Manual Transaxle Unit Reassembly

Install the No. 5 synchronizer ring middle, No. 5 synchronizer ring outer and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, fix them in place with the synchronizer pull ring snap ring.

Check that the No. 5 synchronizer ring middle rotates smoothly.

Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub.

Install the No. 3 synchromesh shifting key spring to the No. 3 transaxle clutch hub.

NOTICE:

Align the projection of the shifting key spring with the hole of the No. 3 clutch hub and install it.

Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transaxle clutch hub.

NOTICE:

1. Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
   
2. Align the projection of the shifting key spring with the hole of the No. 3 clutch hub and install it.
   

Using SST and a hammer, tap in a new front transaxle case cover oil seal.

SST

09316-20011
09950-60020(09951-00910)
09950-70010(09951-07150)

Standard depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

Coat the lip of the oil seal with MP grease.

Using SST and a hammer, tap in the front tapered roller bearing (outer race) to the front differential case.

SST

09950-60020(09951-00910)
09950-70010(09951-07100,09951-07150)

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

SST

09950-70010(09951-07100,09951-07150)
09608-10010

Install the rear shim.

Using SST and a hammer, tap in the rear tapered roller bearing (outer race).

SST

09950-60020(09951-00890)
09950-70010(09951-07100)

Using SST and a press, press in the rear tapered roller bearing (inner race).

SST

09631-12090
09950-60010(09951-00600)
09950-70010(09951-07100)

Using SST and a hammer, tap in a new oil seal to the transaxle case.

SST

09608-32010
09950-70010(09951-07150)

Standard depth:

3.0 to 4.0 mm (0.118 to 0.158 in.)

Coat the oil seal lip with MP grease.

Using SST and a hammer, tap in the rear bearing (outer race) to the transaxle case.

SST

09950-60020(09951-00680)
09950-70010(09951-07100)

Standard clearance:

3.8 to 4.4 mm (0.150 to 0.173 in.)

Coat the shaft cover with MP grease, and install it to the transaxle case.

NOTICE:

Align the projection of the output shaft with the transaxle groove and install it.

Using SST and a hammer, tap in the front bearing (outer race).

SST

09950-60020(09951-00730)
09950-70010(09951-07100)

Install the output shaft to the transaxle case.

Install the transaxle case to the transaxle case with the 14 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the 3 bolts on the transaxle side.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the output shaft rear bearing shim to the output shaft.

Using a T45 "torx" socket, install the rear bearing retainer to the transaxle case with the 7 "torx" screws.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Turn the output shaft in both directions and check that it turns smoothly.

Temporarily install the output shaft rear set nut.

Using a socket wrench and torque wrench, inspect the preload.

Standard preload:

Bearing	Specified Condition
New	0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.lbf)
Used	0.5 to 1.0 N*m (5.10 to 10.20 kgf*cm, 4.4 to 8.9 in.lbf)

If preload is out of the specification, select a proper output shaft rear bearing shim and adjust the preload.

HINT:

The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf).

Standard shim thickness:

Part No	Mark	Thickness
90564-59001	0	1.30 mm (0.0512 in.)
90564-59002	1	1.35 mm (0.0531 in.)
90564-59003	2	1.40 mm (0.0551 in.)
90564-59004	3	1.45 mm (0.0571 in.)
90564-59005	4	1.50 mm (0.0591 in.)
90564-59006	5	1.55 mm (0.0610 in.)
90564-59007	6	1.60 mm (0.0630 in.)
90564-59008	7	1.65 mm (0.0650 in.)
90564-59009	8	1.70 mm (0.0669 in.)
90564-59010	9	1.75 mm (0.0689 in.)
90564-59011	A	1.80 mm (0.0669 in.)
90564-59012	B	1.85 mm (0.0728 in.)
90564-59013	C	1.90 mm (0.0748 in.)
90564-59014	D	1.95 mm (0.0768 in.)
90564-59015	E	2.00 mm (0.787 in.)
90564-59016	F	2.05 mm (0.0807 in.)
90564-59017	G	2.10 mm (0.0827 in.)
90564-59018	H	2.15 mm (0.0846 in.)
90564-59019	J	2.20 mm (0.0866 in. )
90564-59020	K	2.25 mm (0.0886 in.)
90564-59021	L	2.30 mm (0.0906 in.)
90564-59022	M	2.35 mm (0.0925 in.)
90564-59023	N	2.40 mm (0.0945 in.)
90564-59024	P	2.45 mm (0.0965 in.)
90564-59025	Q	2.50 mm (0.0984 in.)

Remove the output shaft rear set nut from the output shaft.

Using a T45 "torx" socket, remove the 7 "torx" screws and rear bearing retainer from the manual transaxle case.

Remove the output shaft rear bearing shim from the output shaft.

Remove the 3 bolts.

Remove the 14 bolts and transaxle case from the transaxle case.

Remove the output shaft assembly from the front transaxle case.

Install the bearing to the transaxle case.

Install the 14 bolts and transaxle case to the transaxle case.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the 3 bolts on the front transaxle case side.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Turn the differential case in both directions and check that it turns smoothly.

Using SST and a torque wrench, measure the preload.

SST

09564-32011

Standard preload:

Bearing	Specified Condition
New	0.8 to 1.6 N*m (8.16 to 16.32 kgf*cm, 7.1 to 14.2 in.*lbf)
Used	0.5 to 1.0 N*m (5.10 to 10.2 kgf*cm, 4.4 to 8.9 in.*lbf)

HINT:

The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf).

Standard shim thickness:

Part No.	Mark	Thickness
90564-56055	0	2.00 mm (0.0787 in.)
90564-56056	1	2.05 mm (0.0807 in.)
90564-56057	2	2.10 mm (0.0827 in.)
90564-56058	3	2.15 mm (0.0846 in.)
90564-56059	4	2.20 mm (0.0866 in.)
90564-56060	5	2.25 mm (0.0886 in.)
90564-56061	6	2.30 mm (0.0906 in.)
90564-56062	7	2.35 mm (0.0925 in.)
90564-56063	8	2.40 mm (0.0945 in.)
90564-56064	9	2.45 mm (0.0965 in.)
90564-56065	A	2.50 mm (0.0984 in.)
90564-56066	B	2.55 mm (0.1004 in.)
90564-56067	C	2.60 mm (0.1024 in.)
90564-56068	D	2.65 mm (0.1043 in.)
90564-56069	E	2.70 mm (0.1063 in.)
90564-56070	F	2.75 mm (0.1083 in.)
90564-56071	G	2.80 mm (0.1102 in.)
90564-56072	H	2.85 mm (0.1122 in.)

Remove the 3 bolts.

Remove the 14 bolts and transaxle case from the transaxle case.

Remove the bearing from the transaxle case.

Using SST and a hammer, tap in a new oil seal to the transaxle case.

SST

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

Standard distance:

1 to 2 mm (0.04 to 0.08 in.)

Coat the lip of the oil seal with MP grease.

Coat the input shaft front bearing with gear oil, and using SST, tap in it to the transaxle case.

SST

09950-60010(09951-00570)
09950-70010(09951-07150)

Standard distance:

4.28 to 4.60 mm (0.1685 to 0.1811 in.)

Install the receiver to the transaxle case with the 3 bolts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Coat the differential case tapered roller bearing with gear oil, and install the differential case to the transaxle case.

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

Slightly lift up on the differential case at an angle, and install the output shaft to the transaxle case.

Apply gear oil to each sliding part of the input shaft.

Install the input shaft to the transaxle case while tilting the output shaft.

Coat the No. 2 gear shift fork with gear oil, and install it to the input shaft assembly.

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

Using a brass bar and hammer, tap in the 2 shift fork shaft snap rings to the No. 3 gear shift fork shaft.

Apply gear oil to each sliding part of the No. 3 gear shift fork shaft, and install it to the transaxle case.

Apply gear oil to each sliding part of the No. 1 gear shift fork, and install it to the output shaft assembly.

Apply gear oil to each sliding part of the No. 2 gear shift fork shaft and No. 1 gear shift head, and install them to the transaxle case.

Install the shift fork set bolt and shift head set bolt to the No. 1 gear shift head and No. 2 gear shift fork.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.

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

Install the No. 1 gear shift fork shaft to the transaxle case.

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

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Install the reverse shift arm bracket to the transaxle case with the 2 bolts.

Torque:

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

Coat the reverse idler gear and thrust washer with gear oil, and install them to the reverse idler gear shaft.

Install the reverse idler gear with the reverse idler gear shaft to the transaxle case.

HINT:

Align the mark of the reverse idler gear shaft with the hole of the bolts.

Clean the transaxle magnet, and install it to the transaxle case.

Install the transmission oil baffle and reverse restrict pin with the bolt.

Torque:

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

Install the reverse restrict pin to the transaxle case.

Using a 5 mm pin punch and hammer, tap in the slotted spring pin.

Standard clearance:

12.5 to 13.5 mm (0.492 to 0.531 in.)

Coat the reverse restrict pin plug with adhesive. Using a 6 mm hexagon wrench, install the plug to the manual transaxle case.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

Torque:

13 N*m{133 kgf*cm, 9.6 ft.*lbf}

Install the oil receiver pipe to the transaxle case with the bolt.

Torque:

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

NOTICE:

Do not damage the pipe.

Install the oil receiver pipe to the transaxle case with the bolt.

Torque:

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

NOTICE:

Do not damage the pipe.

Apply seal packing to the transaxle case in a continuous line, as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:

Install the part within 10 minutes after applying packing material.

Install the transaxle case to the transaxle case with the 14 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Coat the 3 bolts with adhesive, and install them on the transaxle case side.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Install the clutch tube bracket with the bolt.

Torque:

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

Coat the reverse idler gear shaft bolt with adhesive, and install a new reverse idler gear shaft gasket and the reverse idler gear shaft bolt to the transaxle case.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

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

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

Install the output shaft rear bearing shim to the output shaft.

Coat the 7 bolts with adhesive. Using a T45 "torx" socket, install the bearing retainer with the bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

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

SST

09309-12020

Coat the needle roller bearing with gear oil, and install it to the input shaft.

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

Using SST, install the No. 3 transaxle clutch hub to the input shaft.

SST

09950-30012(09951-03010,09953-03010,09954-03010)

NOTICE:

Align the projection of the synchronizer ring with the hole of the 5th gear and install it.

Install the No. 3 transaxle hub sleeve and No. 3 gear shift fork to the No. 3 transaxle clutch hub.

Coat the shift fork set bolt with adhesive, and install it to the No. 3 gear shift fork.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Select an appropriate No. 3 transaxle clutch hub shaft snap ring that allows the minimum amount of axial play. Using a brass bar and hammer, tap in the No. 3 transaxle clutch hub shaft snap ring.

Standard clearance:

0.1 mm (0.004 in.) or less

Standard snap ring:

Part No.	Mark	Thickness
90520-27061	a	1.75 to 1.80 mm (0.0689 to 0.0709 in.)
90520-27062	b	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
90520-27063	c	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
90520-27064	d	1.90 to 1.95 mm (0.0748 to 0.0768 in.)
90520-27065	e	1.95 to 2.00 mm (0.0768 to 0.0787 in.)
90520-27066	f	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
90520-27067	g	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
90520-27068	h	2.10 to 2.15 mm (0.0827 to 0.0846 in.)
90520-27069	j	2.15 to 2.20 mm (0.0846 to 0.0866 in.)

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

Standard clearance:

0.009 to 0.050 mm (0.0004 to 0.0020 in.)

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

Standard clearance:

0.10 to 0.65 mm (0.0039 to 0.0260 in.)

Engage the 2 gears simultaneously to lock the transaxle.

Install a new transaxle output shaft rear set nut.

Torque:

123 N*m{1,254 kgf*cm, 90 ft.*lbf}

Using a chisel and hammer, stake the rear set nut.

Disengage the 2 gears.

Apply seal packing to the transaxle case cover, as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent

NOTICE:

Install the part within 10 minutes after applying packing material.

Install the transaxle case cover to the transaxle case with the 10 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install a new gasket and the drain plug to the transaxle case.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Install a new gasket and the filler plug to the transaxle case.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Coat the shift and select lever shaft with gear oil, and install it to the transaxle case.

Coat the 4 bolts with adhesive, and install a new gasket and the control shaft cover with the 4 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

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

Install a new gasket and the back-up light switch to the manual transaxle case.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Install a new gasket and the breather plug to the case.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Install the No. 1 lock ball to the transaxle case.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the control shift lever with the shift outer lever lock pin to the shift and select lever shaft.

Install the spring washer with the nut.

Torque:

6.4 N*m{65 kgf*cm, 57 in.*lbf}

Install the shift and select lever bush to the selecting bellcrank.

Coat the 2 bolts with adhesive, and install the selecting bellcrank to the transaxle case with the bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Torque:

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

Install a new O-ring to the hole cover.

Install the hole cover to the transaxle case with the bolt.

Torque:

5.5 N*m{56 kgf*cm, 48 ft.*lbf}

Install the clutch release fork boot to the transaxle case.

Using a deep socket wrench, install the release fork support to the transaxle case.

Torque:

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

Coat the clutch release bearing with Multemp 8158 Grease or equivalent, and install it to the clutch release fork with the clutch release bearing clip.

Grease:

Multemp 8158 Grease or equivalent

Apply clutch spline grease to the input shaft spline.

Install the clutch release fork to the input shaft.

Grease:

Toyota Genuine Clutch Spline Grease or equivalent