Manual Transaxle Unit (For Sedan) Reassembly

Coat the output shaft cover with MP grease and install it onto the front transaxle case.

NOTICE:

Insert the output shaft cover projection into the case side hollow.

Coat a new output shaft front bearing with gear oil. Using SST and a press, install it onto the front transaxle case.

SST

09950-60010(09951-00550)
09950-70010(09951-07150)

NOTICE:

1. Install the new bearing in the correct direction, as shown in the illustration.
   
2. When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.
   

Using SST and a hammer, install a new front transaxle case oil seal onto the front transalxe case.

SST

09950-60010(09951-00370)
09950-70010(09951-07150)

Drive in depth:

15.6 to 16.0 mm (0.6141 to 0.6299 in.)

Coat the lip of the front transaxle case oil seal with MP grease.

Coat a new input shaft front bearing with gear oil, and using SST and a press, install it onto the front transaxle case.

SST

09950-60010(09951-00420)
09950-70010(09951-07150)

Drive in depth:

0 to 0.3 mm (0 to 0.0118 in.)

Using SST and a hammer, install the shift and select lever shaft slide ball bearing onto the transmission case.

SST

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

Drive in depth:

0 to 0.5 mm (0 to 0.0020 in.)

Using SST, install the shift and select lever shaft oil seal onto the transmission case.

SST

09950-70010(09951-07150)
09950-60010(09951-00240)

Drive in depth:

9.7 to 10.3 mm (0.382 to 0.406 in.)

Using SST and a press, install the front differential case front tapered roller bearing (inner race) onto the front differential case.

SST

09350-32014(09351-32120)
09950-60010(09951-00530)

Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the front transaxle case.

SST

09950-60020(09951-00680)
09950-70010(09951-07150)

Using SST and a press, install the front differential case rear tapered roller bearing (inner race) onto the differential case.

SST

09350-32014(09351-32120)
09950-60010(09951-00530)

Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with plate washer onto the transmission case.

SST

09309-36010
09950-60020(09951-00710)
09950-70010(09951-07150)

HINT:

Use a plate washer of the same thickness as the removed one.

Coat the differential case assembly with gear oil, and install it onto the front transaxle case.

Install the manual transmission case with the 16 bolts.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle.

SST

09564-32011

Using SST and a torque wrench, measure the preload.

SST

09564-32011

Preload (at starting):

New bearing:

0.78 to 1.57 N*m (7.95 to 16.0 kgf*cm, 6.9 to 13.89 in.*lbf)

Used bearing:

0.49 to 0.98 N*m (5.0 to 10.0 kgf*cm, 4.34 to 8.67 in.*lbf)

Plate washer thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
AA	2.10 (0.0827)	LL	2.60 (0.1024)
BB	2.15 (0.0846)	MM	2.65 (0.1043)
CC	2.20 (0.0866)	NN	2.70 (0.1063)
DD	2.25 (0.0886)	PP	2.75 (0.1083)
EE	2.30 (0.0906)	QQ	2.80 (0.1102)
FF	2.35 (0.0925)	RR	2.85 (0.1122)
GG	2.40 (0.0945)	SS	2.90 (0.1142)
HH	2.45 (0.0965)	TT	2.95 (0.1161)
JJ	2.50 (0.0984)	UU	3.00 (0.1181)
KK	2.55 (0.1004)	-	-

HINT:

The preload changes by approximately 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) per each 0.05 mm (0.0020 in.) change in plate washer thickness.

Remove the 16 bolts and the manual transmission case.

Remove the differential case assembly from the front transaxle case.

Using SST and a hammer, install a new transmission case oil seal onto the manual transmission case.

SST

09316-60011(09316-00011)

Drive in depth:

9.6 to 10.2 mm (0.378 to 0.402 in.)

Coat the lip of the front transmission case oil seal with MP grease.

Using SST and a hammer, install a new transaxle case oil seal onto the front transaxle case.

Drive in depth:

1.6 to 2.2 mm (0.063 to 0.087 in.)

SST

09710-20011(09710-06071)
09950-70010(09951-07150)

Coat the lip of the transaxle case oil seal with MP grease.

Clean the transmission magnet and install it onto the front transaxle case.

Install the bearing lock plate onto the front transaxle case with the bolt.

Torque:

11 N*m{115 kgf*cm, 8.3 ft.*lbf}

Install oil receiver pipe No. 1 onto the manual transmission case with the bolt.

Torque:

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

NOTICE:

1. Do not deform oil receiver pipe No. 1.
   
2. Install the oil receiver pipe No. 1 while holding it against the manual transmission case, as shown in the illustration.
   

Install the oil receiver pipe No. 2 onto the manual transmission case with the bolt.

Torque:

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

NOTICE:

1. Do not deform oil receiver pipe No. 2.
   
2. Install the oil receiver pipe No. 2 while holding it against the manual transmission case, as shown in the illustration.
   

Install the reverse restrict pin assembly onto the manual transmission case.

NOTICE:

Set the reverse restrict pin assembly in the correct orientation.

Using a pin punch (φ5 mm) and a hammer, install the slotted pin onto the reverse restrict pin assembly.

Drive in depth:

15.5 to 16.5 mm (0.6102 to 0.6496 in.)

Apply sealant to the reverse restrict pin plug.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case.

Torque:

13 N*m{130 kgf*cm, 9.3 ft.*lbf}

Install the manual transaxle case receiver onto the front transaxle case with the bolt.

Torque:

11 N*m{115 kgf*cm, 8.3 ft.*lbf}

Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.

Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.

Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil and install them as shown in the illustration.

HINT:

Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.

Coat gear shift fork No. 1 and gear shift fork No. 2 with gear oil and install them.

Coat gear shift fork shaft No. 1 with gear oil and install it.

Apply sealant to the shift fork set bolt.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Install the shift fork set bolt.

Torque:

16 N*m{160 kgf*cm, 12 ft.*lbf}

Using a brass bar and a hammer, install a new shaft snap ring onto gear shift fork shaft No. 1.

Coat the 2 shift fork balls with MP grease and install them onto the reverse shift fork.

Install the reverse shift fork onto gear shift fork shaft No. 3.

Using a brass bar and a hammer, install 2 new shift fork shaft snap rings onto shift fork shaft No. 3.

Coat gear shift fork shaft No. 3 with gear oil and install it.

Coat gear shift head No. 1 and gear shift fork shaft No. 2 with gear oil and install them.

NOTICE:

To avoid interference by the 2 shift fork balls, lift up gear shift fork shaft No. 3 to the position shown in the illustration.

Coat the 2 shift lock bolts with sealant and install them onto gear shift fork No. 2 and shift head No. 1.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

16 N*m{160 kgf*cm, 12 ft.*lbf}

Install the reverse shift arm bracket assembly onto the front transaxle case with 2 bolts.

Torque:

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

Apply FIPG to the manual transmission case, as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

NOTICE:

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

Install the 13 bolts onto the manual transmission side.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Install the 3 bolts onto the manual transaxle side.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Coat the reverse idler gear shaft bolt with sealant and install it with a new gasket.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Coat lock ball assembly No. 2 with sealant and install it with a hexagon wrench.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Install the 2 shift detent balls, 2 shift detent ball springs and 2 shift detent ball spring seats No. 1 onto the manual transmission case.

Coat the 2 shift detent ball plugs with sealant and install them using a hexagon wrench.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Install the shift detent ball, shift detent ball compression spring and shift detent ball spring seat No. 1 onto the front transaxle case.

Coat the shift detent ball plug with sealant and install it using a hexagon wrench.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Using a snap ring expander, install the input shaft rear bearing hole snap ring onto the input shaft.

Using a snap ring expander, install the output shaft rear bearing hole snap ring onto the output shaft.

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

Coat the 5 bolts with sealant, and install the bearing retainer rear onto the manual transmission case with the 5 bolts.

Torque:

27 N*m{280 kgf*cm, 20 ft.*lbf}

Using SST, install the 5th driven gear onto the output shaft.

SST

09309-12020

Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.

Coat the 5th gear with gear oil and install it onto the input shaft.

Coat synchronizer ring No. 3 with gear oil and install it onto the 5th gear.

Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the transmission clutch hub No. 3, as shown in the illustration.

NOTICE:

Do not set the 2 shifting key spring openings in the same position.

Using SST and a hammer, install transmission clutch hub No. 3 onto the input shaft.

SST

09636-20010

NOTICE:

1. Do not install transmission clutch hub No. 3 in the wrong direction.
   
2. Install the transmission clutch hub No. 3 with the synchronizer ring No. 3 key groove and synchromesh shifting key No. 3 aligned.
   
3. Check that the 5th gear is rotating.
   
4. Place a suitable sized wooden block to support the input shaft.
   

Select a clutch hub No. 3 shaft snap ring that will allow minimum axial play.

Clearance:

0.1 mm or less

Snap ring thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.25 (0.0886)	E	2.49 (0.0980)
B	2.31 (0.0909)	F	2.55 (0.1004)
C	2.37 (0.0933)	G	2.61 (0.1028)
D	2.43 (0.0957)	-	-

Using a brass bar and a hammer, install the snap ring onto the input shaft.

Using a dial indicator, measure the 5th gear thrust clearance.

Standard clearance:

0.1 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

Using a dial indicator, measure 5th gear radial clearance.

Standard clearance:

KOYO made:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

KOYO made:

0.058 mm (0.0023 in.)

NSK made:

0.056 mm (0.0022 in.)

Coat transmission clutch hub sleeve No. 3 with gear oil and install it together with gear shift fork No. 3 onto transmission clutch hub No. 3.

HINT:

Set the transmission clutch hub No. 3 in the correct orientation.

Coat the gear shift fork lock bolt with sealant, and install it onto gear shift fork No. 3.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

16 N*m{160 kgf*cm, 12 ft.*lbf}

Engage the 2 gears simultaneously to lock the transmission.

Coat a new manual transmission output shaft rear set nut with sealant.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Install the new manual transmission output shaft rear set nut.

Torque:

118 N*m{1,200 kgf*cm, 87 ft.*lbf}

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

Disengage the 2 gears.

Apply FIPG to the manual transaxle case cover sub-assembly as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

NOTICE:

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

Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.

Torque:

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

Coat the shift and select lever shaft assembly with gear oil, and install it onto the transmission case.

Using SST and a hammer, install a new control shaft cover oil seal onto the control shaft cover.

Drive in depth:

0.2 to 1.2 mm (0.0079 to 0.0472 in.)

SST

09950-60010(09951-00280)
09950-70010(09951-07150)

Coat the control shaft cover oil seal with MP grease.

Coat the 4 bolts with sealant. Install a new gasket and control shaft cover onto the manual transmission case with the 4 bolts.

Torque:

20 N*m{200 kgf*cm, 14 ft.*lbf}

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

NOTICE:

Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.

Coat the shift gate pin with sealant.

Install the washer and shift gate pin.

Torque:

11 N*m{112 kgf*cm, 8.1 ft.*lbf}

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Coat lock ball assembly No. 1 with sealant, install it onto the manual transmission case.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Install the dust boot onto the control shaft cover.

Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.

Install the spring washer with the nut.

Torque:

12 N*m{120 kgf*cm, 8.7 ft.*lbf}

Install the dust boot onto the shift and select lever shaft oil seal.

Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.

Install the spring washer with the nut.

Torque:

12 N*m{120 kgf*cm, 8.7 ft.*lbf}

Install the selecting bell crank assembly together with the control shift lever bush onto the manual transmission case with the 2 bolts and nut.

Torque:

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

12 N*m{120 kgf*cm, 8.7 ft.*lbf} for nut

NOTICE:

Apply MP grease to the inside circumferential surface of the control shift lever bush.

Using SST, install the back-up light switch assembly onto the manual transmission case with a new gasket.

SST

09817-16011

Torque:

40 N*m{410 kgf*cm, 30 ft.*lbf}

Install the back-up light switch wire harness into the 2 clamps.

Install a new O-ring onto the speedometer sensor.

Install the speedometer sensor onto the transaxle case with the bolt.

Torque:

11 N*m{115 kgf*cm, 8.3 ft.*lbf}

Install a new O-ring onto the speedometer driven hole cover sub-assembly.

Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt.

Torque:

11 N*m{115 kgf*cm, 8.3 ft.*lbf}

Install the manual transmission filler plug onto the manual transmission case with a new gasket.

Torque:

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

Install the drain plug onto the manual transmission case with a new gasket.

Torque:

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