Manual Transaxle Unit: Reassembly

WARNING: This page is about a different variant/trim than selected.

INSPECT TRANSMISSION HUB SLEEVE NO. 3 (See INSPECTION )
INSPECT SYNCHRONIZER RING NO. 3 (for 6th Gear) (See INSPECTION )
INSPECT 6TH GEAR SUB-ASSEMBLY (See INSPECTION )
INSPECT SYNCHRONIZER RING NO. 3 (for 5th Gear) (See INSPECTION )
INSPECT 5TH GEAR (See INSPECTION )
INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY (See INSPECTION )
INSTALL TRANSMISSION HUB SLEEVE NO. 3
1. Coat the transmission hub sleeve No. 3 with gear oil, and install it to the transmission clutch hub No. 3.
  NOTE: Do not set the transmission clutch hub No. 3 in an incorrect orientation.
2. Using a screwdriver, install the 2 synchromesh shifting key spring No. 3 and 3 synchromesh shifting key No. 3.
  NOTE: Do not set the openings of the shifting key springs in the same position.
  
  Fig 1: Installing Transmission Hub Sleeve No.3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT (MTM) COVER
1. Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.
  
  Fig 2: Installing Output Shaft (MTM) Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install the transaxle case oil seal to the transaxle case.
  SST 09726-27012 (09726-02041), 09950-70010 (09951-07100)
  
  Driven in depth:
  
  1.6 to 2.2 mm (0.063 to 0.087 in.)
  
  Fig 3: Installing Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 4: Installing FR Differential Case Front Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the front differential case front plate washer and FR differential case front tapered roller bearing (outer race) to the transaxle case.
  SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
  
  Fig 5: Installing FR Differential Case Front Tapered Roller Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST and a press, install the FR differential case rear tapered roller bearing (inner race) to the front differential case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 6: Installing FR Differential Case Rear Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install the front differential case rear plate washer and FR differential case rear tapered roller bearing (outer race) to the manual transmission case.
  SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)
  
  Fig 7: Installing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT FRONT BEARING
1. Coat a new output shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.
  SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)
  
  Fig 8: Installing Output Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

Coat the differential case assembly with gear oil, and install it to the transaxle case.
Install the manual transmission case with the 16 bolts.
Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)

Fig 9: Installing Manual Transmission Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a torque wrench, turn the deferential case assembly right and left 2 or 3 times to allow the bearings to settle.
SST 09564-32011

Fig 10: Adjusting Differential Side Bearing Preload
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a torque wrench, measure the preload.

SST 09564-32011

Fig 11: Measuring Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Preload:

PRELOAD

Bearing	Torque
New	0.78 to 1.57 Nm (8 to 16 kgfcm, 7 to 14 in.*lbf)
Used	0.49 to 0.98 Nm (5 to 10 kgfcm, 4 to 9 in.*lbf)

If the preload is out of specification, select a proper front differential case rear plate washer and adjust it.

Washer thickness:

WASHER THICKNESS

Part No.	Thickness: mm (in.)	Make
90564-41014	2.10 (0.0827)	AA
90564-41015	2.15 (0.0846)	BB
90564-41016	2.20 (0.0866)	CC
90564-41017	2.25 (0.0886)	DD
90564-41018	2.30 (0.0906)	EE
90564-41019	2.35 (0.0925)	FF
90564-41020	2.40 (0.0945)	GG
90564-41021	2.45 (0.0965)	HH
90564-41022	2.50 (0.0984)	JJ
90564-41023	2.55 (0.1004)	KK
90564-41024	2.60 (0.1024)	LL
90564-41025	2.65 (0.1043)	MM
90564-41026	2.70 (0.1063)	NN
90564-41027	2.75 (0.1083)	PP
90564-41028	2.80 (0.1102)	QQ
90564-41029	2.85 (0.1122)	RR
90564-41030	2.90 (0.1142)	SS
90564-41031	2.95 (0.1161)	TT
90564-41032	3.00 (0.1181)	UU

Remove the 16 bolts and manual transmission case.
Remove the differential case assembly from the transaxle case.

INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.
  SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
  
  Driven in depth:
  
  15.6 to 16.0 mm (0.6142 to 0.6299 in.)
2. Coat the lip of the front transaxle case oil seal with MP grease.
  
  Fig 12: Installing Front Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT FRONT BEARING
1. Coat a new input shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.
  SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
  
  Driven in depth:
  
  0 to 0.30 mm (0 to 0.0118 in.)
  
  Fig 13: Installing Input Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION MAGNET
1. Clean the transmission magnet, and install it to the transaxle case.
  
  Fig 14: Installing Transmission Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING LOCK PLATE
1. Install the bearing lock plate with the bolt to the transaxle case.
  Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf)
  
  Fig 15: Installing Bearing Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSAXLE CASE RECEIVER
1. Install the manual transaxle case receiver with the bolt to the transaxle case.
  Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf)
  
  Fig 16: Installing Manual Transaxle Case Receiver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL CASE ASSEMBLY
1. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the transaxle case.
  
  Fig 17: Installing Differential Case Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Install the reverse shift arm bracket assembly with the 2 bolts to the transaxle case.
  Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  
  Fig 18: Installing Reverse Shift Arm Bracket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT ASSEMBLY
1. Coat the sliding and rotating surfaces of the input and output shafts with gear oil, and install them to the transaxle case.
  
  Fig 19: Installing Input Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
1. Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them to the transaxle case.
  HINT:
  
  Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.
  
  Fig 20: Installing Reverse Idler Gear Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GEAR SHIFT FORK SHAFT NO. 2
1. Coat the gear shift fork No. 2 and gear shift fork No. 1 with gear oil, and install them to the input and output shafts.
  
  Fig 21: Installing Gear Shift Fork No. 1 And Gear Shift Fork No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift fork shaft No. 2 with gear oil, and install the gear shift head No. 1, reverse shift fork and gear shift fork shaft No. 2.
  
  Fig 22: Installing Gear Shift Fork Shaft No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No. 2 and gear shift head No. 1.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
  
  Fig 23: Installing Shift Lock Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GEAR SHIFT FORK SHAFT NO. 3
1. Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No. 3.
  
  Fig 24: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift fork shaft No. 3 with gear oil, and install it to the transaxle case.
  
  Fig 25: Installing Gear Shift Fork Shaft No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GEAR SHIFT FORK SHAFT SUBASSEMBLY NO. 1
1. Coat the gear shift fork shaft sub-assembly No. 1 with gear oil, and install it to the transaxle case.
2. Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No. 1.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
  
  Fig 26: Installing Shift Fork Lock Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, install the shaft snap ring.
  
  Fig 27: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT DETENT BALL
1. Install the shift detent ball, shift detent ball compression spring and shift detent ball compression spring seat to the transaxle case.
  
  Fig 28: Installing Shift Detent Ball, Shift Detent Ball Compression Spring And Shift Detent Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the shift detent ball plug with sealant, and using SST, install it to the transaxle case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 29: Installing Shift Detent Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL RECEIVER PIPE NO. 2 (MTM)
1. Install the oil receiver pipe No. 2 (MTM) with the bolt to the manual transmission case.
  Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  
  Fig 30: Installing Oil Receiver Pipe No.2 (MTM)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL RECEIVER PIPE NO. 1 (MTM)
1. Install the oil receiver pipe No. 1 (MTM) with the bolt to the manual transmission case.
  Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  
  Fig 31: Installing Oil Receiver Pipe No.1 (MTM)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE
1. Apply FIPG to the manual transmission case, as shown in the illustration.
  FIPG:
  
  Part No. 08826-00090, THREE BOND 1281 or equivalent
  
  NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
  
  Fig 32: Applying FIPG To Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 13 bolts to the manual transmission side.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 33: Installing Bolts To Manual Transmission Side
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 3 bolts to the transaxle case side.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 34: Installing Bolts To Transaxle Case Side
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE IDLER GEAR SHAFT BOLT
1. Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 35: Installing Reverse Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE PLUG
1. Coat the transmission case plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 36: Installing Manual Transmission Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE RESTRICT PIN PLUG
1. Coat the transmission case plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Fig 37: Installing Reverse Restrict Pin Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.
  
  Fig 38: Installing Input Shaft Rear Bearing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.
  
  Fig 39: Installing Output Shaft Rear Bearing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, install the transmission case oil seal to the manual transmission case.
  SST 09316-60011 (09316-00011)
  
  Driven in depth:
  
  9.6 to 10.2 mm (0.378 to 0.402 in.)
2. Coat the lip of the transmission case oil seal with MP grease.
  
  Fig 40: Installing Transmission Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT DETENT BALL
1. Install the 2 shift detent balls, 2 shift detent ball springs and 2 shift detent ball spring seats to the manual transmission case.
  
  Fig 41: Installing Shift Detent Balls, Shift Detent Ball Springs And Shift Detent Ball Spring Seats
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift detent ball plugs with sealant, and install them to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 42: Installing Shift Detent Ball Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK UP LIGHT SWITCH ASSEMBLY
1. Using SST, install the back up light switch assembly with a new gasket to the manual transmission case.
  SST 09817-16011
  
  Torque: 40 N*m (411 kgf*cm, 30 ft.*lbf)
  
  Fig 43: Installing Back Up Light Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Coat the shift & select lever shaft assembly with gear oil.
2. Coat the 2 bolts with sealant, and install them, 2 bolts, a new gasket and the shift & select lever shaft assembly to the manual transmission case.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
  
  Fig 44: Installing Shift And Select Lever Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LOCK BALL ASSEMBLY NO. 1
1. Coat the lock ball assembly No. 1 with sealant, and install it to the manual transmission case.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 45: Installing Lock Ball Assembly No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING RETAINER REAR (MTM)
1. Coat the 5 bolts with sealant, and install the bearing retainer rear to the manual transmission case with the bolts.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
  
  Torque: 27 N*m (279 kgf*cm, 20 ft.*lbf)
  
  Fig 46: Installing Bearing Retainer Rear (MTM)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT FORK SHAFT SNAP RING
1. Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No. 2.
  
  Fig 47: Installing Shift Fork Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH DRIVEN GEAR
1. Using SST, install the 5th driven gear to the output shaft.
  SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)
  
  Fig 48: Installing 5th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT GEAR SPACER
1. Install the output gear spacer to the output shaft.
  
  Fig 49: Installing Output Gear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR NEEDLE ROLLER BEARING
1. Coat the two 5th gear bearing spacers and 5th gear needle roller bearing with gear oil, and install them to the input shaft.
  
  Fig 50: Installing 5th Gear Bearing Spacers And 5th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, install the transmission clutch hub No. 3 shaft snap ring to the input shaft.
  
  Fig 51: Installing Transmission Clutch Hub No. 3 Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR
1. Coat the 5th gear with gear oil, and install it to the input shaft.
  
  Fig 52: Installing 5th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO. 3 (for 5th Gear)
1. Coat the synchronizer ring No. 3 with gear oil, and install it to the 5th gear.
  
  Fig 53: Installing Synchronizer Ring No.3 (For 5th Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO. 3

Using SST and a hammer, install the transmission clutch hub No. 3 with the gear shift fork No. 3 to the input shaft.
SST 09608-04031
NOTE:
- Before driving in the transmission clutch hub No. 3, place a suitable sized wooden block under the rear side of the input shaft, as shown in the illustration.
- When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded and might be damaged.
  
  Fig 54: Installing Transmission Clutch Hub No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No. 3.
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)

Fig 55: Installing Shift Fork Lock Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select the snap ring that allows the minimum amount of axial play.

Clearance:

0.1 mm (0.004 in.) or less

Snap ring thickness:

SNAP RING THICKNESS

Part No.	Thickness: mm (in.)	Mark
90520-20074	1.75 (0.0689)	A
90520-20075	1.80 (0.0709)	B
90520-20076	1.85 (0.0728)	C
90520-20077	1.90 (0.0748)	D
90520-20078	1.95 (0.0768)	E
90520-20079	2.00 (0.0787)	F
90520-20080	2.05 (0.0807)	G
90520-20081	2.10 (0.0827)	H
90520-20082	2.15 (0.0846)	J

Using a brass bar and a hammer, install the transmission clutch hub No. 3 snap ring to the input shaft.

Fig 56: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL COUNTER GEAR 6TH
1. Using SST, install the counter gear 6th to the output shaft.
  SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)
  
  Fig 57: Installing Counter Gear 6th
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO. 3 (for 6th Gear)
1. Coat the synchronizer ring No. 3 with gear oil, and install it to the transmission clutch hub No. 3.
  
  Fig 58: Installing Synchronizer Ring No.3 (For 6th Gear)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 6TH GEAR NEEDLE ROLLER BEARING
1. Coat the 6th gear needle roller bearing and 6th gear spacer with gear oil, and install them to the input shaft.
  
  Fig 59: Installing 6th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 6TH GEAR SUB-ASSEMBLY
1. Coat the 6th gear sub-assembly with gear oil, and install it to the input shaft.
  
  Fig 60: Installing 6th Gear Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

Using SST, a steel block and a hammer, install the input shaft rear radial ball bearing to the input shaft.
SST 09608-04031

Fig 61: Installing Input Shaft Rear Radial Ball Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select the input shaft snap ring that allows the minimum amount of axial play.

Clearance:

0.1 mm (0.004 in.) or less

Snap ring thickness:

Fig 62: Installing Snap Ring

SNAP RING THICKNESS

Part No.	Thickness: mm (in.)	Mark
90520-17006	1.70 (0.0669)	A
90520-17007	1.75 (0.0689)	B
90520-17008	1.80 (0.0709)	C
90520-17009	1.85 (0.0728)	D
90520-17010	1.90 (0.0748)	E
90520-17011	1.95 (0.0768)	F
90520-17012	2.00 (0.0787)	G
90520-17013	2.05 (0.0807)	H
90520-17014	2.10 (0.0827)	J
90520-17015	2.15 (0.0846)	K
90520-17016	2.20 (0.0866)	L
90520-17017	2.25 (0.0886)	M

Using a brass bar and hammer, install the input shaft snap ring to the input shaft.

INSTALL OUTPUT SHAFT REAR BEARING

Using SST, install the output shaft rear bearing to the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)

Fig 63: Installing Output Shaft Rear Bearing To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select the output shaft RR snap ring that allows the minimum amount of axial play.

Clearance:

0.1 mm (0.004 in.) or less

Snap ring thickness:

SNAP RING THICKNESS

Part No.	Thickness: mm (in.)	Mark
90520-18003	2.31 (0.0909)	B
90520-18004	2.37 (0.0933)	C
90520-18006	2.43 (0.0957)	D
90520-18007	2.49 (0.0980)	E
90520-18008	2.55 (0.1004)	F
90520-18009	2.61 (0.1028)	G
90520-18013	2.67 (0.1051)	H
90520-18011	2.73 (0.1075)	J
90520-18014	2.79 (0.1098)	K
90520-18015	2.85 (0.1122)	L
90520-18016	2.91 (0.1146)	M

Using a brass bar and hammer, install the output shaft RR snap ring to the output shaft.

Fig 64: Installing Output Shaft RR Snap Ring To Output Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR RADIAL CLEARANCE (See INSPECTION )
INSPECT 6TH GEAR RADIAL CLEARANCE (See DISASSEMBLY )
INSPECT 5TH GEAR THRUST CLEARANCE (See DISASSEMBLY )
INSPECT 6TH GEAR THRUST CLEARANCE (See DISASSEMBLY )
INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
1. Apply FIPG to the manual transmission case cover sub-assembly.
  FIPG:
  
  Parts No. 08826-00090, THREE BOND 1281 or equivalent
  
  NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
  
  Fig 65: Applying FIPG To Manual Transmission Case Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the manual transmission case cover subassembly with the 9 bolts to the manual transmission case.
  Torque: 8 N*m (185 kgf*cm, 13 ft.*lbf)
  
  Fig 66: Installing Manual Transmission Case Cover Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY
1. Install the drain (MTM) plug sub-assembly with a new gasket to the manual transmission case.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 67: Installing Drain (MTM) Plug Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION FILLER PLUG
1. Install the manual transmission filler plug with a new gasket to the manual transmission case cover.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 68: Installing Manual Transmission Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SELECTING BELL CRANK ASSEMBLY
1. Install the selecting bell crank assembly and control shift lever bush with the 2 bolts to the manual transmission case.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).
  
  Fig 69: Installing Selecting Bell Crank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
1. Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case.
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
  
  Fig 70: Installing Floor Shift Control Lever Housing Support Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK BOOT
1. Install the clutch release fork boot to the transaxle case.
  
  Fig 71: Installing Clutch Release Fork Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RELEASE FORK SUPPORT
1. Install the release fork support to the transaxle case.
  Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf)
2. Coat the release fork support with release hub grease.
  Release hub grease:
  
  Part No. 08887-01806, RELEASE HUB GREASE or equivalent
  
  Fig 72: Installing Release Fork Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE BEARING ASSEMBLY
1. Coat the clutch release bearing assembly with release hub grease, and install it to the clutch release fork sub-assembly with the bearing clip.
  Release hub grease:
  
  Part No. 08887-01806, RELEASE HUB GREASE or equivalent
  
  Fig 73: Installing Clutch Release Bearing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
1. Apply clutch spline grease to the input shaft spline.
  Clutch spline grease:
  
  Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent
2. Install the clutch release fork sub-assembly to the input shaft.
INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
1. Install a new O-ring to the speedometer driven hole cover sub-assembly.
2. Install the speedometer driven hole cover subassembly with the bolt to the transaxle case.
  Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf)
  
  Fig 74: Installing Clutch Release Fork Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002