Manual Transaxle Unit Reassembly

Using SST and a press, press a new front differential case front tapered roller bearing onto the differential case.

SST

09316-20011
09950-60010(09951-00580,09952-06010)
09950-60020(09951-00910)
09950-40011(09957-04010)
09950-70010(09951-07100)

Install the front differential oil baffle into the front transaxle case.

Using SST and a press, press the front differential case front tapered roller bearing (outer race) into the front transaxle case.

SST

09950-60010(09952-06010)
09950-60020
09950-70010(09951-07100)

Using SST and a press, press a new front differential case rear tapered roller bearing onto the differential case.

SST

09316-20011
09950-60010(09951-00580,09952-06010)
09950-60020(09951-00910)
09950-40011(09957-04010)
09950-70010(09951-07100)

Using SST, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer as shown in the illustration.

SST

09950-60020(09951-00770,09951-00890)

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

Install the manual transmission case with the 17 bolts.

Torque:

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

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

SST

09564-50010

Using SST and a torque wrench, measure the preload.

SST

09564-50010

Standard preload (at starting):

New bearing:

1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)

Used bearing:

0.24 to 0.37 N*m (2.44 to 3.77 kgf*cm, 2.12 to 3.27 in.*lbf)

Standard Shim Thickness:

Mark	Specified Condition	Mark	Specified Condition
A	2.05 mm (0.0807 in.)	K	2.50 mm (0.0984 in.)
B	2.10 mm (0.0827 in.)	L	2.55 mm (0.100 in.)
C	2.15 mm (0.0846 in.)	M	2.60 mm (0.102 in.)
D	2.20 mm (0.0866 in.)	N	2.65 mm (0.104 in.)
E	2.25 mm (0.0886 in.)	P	2.70 mm (0.106 in.)
F	2.30 mm (0.0906 in.)	Q	2.75 mm (0.108 in.)
G	2.35 mm (0.0925 in.)	R	2.80 mm (0.110 in.)
H	2.40 mm (0.0945 in.)	S	2.85 mm (0.112 in.)
J	2.45 mm (0.0965 in.)	T	2.90 mm (0.114 in.)

HINT:

1. Select a thicker plate washer to increase the preload, or a thinner plate washer to decrease the preload.
   
2. Make a memo as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.
   

Remove the 17 bolts and manual transmission case.

Remove the differential case from the front transaxle case.

Replace the installed front differential case rear plate washer with the one selected above.

Install the output shaft covernto the front transaxle case.

NOTICE:

Insert the output shaft cover key into the case groove.

Using SST and a press, press the front output shaft bearing (outer race) into the front transaxle case.

SST

09950-60010(09951-00620,09952-06010)
09950-60020(09951-00710)
09950-70010(09951-07100)

Using SST and a press, press the rear output shaft bearing (outer race) together with the rear output shaft bearing shim into the manual transmission case.

SST

09950-60010(09951-00490,09951-00620,09952-06010)
09950-70010(09951-07150)

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

Coat the output shaft assembly with gear oil and install it to the front transaxle case.

Install the manual transmission case with the 17 bolts.

Torque:

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

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

SST

09564-50010

Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing preload using the following formula.

SST

09564-50010

Formula:

Value A - Differential side bearing preload = Output shaft bearing preload

Preload (at starting):

New bearing:

3.17 to 6.35 N*m (32 to 65 kgf*cm, 28 to 56 in.*lbf)

Used bearing:

2.61 to 5.24 N*m (27 to 53 kgf*cm, 23 to 46 in.*lbf)

Standard Bearing Shim Thickness:

Mark	Specified Condition	Mark	Specified Condition
A	1.30 mm (0.511 in.)	P	1.95 mm (0.768 in.)
B	1.35 mm (0.531 in.)	Q	2.00 mm (0.787 in.)
C	1.40 mm (0.551 in.)	R	2.05 mm (0.807 in.)
D	1.45 mm (0.571 in.)	S	2.10 mm (0.827 in.)
E	1.50 mm (0.591 in.)	T	2.15 mm (0.846 in.)
F	1.55 mm (0.610 in.)	U	2.20 mm (0.866 in.)
G	1.60 mm (0.630 in.)	V	2.25 mm (0.886 in.)
H	1.65 mm (0.650 in.)	W	2.30 mm (0.906 in.)
J	1.70 mm (0.669 in.)	X	2.35 mm (0.925 in.)
K	1.75 mm (0.689 in.)	Y	2.40 mm (0.945 in.)
L	1.80 mm (0.709 in.)	Z	2.45 mm (0.965 in.)
M	1.85 mm (0.728 in.)	1	2.50 mm (0.984 in.)
N	1.90 mm (0.748 in.)	-	-

HINT:

Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

Remove the 17 bolts and manual transmission case.

Remove the output shaft assembly from the front transaxle case.

Remove the differential case from the front transaxle case.

Replace the installed rear output shaft bearing shim with the one selected above.

Using SST and a hammer, tap in a new outer shift lever oil seal to the manual transmission case.

SST

09950-60010(09951-00280)
09950-70010(09951-07100)

Standard depth:

0.5 to 1.0 mm (0.0197 to 0.0393 in.)

Coat the lip of the outer shaft lever oil seal with MP grease.

Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.

Using a 5 mm pin punch and hammer, tap in the inner shift lever slotted spring pin to the inner No. 1 shift lever.

Standard depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

Install the No. 1 oil receiver pipe to the manual transmission case.

HINT:

Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

Using a plastic-faced hammer, tap in 5 new straight pins to the specified protrusion height.

Protrusion height:

10.5 to 11.5 mm (0.413 to 0.452 in.)

Text in Illustration

*1	Protrusion

Using SST and a hammer, tap in the breather plug to the front transaxle case.

SST

09350-30020(09350-07110)

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

SST

09612-22011

Standard depth:

1.0 to 2.0 mm (0.0393 to 0.0787 in.)

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

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

Install the input shaft cover to the manual transmission case.

NOTICE:

Insert the input shaft cover key into the manual transmission case groove.

Install the rear input shaft bearing shim onto the manual transmission case.

NOTICE:

Apply grease to the shim to prevent it from falling off the case during assembly.

Measure the distance between the end of the manual transmission case and installation surface of the rear input shaft bearing shim (Dimension A).

Measure the distance between the end of the front transaxle case and installation surface of the front input shaft bearing (Dimension B).

Measure the distance between both input shaft bearing outer races (Dimension C).

NOTICE:

Measure Dimension C with each bearing having no axial clearance.

Calculate the rear input shaft bearing shim clearance using the following formula.

Formula:

(Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

Standard Rear Input Shaft Bearing Shim Thickness:

Mark	Specified Condition	Mark	Specified Condition
A	1.15 mm (0.0453)	H	1.50 mm (0.0591)
B	1.20 mm (0.0472)	J	1.55 mm (0.0610)
C	1.25 mm (0.0492)	K	1.60 mm (0.0630)
D	1.30 mm (0.0512)	L	1.65 mm (0.0650)
E	1.35 mm (0.0531)	M	1.70 mm (0.0669)
F	1.40 mm (0.0551)	N	1.75 mm (0.0689)
G	1.45 mm (0.0571)	P	1.80 mm (0.0709)

Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the one selected above.

NOTICE:

Do not apply MP grease to the oil grooves.

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

Apply gear oil to all sliding and rotating parts.

Coat the No. 1 gear shift fork shaft with gear oil and install it onto the output shaft assembly.

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

Temporarily install the output shaft with No. 1 gear shift fork shaft to the input shaft assembly, and tie them with a rope or string.

Install the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.

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

SST

09950-60010(09951-00250)
09950-70010(09951-07100)

Standard depth:

0.5 to 1.0 mm (0.0197 to 0.0393 in.)

Coat the lip of the outer select lever oil seal with MP grease.

Install the outer select lever and inner select lever to the front transaxle case.

HINT:

Install the lever with its mark positioned outside of the front transaxle case.

Coat the threads of the inner select lever bolt with adhesive and install it.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Install the shift interlock plate and shift and select lever shaft assembly to the front transaxle case, and then turn them counterclockwise.

HINT:

When installing the shift interlock plate, make sure to engage it with the inner select lever.

Coat the threads of the 2 bolts with adhesive, and then install the reverse shift arm bracket with the 2 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque:

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

Using a 5 mm pin punch and a hammer, install the reverse shift fork slotted pin onto the reverse shift fork shaft.

Standard driven in depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

NOTICE:

Confirm the installation direction.

Coat the reverse shift fork shaft assembly with gear oil and install it onto the front 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:

Raise the edge of the reverse shift arm bracket assembly and connect the reverse shift arm bracket assembly to the reverse shift fork shaft assembly.

NOTICE:

Using the bolt hole of the case for reference, align the I-groove mark of the reverse idler gear shaft within the range shown (approximately 20°).

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 packing diameter:

1.2 mm (0.0472 in.)

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
   

Push the outer No. 1 shift lever and install the manual transmission case.

HINT:

Pushing the outer No. 1 shift lever allows the manual transmission case to be installed.

Turn the outer No. 1 shift lever counterclockwise and then pull it.

Install the manual transmission case with the 17 bolts.

Torque:

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

Install the outer shift lever E-ring to the outer No. 1 shift lever.

for LH side:

1. Using SST and a hammer, tap in a new transmission case oil seal to the manual transmission case.
   

   SST

   09608-32010
   09950-70010(09951-07100)
   

   Standard depth:

   -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
   

   NOTICE:

   Do not damage the oil seal lip.

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

for RH side:

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

   SST

   09710-30050
   09950-70010(09951-07100)
   

   Standard depth:

   -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)
   

   NOTICE:

   Do not damage the oil seal lip.

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

Install the 2 shift detent balls and 2 compression springs to the manual transmission case.

NOTICE:

Be careful not to drop the ball into the manual transmission case.

Coat the threads of the 2 shift detent ball plugs with adhesive and install them using a 6 mm hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque:

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

Install the shift detent ball and compression spring to the manual transmission case.

NOTICE:

Be careful not to drop the lock ball pin into the manual transmission case.

Coat the threads of the shift detent ball plug with adhesive and install it using a 6 mm hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque:

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

Install the lock ball pin and compression spring to the manual transmission case.

NOTICE:

Be careful not to drop the lock ball pin into the manual transmission case.

Coat the threads of the plug with adhesive and install it using a 10 mm hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque:

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

Install the lock ball pin and compression spring to the manual transmission case.

NOTICE:

Be careful not to drop the lock ball pin into the manual transmission case.

Coat the threads of the plug with adhesive and install it using a 10 mm hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque:

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

Install a new gasket and the reverse idler gear shaft bolt to the manual transmission case.

Torque:

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

Install the release cylinder bleeder plug to the clutch release bleeder.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.

Temporarily install the clutch release cylinder to bleeder tube to a new clutch release with bearing cylinder assembly.

Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.

Install the clutch release with bearing cylinder assembly with 3 new bolts.

Torque:

23 N*m{229 kgf*cm, 17 ft.*lbf}

NOTICE:

1. The clutch release with bearing cylinder and installation bolts cannot be reused and must be replaced with new ones.
   
2. Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder fits securely with the transaxle during installation. The first bolt should be tightened by hand while holding the clutch release with bearing cylinder.
   
3. Make sure that none of the clutch spline grease adheres to the clutch release with bearing cylinder.
   
4. The clutch release with bearing cylinder cannot be disassembled.
   

Install the clutch tube boot to the manual transaxle assembly.

Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

Temporarily install the clutch release bleeder sub-assembly with the 2 bolts.

Using a union nut wrench, install the clutch release cylinder to bleeder tube to the clutch release with bearing cylinder assembly.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

Apply clutch spline grease to the input shaft spline.

Grease:

Toyota Genuine Clutch Spline Grease or equivalent

Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

Install the clutch release bleeder sub-assembly with the 2 bolts.

Torque:

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

Using a union nut wrench, install the clutch release cylinder to bleeder tube.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

Using SST, apply a pressure of 100 kPa (1.0 kgf/cm², 15 psi) to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

SST

09992-00242

Install the control cable bracket to the manual transmission case with the 3 bolts.

Torque:

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

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

Torque:

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

Using a 27 mm deep socket wrench, install a new gasket and the back-up light switch to the manual transmission case.

Torque:

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

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

Torque:

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

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

Torque:

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