Manual Transmission Unit Reassembly

Install the output shaft by lightly tapping on the back side of the intermediate plate with a plastic-faced hammer.

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

Install the No. 2 synchronizer ring to the input shaft.

Install the input shaft to the output shaft.

HINT:

Align the shifting key of the synchronizer ring with the groove of the clutch hub.

Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.

Install the counter gear to the intermediate plate.

Install the center bearing to the counter gear.

Using a snap ring expander, install the snap ring to the outer race.

Using a brass bar and hammer, lightly tap the bearing outer race uniformly to install it.

NOTICE:

Do not drop the counter gear. Hold the front side of the counter gear.

Install the output shaft rear bearing retainer to the intermediate plate with the 4 bolts.

Torque:

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

Apply a light coat of gear oil to the sleeve and hub.

Install the No. 1 transmission hub sleeve, 3 shifting keys and 3 springs to the No. 4 transmission clutch hub.

NOTICE:

Do not mistake the installation direction of the No. 1 transmission hub sleeve, No. 4 transmission clutch hub, and shifting keys.

Coat the reverse gear bearing with gear oil, and install it to the reverse gear.

Coat the reverse synchronizer ring set with gear oil, and install it to the reverse gear.

Coat the reverse gear with gear oil, and install it to the output shaft.

Using SST and a hammer, install the No. 4 transmission clutch hub.

SST

09316-60011(09316-00011)

HINT:

Align the shifting key of the synchronizer ring with the groove of the clutch hub.

Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.

Select a new snap ring that will allow minimum clearance.

Standard Clearance:

0.1 mm (0.00393 in.) or less

Snap Ring Thickness:

Part No.	Thickness	Mark
90520-34018	2.40 to 2.45 mm (0.0945 to 0.0965 in.)	A
90520-34019	2.45 to 2.50 mm (0.0965 to 0.0984 in.)	B
90520-34020	2.50 to 2.55 mm (0.0984 to 0.100 in.)	C
90520-34021	2.55 to 2.60 mm (0.100 to 0.102 in.)	D
90520-34022	2.60 to 2.65 mm (0.102 to 0.104 in.)	E
90520-34023	2.65 to 2.70 mm (0.104 to 0.106 in.)	F

Using a brass bar and hammer, install the snap ring to the output shaft.

Using a feeler gauge, measure the reverse gear thrust clearance.

Standard Clearance:

0.15 to 0.52 mm (0.00591 to 0.0204 in.)

Install the No. 2 gear shift fork.

Install the No. 2 gear shift fork shaft to the No. 2 gear shift fork and intermediate plate with the bolt.

Torque:

46 N*m{472 kgf*cm, 34 ft.*lbf}

Install the No. 1 gear shift fork.

Using a magnet hand, install the interlock pin to the intermediate plate.

Apply MP grease to the interlock pin.

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

Install the No. 1 gear shift fork shaft to the No. 2 gear shift fork and intermediate plate with the bolt.

Torque:

46 N*m{472 kgf*cm, 34 ft.*lbf}

Install the No. 3 gear shift fork.

Using a magnet hand, install the interlock pin to the intermediate plate.

Apply MP grease to the interlock pin.

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

Install the No. 3 gear shift fork shaft to the No. 3 gear shift fork and intermediate plate with the bolt.

Torque:

46 N*m{472 kgf*cm, 34 ft.*lbf}

Install the reverse shift fork.

Using a magnet hand, install the ball to the intermediate plate.

Using a magnet hand, install the ball to the reverse shift head.

Install the No. 4 gear shift fork shaft to the reverse gear shift fork and intermediate plate with the bolt.

Torque:

34 N*m{350 kgf*cm, 25 ft.*lbf}

Using a brass bar and hammer, install the 4 snap rings.

Install the 4 balls and 4 springs to the intermediate plate.

Apply adhesive to 2 or 3 threads of the 4 detent ball plugs.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using a T40 "TORX" socket wrench, install the 4 detent ball plugs.

Torque:

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

Install the transmission case receiver to the intermediate plate with the 3 bolts.

Torque:

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

Using a plastic-faced hammer, tap 4 new straight pins into the intermediate plate.

Standard Protrusion Height:

7.0 to 9.0 mm (0.276 to 0.354 in.)

Using a plastic-faced hammer, tap 2 new straight pins into the transmission case.

Standard Protrusion Height:

4.0 to 6.0 mm (0.158 to 0.236 in.)

Using a plastic-faced hammer, tap 2 new straight pins into the transmission case.

Standard Protrusion Height:

9.0 to 11.0 mm (0.355 to 0.433 in.)

Install the oil receiver pipe to the transmission case with the 2 bolts.

Torque:

12 N*m{120 kgf*cm, 9 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

NOTICE:

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

Install the transmission case by lightly tapping it into place with a plastic-faced hammer.

NOTICE:

Make sure that the oil receiver installed on the transmission side is above the oil application area of the intermediate plate side oil receiver.

Using a snap ring expander, install the 2 snap rings to the counter gear and input shaft.

Install the woodruff key to the reverse idler gear shaft.

Install the reverse idler gear shaft to the intermediate plate.

Install the thrust washer to the reverse idler gear shaft.

NOTICE:

1. Align the protrusion of the washer with the groove of the intermediate plate during installation.
   
2. Install the washer so that the dimpled surface of the washer contacts the reverse idler gear thrust surface.
   

Install the bearing to the reverse idler gear shaft.

Install the reverse idler gear to the reverse idler gear shaft.

Install the thrust washer to the reverse idler gear shaft.

NOTICE:

Install the washer so that the dimpled surface of the washer contacts the reverse idler gear thrust surface.

Install the transmission magnet to the intermediate plate.

Install a new O-ring to the oil strainer.

Apply a light coat of gear oil to the O-ring.

Install the oil strainer to the transfer adapter with the 2 bolts.

Torque:

12 N*m{120 kgf*cm, 9 ft.*lbf}

Using a plastic-faced hammer, tap in 4 new straight pins and 2 new ring pins to the transfer adapter.

Standard Protrusion Height A (Straight Pin):

4.0 to 6.0 mm (0.157 to 0.236 in.)

Standard Protrusion Height B (Ring Pin):

4.0 to 6.0 mm (0.157 to 0.236 in.)

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 packing (FIPG) material must be removed and reapplied.

Install the transfer adapter and bracket to the transmission case with the 11 bolts.

Torque:

37 N*m{380 kgf*cm, 27 ft.*lbf}

Bolt Length:

Item	Length
Bolt A	110 mm (4.33 in.)
Bolt B	70 mm (2.75 in.)

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

Torque:

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

Install the shift and select lever, shift lever housing, and shift and select lever shaft to the transmission as shown in the illustration.

Install the 2 bolts to the shift and select lever.

Torque:

38 N*m{390 kgf*cm, 28 ft.*lbf}

Install the bolt to the shift lever housing.

Torque:

38 N*m{390 kgf*cm, 28 ft.*lbf}

Using a 14 mm hexagon wrench, install the interlock hole plug to the transfer adapter.

Torque:

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

Using SST and a press, drive in a new oil seal.

SST

09950-60010(09951-00460)
09950-70010(09951-07150)

Standard Drive in Depth:

15.4 to 16.2 mm (0.607 to 0.637 in.)

Apply gear oil to the lip of the 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

NOTICE:

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

Apply adhesive to 2 or 3 threads of the bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Torque:

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

Using SST and a hammer, tap a new oil seal into the oil pump cover in accordance with the dimension specified in the illustration.

SST

09950-70010(09951-07150)
09950-60010(09951-00640)

Apply MP grease to the straight pins.

Install the 2 straight pins.

Install a new O-ring to the oil pump cover.

Align the oil pump drive rotor groove with the straight pin, and install the oil pump cover to the transfer adapter.

Apply adhesive to 2 or 3 threads of the bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the oil pump cover to the transfer adapter with the 5 bolts.

Torque:

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

Install the No. 1 reverse restrict pin and spring to the shift lever retainer.

Using a 5 mm pin punch and hammer, tap a new slotted pin into the shift lever retainer.

Apply seal packing to the shift lever retainer, 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 packing (FIPG) material must be removed and reapplied.

Apply adhesive to 2 or 3 threads of the bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the shift lever retainer to the transfer adapter with the 4 bolts.

Torque:

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

Apply adhesive to 2 or 3 threads of the reverse restrict pins.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the 2 reverse restrict pins to the shift lever retainer.

Torque:

37 N*m{380 kgf*cm, 27 ft.*lbf}

Apply seal packing to the control shaft 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 packing (FIPG) material must be removed and reapplied.

Apply adhesive to 2 or 3 threads of the bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the control shaft cover to the manual transmission with the 6 bolts.

Torque:

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

Using SST, install a new gasket and the shift position switch to the transmission.

SST

09817-16011

Torque:

44 N*m{450 kgf*cm, 33 ft.*lbf}

Connect the wire harness clamp.

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

SST

09817-16011

Torque:

44 N*m{450 kgf*cm, 33 ft.*lbf}

Connect the wire harness clamp.

Using a T55 "TORX" socket wrench, install a new gasket and the manual transmission case plug to the transmission.

Torque:

37 N*m{380 kgf*cm, 27 ft.*lbf}

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

Torque:

37 N*m{380 kgf*cm, 27 ft.*lbf}

Temporarily install a new gasket and the filler plug to the manual transmission.

Torque:

37 N*m{380 kgf*cm, 27 ft.*lbf}

HINT:

The filler plug will be tightened to a torque specification in the "Inspect Transmission Oil" procedure.

Apply adhesive to 2 or 3 threads of the bolts labeled A only.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the clutch housing with the 10 bolts.

Torque:

37 N*m{380 kgf*cm, 27 ft.*lbf}

Bolt Length:

Item	Length
Bolt A	45 mm (1.77 in.)
Bolt B	45 mm (1.77 in.)
Bolt C	35 mm (1.38 in.)

Connect the breather hose with the clamp.

Install the wire harness clamp.

Connect the breather hose with the clamp.