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Sequential Manual Transmission Assembly: Disassembly

  1. REMOVE FILLER PLUG AND DRAIN PLUG WITH GASKETS 

    Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

  2. REMOVE 2 BACK-UP LIGHT SWITCHES WITH GASKETS 

    Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 

    Fig 1: Identifying Shift And Select Lever Shaft Assembly Bolts
    G02631522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    NOTE: At the time of reassembly, set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
    1. Remove the neutral start switch.

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

    2. Remove the 4 bolts, shift and select lever shaft assembly and gasket.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

    Fig 2: Identifying Shift And Select Lever Shaft Assembly Bolts
    G02631523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSMISSION CASE COVER 
    1. Remove the 9 bolts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    2. Using a brass bar and a hammer, carefully tap the projection of the transmission case cover to remove the transmission case cover from the transmission case.

    HINT:

    At the time of reassembly, apply FIPG to the transmission case cover as shown in the illustration.

    1. FIPG: 
    2. Part No. 08826-00090, THREE BOND 1281 or equivalent 
    Fig 3: Applying FIPG To Transmission Case Cover
    G02631524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT 6TH GEAR THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance.

    1. Standard clearance: 
    2. 0.10 to 0.60 mm (0.0039 to 0.0236 in.) 
    3. Maximum clearance: 
    4. 0.60 mm (0.0236 in.) 
    Fig 4: Measuring Thrust Clearance Using A Dial Indicator
    G02631525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT 6TH GEAR RADIAL CLEARANCE 

    Using a dial indicator, measure the radial clearance.

    1. Standard clearance: 
    2. 0.009 to 0.050 mm (0.0003 to 0.0020 in.) 
    3. Maximum clearance: 
    4. 0.050 mm (0.0020 in.) 

    If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

    Fig 5: Measuring Radial Clearance Using A Dial Indicator
    G02631526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING, 6TH DRIVEN GEAR AND SPACER 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      At the time of reassembly, please refer to the following item. Select a snap ring from the table below that will make the thrust clearance of the output shaft rear radial ball bearing less than 0.1 mm (0.0039 in.).

      SNAP RING SPECIFICATION TABLE

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      B 2.31(0.0909) H 2.67(0.1051)
      C 2.37(0.0933) J 2.73(0.1075)
      D 2.43(0.0957) K 2.79(0.1098)
      E 2.49(0.0980) L 2.85(0.1122)
      F 2.55(0.1004) M 2.91(0.1146)
      G 2.61(0.1028) - -
      Fig 6: Removing Snap Ring Using 2 Screwdrivers And A Hammer
      G02631527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rear radial ball bearing and 6th driven gear.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011)

      Fig 7: Removing Rear Radial Ball Bearing And 6th Driven Gear Using SST
      G02631528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of reassembly, please refer to the following items.

      • Using SST and a hammer, drive in the 6th driven gear.

        SST 09325-12010

        NOTE: Be sure to install the 6th driven gear in the correct direction, as shown in the illustration.
        Fig 8: Installing 6th Driven Gear Using SST And A Hammer
        G02631529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer.

        SST 09517-12010

    3. Remove the spacer.
    Fig 9: Installing Bearing Using SST And A Hammer
    G02631530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE INPUT SHAFT REAR RADIAL BALL BEARING AND 6TH GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      At the time of reassembly, please refer to the following item. Select a snap ring from the table below that will make the thrust clearance of the No. 3 clutch hub less than 0.1 mm (0.0039 in.).

      SNAP RING SPECIFICATION TABLE

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 1.70(0.0669) G 2.00(0.0787)
      B 1.75(0.0689) H 2.05(0.0807)
      C 1.80(0.0709) J 2.10(0.0827)
      D 1.85(0.0728) K 2.15(0.0846)
      E 1.90(0.0748) L 2.20(0.0866)
      F 1.95(0.0768) M 2.25(0.0886)
      Fig 10: Removing Snap Ring Using 2 Screwdrivers And A Hammer
      G02631531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rear radial ball bearing and 6th gear.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011)

      Fig 11: Removing Rear Radial Ball Bearing And 6th Gear Using SST
      G02631532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of reassembly, please refer to the following item. Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer.

      1. SST 09517-12010
    3. Remove the needle roller bearing and spacer.
    Fig 12: Installing Bearing Using SST And A Hammer
    G02631533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 3 SYNCHRONIZER RING (FOR 6TH GEAR) 
    NOTE: At the time of reassembly, please refer to the following items.
    • Align the No. 3 synchronizer ring slots with the No. 3 shifting keys.
    • Distinguish the No. 3 synchronizer ring (for the 6th gear) by the teeth on the synchronizer ring.
    Fig 13: Identifying Synchronizer Ring Teeth
    G02631534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 3 GEAR SHIFT FORK AND NO. 3 HUB SLEEVE 

    Remove the bolt, No. 3 gear shift fork and No. 3 hub sleeve.

    1. Sealant: 
    2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 
    Fig 14: Identifying No. 3 Gear Shift Fork, No. 3 Hub Sleeve And Bolt
    G02631535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT 5TH GEAR THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance.

    1. Standard clearance: 
    2. 0.10 to 0.62 mm (0.0039 to 0.0244 in.) 
    3. Maximum clearance: 
    4. 0.62 mm (0.0244 in.) 
    Fig 15: Measuring Thrust Clearance Using A Dial Indicator
    G02631536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT 5TH GEAR RADIAL CLEARANCE 

    Using a dial indicator, measure the radial clearance.

    1. Standard clearance: 
    2. 0.015 to 0.056 mm (0.0006 to 0.0022 in.) 
    3. Maximum clearance: 
    4. 0.056 mm (0.0022 in.) 

    If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

    Fig 16: Measuring Radial Clearance Using A Dial Indicator
    G02631537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE 5TH GEAR, NO. 3 SYNCHRONIZER RING (FOR 5TH GEAR) AND NO. 3 CLUTCH HUB ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      At the time of reassembly, please refer to the following item. Select a snap ring from the table below that will make the thrust clearance of the No. 3 clutch hub less than 0.1 mm (0.0039 in.).

      SNAP RING SPECIFICATION TABLE

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 1.75(0.0689) F 2.00(0.0787)
      B 1.80(0.0709) G 2.05(0.0807)
      C 1.85(0.0728) H 2.10(0.0827)
      D 1.90(0.0748) J 2.15(0.0846)
      E 1.95(0.0768) - -
      Fig 17: Removing Snap Ring Using 2 Screwdrivers And A Hammer
      G02631538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the No. 3 clutch hub assembly.

      SST 09950-30012 (09951-03010, 09953-03010), 09950-50013 (09954-05031)

      Fig 18: Removing No. 3 Clutch Hub Assembly Using SST
      G02631539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      At the time of reassembly, please refer to the following items.

      • Before driving in the No. 3 clutch hub assembly and input shaft rear radial ball bearing, place the suitable sized wooden block on the rear side of the input shaft, as shown in the illustration. When driving them in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft center bearing is overloaded, it might be damaged.
        Fig 19: Placing Wooden Block On Rear Side Of Input Shaft
        G02631540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Using SST and a hammer, drive in the No. 3 clutch hub assembly.

        SST 09612-22011

      NOTE:
      • Align the No. 3 synchronizer ring slots with the No. 3 shifting keys.
      • Be sure to install the No. 3 clutch hub assembly in the correct direction, as shown in the illustration.
      Fig 20: Installing No. 3 Clutch Hub Assembly Using SST And A Hammer
      G02631541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 3 synchronizer ring (for the 5th gear) and 5th gear from the input shaft.
      NOTE: At the time of reassembly, please refer to the following item.
      Distinguish the No. 3 synchronizer ring (for the 5th gear) by the teeth on the synchronizer ring.
    4. Using 2 screwdrivers and a hammer, tap out the snap ring.
    5. Remove the needle roller bearing and 2 spacers.
  14. REMOVE 5TH DRIVEN GEAR 

    Using SST, remove the 5th driven gear.

    SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03021)

    Fig 21: Identifying Synchronizer Ring Teeth
    G02631542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 22: Removing 5th Driven Gear Using SST
    G02631543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of reassembly, please refer to the following item. Using SST and a hammer, drive in the 5th driven gear.

    SST 09612-22011

    Fig 23: Installing 5th Driven Gear Using SST And A Hammer
    G02631544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR BEARING RETAINER 

    Remove the 5 bolts and rear bearing retainer.

    1. Sealant: 
    2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Torque: 27 N.m (280 kgf.cm, 20 ft.lbf) 
    Fig 24: Identifying Rear Bearing Retainer Bolts
    G02631545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BEARING SNAP RING 

    Using a snap ring expander, remove the 2 snap rings.

    HINT:

    If it is difficult to remove and install the snap rings, pull up the shafts.

    Fig 25: Removing Snap Rings Using A Snap Ring Expander
    G02631546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET 

    Sealant: 

    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

  18. REMOVE SNAP RING FROM NO. 2 SHIFT FORK SHAFT 

    Using 2 screwdrivers and a hammer, tap out the snap ring.

    Fig 26: Identifying No. 2 Shift Fork Shaft Snap Ring
    G02631547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND BALL 
    1. Using a hexagon wrench, remove the 3 straight screw plugs.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

    2. Using a magnetic finger, remove the 3 seats, springs and balls.
    Fig 27: Removing Seats, Springs And Balls
    G02631548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE STRAIGHT SCREW PLUG 

    Using a hexagon wrench, remove the 2 straight screw plugs.

    1. Sealant: 
    2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Torque: 
    4. Plug A: 13 N.m (130 kgf.cm, 9 ft.lbf) 
    5. Plug B: 29 N.m (300 kgf.cm, 22 ft.lbf) 
    Fig 28: Identifying Plugs A And B
    G02631549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSMISSION CASE 
    1. Remove the 16 bolts.

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

    2. Using a plastic-faced hammer, carefully tap the projection of the transmission case to remove the transmission case from the transaxle case.
    Fig 29: Removing Bolts
    G02631550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of reassembly, apply FIPG to the transaxle case as shown in the illustration.

    1. FIPG: 
    2. Part No. 08826-00090, THREE BOND 1281 or equivalent 
    Fig 30: Applying FIPG To Transaxle Case
    G02631551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE OIL RECEIVER PIPE 

    Remove the 2 bolts and 2 oil receiver pipes from the transmission case.

    1. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 
    NOTE: At the time of reassembly, please refer to the following items.
    • Prevent the oil receiver pipes from being deformed.
    • Install the oil receiver pipes while placing it against the transmission case, as shown in the illustration.
  23. REMOVE REVERSE SHIFT ARM BRACKET 

    Remove the 2 bolts and reverse shift arm bracket.

    1. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 
    Fig 31: Installing Oil Receiver Pipes
    G02631552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 32: Identifying Reverse Shift Arm Bracket Bolts
    G02631553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: At the time of reassembly, please refer to the following items.
    • Set the pin on the top of the reverse shift arm into a groove on the reverse idler gear.
    • Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing.
    Fig 33: Fitting Claw Of Reverse Shift Arm Bracket With Notch Of Input Shaft Front Bearing
    G02631554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT 
    NOTE: At the time of reassembly, please refer to the following item.
    Install the reverse idler gear, thrust washer and shaft, as shown in the illustration.
    Fig 34: Aligning Alignment Marks
    G02631555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK SHAFT 
    1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from each gear shift fork shaft.
    2. Remove the 3 bolts from the No. 1 gear shift head, No. 1 and No. 2 gear shift forks.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

    Fig 35: Removing Snap Rings Using 2 Screwdrivers And A Hammer
    G02631556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: At the time of reassembly, please refer to the following item.
    Make sure that the 3 gear shift heads are positioned, as shown in the illustration.
    Fig 36: Identifying Gear Shift Head Positions
    G02631557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 GEAR SHIFT FORK SHAFT 

    Remove the No. 2 gear shift fork shaft from the No. 2 gear shift fork, No. 1 gear shift head, No. 1 gear shift fork, reverse shift fork and transaxle case.

    Fig 37: Removing No. 2 Gear Shift Fork Shaft
    G02631558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 1 GEAR SHIFT FORK SHAFT 

    Remove the No. 1 gear shift fork shaft from the No. 1 gear shift fork and transaxle case.

    Fig 38: Removing No. 1 Gear Shift Fork Shaft
    G02631559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 1 GEAR SHIFT HEAD 
    Fig 39: Removing No. 1 Gear Shift Head
    G02631560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 GEAR SHIFT FORK FROM REVERSE GEAR GROOVE 
    Fig 40: Removing No. 1 Gear Shift Fork From Reverse Gear Groove
    G02631561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 3 GEAR SHIFT FORK SHAFT AND REVERSE SHIFT FORK 
    1. Remove the No. 3 gear shift fork shaft from the reverse shift fork and transaxle case.
    2. Remove the reverse shift fork.
    Fig 41: Removing No. 3 Gear Shift Fork Shaft
    G02631562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 2 GEAR SHIFT FORK FROM NO. 2 HUB SLEEVE GROOVE 
  32. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE 
  33. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    NOTE: At the time of reassembly, please refer to the following item.
    Before reassembly, inspect the differential tapered roller bearing preload. (See REASSEMBLY  )
  34. REMOVE MAGNET FROM TRANSAXLE CASE 
  35. REMOVE TRANSAXLE CASE RECEIVER 
    1. Remove the bolt and transaxle case receiver from the transaxle case.
    Fig 42: Removing No. 2 Gear Shift Fork From No. 2 Hub Sleeve Groove
    G02631563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY 
    1. Using a screwdriver, remove the 2 shifting key springs.
      NOTE: At the time of reassembly, please refer to the following item.
      Position the shifting key springs so that their end gaps are not aligned.
    2. Remove the 3 No. 3 shifting keys from the No. 3 clutch hub.
    Fig 43: Disassembling No. 3 Clutch Hub Assembly
    G02631564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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