Manual Transmission Unit Reassembly

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

Using a plastic-faced hammer, install the output shaft by tapping the intermediate plate.

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

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

NOTICE:

1. Install the No. 2 synchronizer ring so the No. 2 synchromesh shifting key fits into the groove of the No. 2 synchronizer ring.
   
2. Check that the input shaft rotates slightly.
   

Temporarily install the counter gear to the intermediate plate.

Using SST and a hammer, tap in a new center bearing to the intermediate plate.

SST

09316-60011(09316-00011)

HINT:

Install the bearing while tapping the tip of the counter gear with a plastic-faced hammer so that the counter gear does not hit the side wall of the output shaft gear by being pushed forward.

Apply gear oil to each sliding part of the reverse idler gear and the reverse idler gear shaft, and install reverse idler gear and the reverse idler shaft to the intermediate plate.

NOTICE:

Install the reverse idler shaft with its groove facing the rear side, and install it from the rear side.

Insert the bearing retainer into the groove of the reverse idler gear shaft and install it with the 4 bolts.

Torque:

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

Apply MP grease to the washer pin, and install it to the counter gear.

Apply gear oil to the thrust washer, and install it to the counter gear.

NOTICE:

Install the thrust washer so that its chamfer side faces forward.

Apply gear oil to the sliding part of the No. 3 transmission hub sleeve, and install it to the counter 5th gear.

NOTICE:

Be sure of the direction of the No. 3 transmission hub sleeve and counter 5th gear.

Install the 2 No. 3 synchromesh shifting keys and No. 3 synchromesh shifting key spring to the counter 5th gear as shown in the illustration.

HINT:

When installing the synchromesh shifting key spring, make sure the protrusion fits into the cutout.

Using a snap ring expander, install the snap ring to the counter 5th gear.

Apply gear oil to the bearing and install it to the counter 5th gear.

Apply gear oil to the 5th gear and No. 3 transmission hub sleeve, and install them to the counter gear.

Apply gear oil to the No. 3 synchronizer ring, and install it to the counter gear.

NOTICE:

Install the No. 3 synchronizer ring so that the No. 3 synchromesh shifting key fits into the groove of the No. 3 synchronizer ring.

Using SST and a press, press in the gear spline piece to the counter gear.

SST

09316-60011(09316-00011)

NOTICE:

Check that the gear rotates freely.

Select a snap ring so that the thrust clearance between the No. 5 gear spline piece and snap ring is within the specification.

Standard clearance:

0.10 mm (0.00393 in.) or less

Snap Ring Thickness:

Thickness

2.80 to 2.85 mm (0.1102 to 0.1122 in.)

2.85 to 2.90 mm (0.1122 to 0.1141 in.)

2.90 to 2.95 mm (0.1141 to 0.1160 in.)

2.95 to 3.00 mm (0.1160 to 0.1181 in.)

3.00 to 3.05 mm (0.1181 to 0.1200 in.)

3.05 to 3.10 mm (0.1200 to 0.1220 in.)

3.10 to 3.15 mm (0.1220 to 0.1240 in.)

Using a brass bar and hammer, tap on the snap ring.

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.00394 to 0.0137 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.00591 to 0.00267 in.)

Using SST and a press, press in the spacer and a new rear bearing to the output shaft.

SST

09309-35010

Select a shaft snap ring so that the thrust clearance between the output shaft bearing shaft and snap ring is within the specification.

Standard clearance:

0.10 mm (0.00393 in.) or less

Snap Ring Thickness:

Thickness	Thickness
2.65 to 2.70 mm (0.1043 to 0.1063 in.)	3.10 to 3.15 mm (0.1220 to 0.1240 in.)
2.70 to 2.75 mm (0.1063 to 0.1083 in.)	3.15 to 3.20 mm (0.1240 to 0.1260 in.)
2.75 to 2.80 mm (0.1083 to 0.1102 in.)	3.20 to 3.25 mm (0.1260 to 0.1280 in.)
2.80 to 2.85 mm (0.1102 to 0.1122 in.)	3.25 to 3.30 mm (0.1280 to 0.1299 in.)
2.85 to 2.90 mm (0.1122 to 0.1141 in.)	3.30 to 3.35 mm (0.1299 to 0.1319 in.)
2.90 to 2.95 mm (0.1141 to 0.1160 in.)	3.35 to 3.40 mm (0.1319 to 0.1339 in.)
2.95 to 3.00 mm (0.1160 to 0.1181 in.)	3.40 to 3.45 mm (0.1339 to 0.1358 in.)
3.00 to 3.05 mm (0.1181 to 0.1200 in.)	3.45 to 3.50 mm (0.1358 to 0.1378 in.)
3.05 to 3.10 mm (0.1200 to 0.1220 in.)	-

Using a brass bar and hammer, tap on the snap ring.

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

Torque:

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

Install the shift arm to the shift fork. Using a screwdriver and hammer, tap on a new E-ring.

Install the tip of the reverse shift arm to the reverse idler gear. Align the end of the reverse shift arm that has the cutout with the reverse shift arm bracket pin, and install the reverse shift arm and reverse shift fork.

Install the compression spring and reverse shift fork ball to the reverse shift fork.

Apply gear oil to the sliding part of the No. 4 shift fork shaft.

Using a screwdriver, install the No. 3 shift fork shaft by pushing the reverse shift fork ball lightly.

Using a brass bar and a hammer, tap on the snap ring to the No. 4 shift fork shaft.

Install the reverse shift fork ball to the reverse shift fork.

Install the No. 1 shift interlock roller to the intermediate plate.

Install the No. 3 shift fork to the No. 3 transmission hub sleeve and No. 3 shift fork shaft to the intermediate plate from the front side.

Using a brass bar and hammer, tap on the snap ring to the shift fork shaft.

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

Install the No. 1 shift interlock roller to the intermediate plate.

Install the No. 1 shift fork to the reverse gear.

Install the No. 1 shift fork shaft to the intermediate plate from the rear side.

Install a new shift fork set bolt to the No. 1 shift fork.

Torque:

20 N*m{199 kgf*cm, 14 ft.*lbf}

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

Install the shift interlock pin and No. 1 shift interlock roller to the intermediate plate.

Install the No. 2 shift fork to the No. 2 transmission hub sleeve.

Apply gear oil to the No. 2 shift fork, and install the shift fork to the intermediate plate from the rear side.

Install a new shift fork set bolt to the No. 2 shift fork.

Torque:

20 N*m{199 kgf*cm, 14 ft.*lbf}

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

Install the 2 compression springs and 2 shifts detent balls to the intermediate plate.

Using a T40 ''TORX'' socket wrench, install the 3 spring seats to the intermediate plate.

Torque:

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

Install the detent ball and low side compression spring to the intermediate plate.

Using a T40 ''TORX'' socket wrench, install the spring seat to the intermediate plate.

Torque:

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

Clean the transmission magnet, and install it to the intermediate plate.

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

Using a plastic-faced hammer, tap the transmission case to attach it to the intermediate plate.

Using a snap ring expander, install the snap ring to the transmission case.

Using a snap rig expander, install the snap ring to the transmission case.

Using SST and a hammer, tap in a new oil seal to the front bearing retainer.

SST

09950-60010(09951-00300,09951-00520,09952-06010)
09950-70010(09951-07100)

Standard depth:

11.20 to 12.20 mm (0.4410 to 0.4803 in.)

Lightly apply MP grease to the lip of the oil seal.

Apply seal packing to the bearing retainer as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

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

Torque:

17 N*m{168 kgf*cm, 12 ft.*lbf}

Check that the input shaft and output shaft rotate smoothly.

Using SST and a hammer, tap in a new oil seal to the transfer adapter.

SST

09710-30050
09950-70010(09951-07100)

Oil seal depth:

45.4 to 46.4 mm (1.788 to 1.826 in.)

Lightly apply MP grease to the lip of the oil seal.

Install the restrict pin to the transfer adapter.

Using a 5 mm pin punch and hammer, tap in the slotted pin to the transfer adapter.

Using a T40 ''TORX'' socket wrench, install the reverse restrict pin plug to the transfer adapter.

Torque:

19 N*m{188 kgf*cm, 14 ft.*lbf}

Install the oil receiver pipe to the transfer adapter.

Apply seal packing to the transfer adapter as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Using a plastic-faced hammer, tap the transfer adapter to attach it to the transmission case.

Install the transfer adapter to the transmission case with the 10 bolts.

Torque:

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

Install the shift and select lever shaft and shift lever housing to the transfer adapter.

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

Install the select return spring on the shift lever retainer.

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

Torque:

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

Install the control shift lever retainer and a new oil deflector.

Install the 4 bolts.

Torque:

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

Install the 2 restrict pins.

Torque:

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

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

SST

09817-16011

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

Install the clutch housing to the transmission case with the 9 bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Install the release fork support to the manual transmission unit.

Torque:

for TR Engine series:

47 N*m{479 kgf*cm, 35 ft.*lbf}

for 1KD-FTV, 2KD-FTV:

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

Install the release bearing hub clip to the clutch release bearing assembly.

Apply Multemp 8158 grease or equivalent to the following areas:

Text in Illustration

*A	for TR Engine series
*B	for 1KD-FTV, 2KD-FTV
	Multemp 8158 grease or equivalent

1. The surfaces of the release fork that contact the release bearing.
   
2. The surfaces of the release fork that contact the push rod of the release cylinder.
   
3. The surfaces of the release fork that contact the release fork support.
   

Grease:

Multemp 8158 grease or equivalent

Install the release fork sub-assembly to the clutch release bearing assembly.

Install the clutch release bearing assembly together with the clutch release fork sub-assembly to the clutch housing.

NOTICE:

After the installation, move the fork forward and backward to check that the release bearing slides smoothly.

Apply the 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}