbf}

Check that the input shaft and output shaft rotate smoothly.

Using SST and a hammer, tap in a new oil seal to the extension housing.

SST

09710-30050
09950-70010(09951-07100)

Standard oil seal depth:

0 +-0.5 mm (0 +-0.020 in.)

NOTICE:

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

Lightly apply MP grease to the lip of the oil seal.

Install the restrict pin to the extension housing.

Using a 5 mm pin punch and hammer, tap in the slotted pin to the extension housing.

Using a T40 ''torx'' socket, install the reverse restrict pin plug to the transfer adapter.

Torque:

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

Install the oil receiver with the bolt.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Install the oil receiver pipe to the extension housing.

Apply seal packing to the extension housing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Insert the shift and select lever to the extension housing.

Connect the shift and select lever to the fork shaft and set the shift lever housing in place.

Align the shift and select lever to the extension housing installation hole and push in the extension housing.

Install the extension housing to the case with the 10 bolts.

Torque:

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

Install the shift lever housing bolt to the shift lever housing.

Torque:

33 N*m{340 kgf*cm, 25 ft.*lbf}

Install the control shift lever retainer and oil deflector.

Install the 6 bolts.

Torque:

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

Install the 2 restrict pins.

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:

44 N*m{450 kgf*cm, 32 ft.*lbf}

Install the clutch housing to the transmission case with the 9 bolts.

Torque:

36 N*m{370 kgf*cm, 27 ft.*lbf}

Install the fork boot to the clutch housing.

Install the release fork support to the clutch housing.

Torque:

47 N*m{480 kgf*cm, 35 ft.*lbf}

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

Grease:

Multemp 8158 Grease or equivalent

Install the clutch release fork.

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

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}