Manual Transmission Unit Reassembly

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 output shaft bearing shaft snap ring to the output shaft center bearing.

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 onto the No. 2 synchromesh shifting key.
   
2. Check that the input shaft rotates smoothly.
   

Install the counter gear to the intermediate plate.

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

SST

09316-60011

HINT:

Install the counter shaft center 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.

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

Apply gear oil to the sliding parts of the reverse idler gear sub-assembly and reverse idler gear shaft, and install the reverse idler gear sub-assembly and reverse idler shaft to the intermediate plate.

NOTICE:

Be sure to install the reverse idler gear shaft from the rear with the groove facing the rear side.

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

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Apply MP grease to the 5th gear thrust washer pin and install it to the counter gear.

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

NOTICE:

Install the 5th gear thrust washer so that its chamfered side faces the front side.

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

NOTICE:

Make sure that the No. 3 transmission hub sleeve and counter 5th gear are facing the proper direction.

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 No. 3 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 counter 5th gear bearing and install it to the counter 5th gear.

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

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

NOTICE:

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

Using SST and a press, press in the No. 5 gear spline piece to the counter gear.

SST

09316-60011(09316-00011)

NOTICE:

Check that the counter 5th gear rotates freely.

Select a counter gear rear shaft snap ring so that the thrust clearance between the No. 5 gear spline piece and counter gear rear shaft snap ring to be within the specification.

Standard clearance:

0.10 mm (0.00394 in.) or less

Snap Ring Thickness:

Thickness

2.85 mm (0.1122 in.)

2.90 mm (0.1141 in.)

2.95 mm (0.1161 in.)

3.00 mm (0.1181 in.)

3.05 mm (0.1200 in.)

3.10 mm (0.1220 in.)

3.15 mm (0.1240 in.)

Secure the intermediate plate in a vise between aluminum plates.

Using a brass bar and hammer, tap on the counter gear rear shaft snap ring.

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.00394 to 0.0137 in.)

1. If the clearance is not as specified, replace the counter 5th gear.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.000591 to 0.00267 in.)

1. If the clearance is not as specified, replace the counter 5th gear bearing with a new one.
   

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

SST

09309-35010

Select a output shaft bearing shaft snap ring so that the thrust clearance between the output shaft bearing shaft and output shaft bearing shaft snap ring to be within the specification.

Standard clearance:

0.10 mm (0.00394 in.) or less

Snap Ring Thickness:

Thickness	Thickness
2.65 mm (0.1043 in.)	3.10 mm (0.1220 in.)
2.70 mm (0.1063 in.)	3.15 mm (0.1240 in.)
2.75 mm (0.1083 in.)	3.20 mm (0.1260 in.)
2.80 mm (0.1102 in.)	3.25 mm (0.1280 in.)
2.85 mm (0.1122 in.)	3.30 mm (0.1299 in.)
2.90 mm (0.1142 in.)	3.35 mm (0.1319 in.)
2.95 mm (0.1161 in.)	3.40 mm (0.1339 in.)
3.00 mm (0.1181 in.)	3.45 mm (0.1358 in.)
3.05 mm (0.1200 in.)	-

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

Install the reverse shift arm to the reverse shift arm bracket with a new snap ring.

Insert the tip of the reverse shift arm into the reverse idler gear sub-assembly.

Install the reverse shift arm bracket with the 2 bolts.

Torque:

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

Install the torsion spring to the reverse shift arm bracket.

NOTICE:

Make sure that the torsion spring is securely installed to the reverse shift arm.

Install the reverse shift fork to the reverse shift arm.

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

Install the straight pin to the reverse shift fork.

Using a brass bar and hammer, tap on the snap ring to the No. 3 gear shift fork shaft.

Using a 5 mm pin punch and hammer, tap on the shift fork set 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 gear shift fork shaft to the intermediate plate from the rear side.

Install a new bolt to the No. 1 shift fork.

Torque:

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

Using a brass bar and hammer, tap in the snap ring to the No. 1 gear 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 gear shift fork shaft and install it to the intermediate plate from the rear side.

Install a new bolt to the No. 2 shift fork.

Torque:

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

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

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

for Type A:
Apply adhesive to 2 or 3 threads of the 2 No. 1 shift detent ball spring seats.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

for Type A:
Using a 6 mm hexagon socket wrench, install the 2 No. 1 shift detent ball spring seats to the intermediate plate.

Torque:

19 N*m{189 kgf*cm, 14 ft.*lbf}

for Type B:
Using a T40 "TORX" socket wrench, install the 2 No. 1 shift detent ball spring seats to the intermediate plate.

Torque:

19 N*m{189 kgf*cm, 14 ft.*lbf}

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

for Type A:
Apply adhesive to 2 or 3 threads of the No. 1 shift detent ball spring seat.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

for Type A:
Using a 6 mm hexagon socket wrench, install the No. 1 shift detent ball spring seat to the intermediate plate.

for Type B:
Using a T40 "TORX" socket wrench, install the No. 1 shift detent ball spring seat to the intermediate plate.

Torque:

19 N*m{189 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

Seal diameter:

1.2 mm (0.0472 in.)

NOTICE:

Assemble parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

Place the manual transmission case on wooden blocks.

Using a plastic-faced hammer, tap the intermediate plate to install the manual transmission case.

Using a snap ring expander, install the No. 1 counter gear front bearing snap ring to the counter gear front bearing.

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

Using SST and a hammer, tap in a new transmission front bearing retainer 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 (0.441 to 0.480 in.)

Apply a light coat of MP grease to the lip of the transmission front bearing retainer oil seal.

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Seal diameter:

1.2 mm (0.0472 in.)

NOTICE:

Assemble parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

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

Torque:

17 N*m{168 kgf*cm, 12 ft.*lbf}

Check that the input shaft and output shaft rotate smoothly.

Using SST and a hammer, tap in a new transfer adapter oil seal to the transfer adapter.

SST

09710-30050
09950-70010(09951-07100)

Standard oil seal depth:

45.4 to 46.4 mm (1.79 to 1.82 in.)

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

Install the reverse restrict pin assembly to the transfer adapter.

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

Using a T40 "TORX" socket wrench, install the reverse restrict pin plug to the transfer adapter.

Torque:

19 N*m{189 kgf*cm, 14 ft.*lbf}

Install the transfer oil receiver pipe to the transfer adapter.

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

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Seal diameter:

1.2 mm (0.0472 in.)

NOTICE:

Assemble parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

Using a plastic-faced hammer, tap the transfer adapter to attach it to the manual transmission case.

Install the transfer adapter to the manual transmission case with the 10 bolts.

Torque:

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

Install the shift and select lever with the shift lever housing to the transfer adapter.

Install the bolt to the shift lever housing.

Torque:

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

Install the floor shift control shift lever retainer sub-assembly and a new gasket with the 4 bolts.

Torque:

18 N*m{184 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 assembly to the manual transmission case.

SST

09817-16011

Torque:

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

Temporarily install the clutch housing with the 7 bolts labeled A.

Apply adhesive to the 2 bolts labeled B.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Temporarily install the 2 bolts labeled B.

Tighten the 9 bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Install the release fork support to the manual transmission unit.

Torque:

47 N*m{479 kgf*cm, 34 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

Install the release fork boot to the clutch housing.

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

Torque:

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

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

Torque:

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