Manual Transmission Unit Reassembly

Install the output shaft to 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:

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

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

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 rear side of the counter gear.

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

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

Torque:

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

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

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

Torque:

18 N*m{178 kgf*cm, 13 ft.*lbf}

Install the reverse shift arm bracket to the intermediate plate with the 2 bolts.

Torque:

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

Install the lock ball.

Install the 5th gear thrust washer.

Coat the counter shaft 5th gear with gear oil.

Install the counter 5th gear, counter shaft 5th gear bearing, 3 synchromesh shifting keys, 2 synchromesh shifting key springs and No. 3 transmission hub sleeve.

HINT:

Be sure to set the No. 3 transmission hub sleeve and 3 synchromesh shifting keys to the counter shaft 5th gear incorrect direction.

Text in Illustration

Front

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

Install the counter shaft 5th gear to the counter gear.

Temporarily install the No. 1 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, install the No. 5 gear spline piece with the No. 1 synchronizer ring slots aligned with the shifting keys.

Fix the intermediate plate in a vise between aluminum plates.

Select a snap ring that will allow minimal axial play.

Standard clearance:

0.10 mm (0.00394 in.) or less

Standard Counter Gear Rear Shaft Snap Ring:

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 the snap ring to the counter gear.

Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

Standard clearance:

0.10 to 0.30 mm (0.00394 to 0.0118 in.)

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

Install the No. 2 gear shift fork and No. 1 gear shift fork.

Pass the No. 2 gear shift fork shaft through the intermediate plate, No. 2 gear shift fork and No. 1 gear shift fork to install it.

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

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

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

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

Coat the No. 1 shift interlock pin with MP grease.

Using a magnet hand, install the No. 1 shift interlock pin to the intermediate plate.

Pass the No. 1 gear shift fork shaft through the intermediate plate and No. 2 gear shift fork to install it.

Install the bolt to the No. 1 shift fork.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

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

Install the shift arm shoe E-ring and the shift arm shoe to the reverse shift arm.

Install the reverse shift arm E-ring and reverse shift fork to the reverse shift arm.

Install the reverse shift arm to the reverse shift arm bracket.

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

Coat the No. 3 shift interlock pin with MP grease.

Using a magnet hand, install the No. 3 shift interlock pin to the intermediate plate.

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

Install the reverse shift head ring to the reverse shift fork shaft.

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

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

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

Coat the 2 shift detent balls with MP grease.

Using a magnet hand, install the 2 shift detent balls to the intermediate plate.

Pass the No. 4 gear shift fork shaft through the reverse shift fork, intermediate plate and reverse shift head to install it.

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

Torque:

20 N*m{204 kgf*cm, 15 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{194 kgf*cm, 14 ft.*lbf}

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

Coat the spring seat and 2 ball plugs with adhesive.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a T40 "TORX" socket, install the spring seat and 2 ball plugs to the intermediate plate.

Torque:

19 N*m{194 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 counter gear 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 front bearing retainer.

SST

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

Standard depth:

12.2 to 13.2 m (0.480 to 0.519 in.)

NOTICE:

Do not damage the oil seal lip.

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

Install a new gasket and the front bearing retainer to the transmission case.

Install the 8 bolts.

Torque:

17 N*m{173 kgf*cm, 13 ft.*lbf}

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

SST

09223-00010

Standard depth:

45 to 46 mm (1.78 to 1.81 in.)

NOTICE:

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

Apply a light coat of MP grease to the lip 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{194 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}

HINT:

Each bolt length is indicated below.

80 mm (3.15 in.) for bolt A

130 mm (5.12 in.) for bolt B

Install the bolt to the shift lever housing.

Torque:

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

Coat the shift detent ball with MP grease, and then install it and the compression spring to the transfer adapter.

Using a T40 "TORX" socket, install the spring seat to the transfer adapter.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install a new gasket to the transfer adapter.

Install the shift lever retainer with the 4 bolts.

Torque:

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

Install the 2 restrict pins to the transfer adaptor.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Install the front transmission case.

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 manual transmission case.

SST

09817-16011

Torque:

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

Install the release fork boot to the front transmission case.

Install the release fork support to the front transmission case.

Torque:

39 N*m{400 kgf*cm, 29 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 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}