Manual Transaxle Unit: Reassembly

INSTALL OUTPUT SHAFT COVER
1. Coat the output shaft cover with MP grease and install it onto the front transaxle case.
  NOTE: Insert the output shaft cover projection into the case side hollow.
  
  Fig 1: Identifying Output Shaft Cover Into Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OUTPUT SHAFT FRONT BEARING
1. Coat a new output shaft front bearing with gear oil. Using SST and a press, install it onto the front transaxle case.
  SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)
  NOTE:
  - Install the new bearing in the correct direction.
    
    Fig 2: Identifying Output Shaft Front Bearing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.
INSTALL FRONT TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install a new front transaxle case oil seal onto the front transaxle case.
  SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)
  
  Drive in depth: 15.6 to 16.0 mm (0.6141 to 0.6299 in.)
2. Coat the lip of the front transaxle case oil seal with MP grease.
  
  Fig 3: Identifying SST, Hammer & New 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 onto the front transaxle case.
  SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)
  
  Drive in depth: 0 to 0.3 mm (0 to 0.0118 in.)
  
  Fig 4: Identifying New Input Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
1. Using SST and a hammer, install the shift and select lever shaft slide ball bearing onto the transmission case.
  SST 09950-60010 (09951-00220), 09950-70010 (09951-07100)
  
  Drive in depth: 0 to 0.5 mm (0 to 0.0020 in.)
  
  Fig 5: Identifying SST, Hammer & Shift & Select Lever Shaft Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT AND SELECT LEVER SHAFT OIL SEAL
1. Using SST, install the shift and select lever shaft oil seal onto the transmission case.
  SST 09950-70010 (09951-07150), 09950-60010 (09951-00240)
  
  Drive in depth: 9.7 to 10.3 mm (0.382 to 0.406 in.)
  
  Fig 6: Identifying SST, Shift & Select Lever Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST and a press, install the front differential case front tapered roller bearing (inner race) onto the front differential case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 7: Identifying SST, Press & Front 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 tapered roller bearing (outer race) together with the plate washer onto the front transaxle case.
  SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)
  
  Fig 8: Identifying SST, Press & Front 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 front differential case rear tapered roller bearing (inner race) onto the differential case.
  SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)
  
  Fig 9: Identifying SST, Press & Front 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 tapered roller bearing (outer race) with plate washer onto the transmission case.
  SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)
  
  HINT:
  
  Use a plate washer of the same thickness as the removed one.
  
  Fig 10: Identifying SST, Press & Front Differential Case Rear Tapered Roller Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

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

Fig 11: Identifying Differential Case Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle.
SST 09564-32011

Fig 12: Turning Differential Case Assembly To Right & Left Using SST & Torque Wrench
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a torque wrench, measure the preload.

SST 09564-32011

Preload (at starting):

New bearing:

0.78 to 1.57 N*m (7.95 to 16.0 kgf*cm, 6.9 to 13.89 in.*lbf)

Used bearing:

0.49 to 0.98 N*m (5.0 to 10.0 kgf*cm, 4.34 to 8.67 in.*lbf)

If the preload is outside the specifications, select another plate washer.

Fig 13: Measuring Preload Using SST & Torque Wrench

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Plate washer thickness

PLATE WASHER THICKNESS SPECIFICATION

Mark	Thickness mm (In.)	Mark	Thickness mm (In.)
AA	2.10 (0.0827)	LL	2.60 (0.1024)
BB	2.15 (0.0846)	MM	2.65 (0.1043)
CC	2.20 (0.0866)	NN	2.70 (0.1063)
DD	2.25 (0.0886)	PP	2.75 (0.1083)
EE	2.30 (0.0906)	QQ	2.80 (0.1102)
FF	2.35 (0.0925)	RR	2.85 (0.1122)
GG	2.40 (0.0945)	SS	2.90 (0.1142)
HH	2.45 (0.0965)	TT	2.95 (0.1161)
JJ	2.50 (0.0984)	UU	3.00 (0.1181)
KK	2.55 (0.1004)	-	-

HINT:

The preload changes by approximately 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) per each 0.05 mm (0.0020 in.) change in plate washer thickness.

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

INSTALL TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, install a new transmission case oil seal onto the manual transmission case.
  SST 09316-60011 (09316-00011)
  
  Drive in depth: 9.6 to 10.2 mm (0.378 to 0.402 in.)
2. Coat the lip of the front transmission case oil seal with MP grease.
  
  Fig 14: Identifying SST, Hammer & New Transmission Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, install a new transaxle case oil seal onto the front transaxle case.
  Drive in depth:
  
  1.6 to 2.2 mm (0.063 to 0.087 in.)
  
  SST 09710-20011 (09710-06071), 09950-70010 (09951-07150)
2. Coat the lip of the transaxle case oil seal with MP grease.
  
  Fig 15: Identifying SST, Hammer & New Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION MAGNET
1. Clean the transmission magnet and install it onto the front transaxle case.
  
  Fig 16: Identifying Transmission Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING LOCK PLATE
1. Install the bearing lock plate onto the front transaxle case with the bolt.
  Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
  
  Fig 17: Identifying Bearing Lock Plate Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL RECEIVER PIPE NO. 1
1. Install oil receiver pipe No. 1 onto the manual transmission case with the bolt.
  Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
  NOTE:
  - Do not deform oil receiver pipe No. 1.
  - Install the oil receiver pipe No. 1 while holding it against the manual transmission case.
    
    Fig 18: Identifying Oil Receiver Pipe No. 1 Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL OIL RECEIVER PIPE NO. 2
  1. Install the oil receiver pipe No. 2 onto the manual transmission case with the bolt.
    Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
    NOTE:
    Do not deform oil receiver pipe No. 2.
    
    Install the oil receiver pipe No. 2 while holding it against the manual transmission case.
    
    Fig 19: Identifying Oil Receiver Pipe No. 2 Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL REVERSE RESTRICT PIN ASSEMBLY
  1. Install the reverse restrict pin assembly onto the manual transmission case.
    NOTE: Set the reverse restrict pin assembly in the correct orientation.
    
    Fig 20: Identifying Reverse Restrict Pin Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using a pin punch (ø5 mm) and a hammer, install the slotted pin onto the reverse restrict pin assembly.
    Drive in depth: 15.5 to 16.5 mm (0.6102 to 0.6496 in.)
    
    Fig 21: Identifying Pin Punch, Hammer & Slotted Pin
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Apply sealant to the reverse restrict pin plug.
    Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  4. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case.
    Torque: 13 N*m (130 kgf*cm, 9.3 ft.*lbf)
    
    Fig 22: Identifying Hexagon Wrench, Torque Wrench & Reverse Restrict Pin Plug
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL MANUAL TRANSAXLE CASE RECEIVER
  1. Install the manual transaxle case receiver onto the front transaxle case with the bolt.
    Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
    
    Fig 23: Identifying Manual Transaxle Case Receiver & Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL DIFFERENTIAL CASE ASSEMBLY
  1. Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.
    
    Fig 24: Identifying Differential Case Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL INPUT SHAFT ASSEMBLY
  1. Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.
    
    Fig 25: Identifying Input Shaft Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. 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.
    HINT:
    
    Align the mark on the reverse idler gear shaft with the bolt hole.
    
    Fig 26: Aligning Mark On Reverse Idler Gear Shaft With Bolt Hole
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL GEAR SHIFT FORK SHAFT NO.1
  1. Coat gear shift fork No. 1 and gear shift fork No. 2 with gear oil and install them.
    
    Fig 27: Identifying Gear Shift Fork No. 1 & Gear Shift Fork No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Coat gear shift fork shaft No. 1 with gear oil and install it.
  3. Apply sealant to the shift fork set bolt.
    Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
    
    Fig 28: Identifying Gear Shift Fork Shaft No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Install the shift fork set bolt.
    Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
  5. Using a brass bar and a hammer, install a new shaft snap ring onto gear shift fork shaft No. 1.
    
    Fig 29: Identifying Brass Bar, Hammer & New Shaft Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL GEAR SHIFT FORK SHAFT NO.3
  1. Coat the 2 shift fork balls with MP grease and install them onto the reverse shift fork.
  2. Install the reverse shift fork onto gear shift fork shaft No. 3.
    
    Fig 30: Identifying Gear Shift Fork Shaft No. 3
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Using a brass bar and a hammer, install 2 new shift fork shaft snap rings onto shift fork shaft No. 3.
    
    Fig 31: Identifying Brass Bar, Hammer & New Shift Fork Shaft Snap Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Coat gear shift fork shaft No. 3 with gear oil and install it.
    
    Fig 32: Identifying Gear Shift Fork Shaft No. 3
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL GEAR SHIFT FORK SHAFT NO.2
  1. Coat gear shift head No. 1 and gear shift fork shaft No. 2 with gear oil and install them.
    NOTE: To avoid interference by the 2 shift fork balls, lift up gear shift fork shaft No. 3.
    
    Fig 33: Identifying Gear Shift Fork Shaft No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Coat the 2 shift lock bolts with sealant and install them onto gear shift fork No. 2 and shift head No. 1.
    Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
    
    Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
    
    Fig 34: Identifying Bolts From Gear Shift Fork No. 2
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
  1. Install the reverse shift arm bracket assembly onto the front transaxle case with 2 bolts.
    Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
    
    Fig 35: Identifying Reverse Shift Arm Bracket Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. INSTALL MANUAL TRANSMISSION CASE
  1. Apply FIPG to the manual transmission case, as shown in Fig 36 .
    FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
    
    NOTE: Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
    
    Fig 36: Identifying FIPG To Manual Transmission Case
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Install the 13 bolts onto the manual transmission side.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 37: Identifying Manual Transmission Side Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Install the 3 bolts onto the manual transaxle side.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 38: Identifying Manual Transaxle Side Bolts
  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.
  Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 39: Identifying Reverse Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LOCK BALL ASSEMBLY NO.2
1. Coat lock ball assembly No. 2 with sealant and install it with a hexagon wrench.
  Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Fig 40: Identifying Lock Ball Assembly No. 2
  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 No. 1 onto the manual transmission case.
  
  Fig 41: Identifying Shift Detent Ball (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift detent ball plugs with sealant and install them using a hexagon wrench.
  Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 42: Identifying Shift Detent Ball (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the shift detent ball, shift detent ball compression spring and shift detent ball spring seat No. 1 onto the front transaxle case.
  
  Fig 43: Identifying Shift Detent Ball Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the shift detent ball plug with sealant and install it using a hexagon wrench.
  Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 44: Identifying Shift Detent Ball 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 onto the input shaft.
  
  Fig 45: Identifying 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 onto the output shaft.
  
  Fig 46: Identifying Output Shaft Rear Bearing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT FORK SHAFT SNAP RING
1. Using a brass bar and a hammer, install a new shift fork shaft snap ring onto the shift fork shaft No. 2.
  
  Fig 47: Identifying Shift Fork Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BEARING RETAINER REAR
1. Coat the 5 bolts with sealant, and install the bearing retainer rear onto the manual transmission case with the 5 bolts.
  Torque: 27 N*m (280 kgf*cm, 20 ft.*lbf)
  
  Fig 48: Identifying Bearing Retainer Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH DRIVEN GEAR
1. Using SST, install the 5th driven gear onto the output shaft.
  SST 09309-12020
  
  Fig 49: Identifying 5th Driven Gear Onto Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR NEEDLE ROLLER BEARING
1. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.
  
  Fig 50: Identifying 5th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 5TH GEAR
1. Coat the 5th gear with gear oil and install it onto the input shaft.
  
  Fig 51: Identifying 5th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SYNCHRONIZER RING NO.3
1. Coat synchronizer ring No. 3 with gear oil and install it onto the 5th gear.
  
  Fig 52: Identifying Synchronizer Ring No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION CLUTCH HUB NO.3

Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the transmission clutch hub No. 3.
NOTE: Do not set the 2 shifting key spring openings in the same position.

Fig 53: Installing Shifting Keys & Shifting Key Springs Onto Transmission Clutch Hub No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using SST and a hammer, install transmission clutch hub No. 3 onto the input shaft.
SST 09636-20010
NOTE:
- Do not install transmission clutch hub No. 3 in the wrong direction.
- Install the transmission clutch hub No. 3 with the synchronizer ring No. 3 key groove and synchromesh shifting key No. 3 aligned.
- Check that the 5th gear is rotating.
- Place a suitable sized wooden block to support the input shaft.
  
  Fig 54: Identifying Transmission Clutch Hub No. 3 Onto Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select a clutch hub No. 3 shaft snap ring that will allow minimum axial play.

Clearance: 0.1 mm or less

Snap ring thickness

Fig 55: Identifying Clutch Hub No. 3 Shaft Snap Ring

SNAP RING THICKNESS SPECIFICATION

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.25 (0.0886)	E	2.49 (0.0980)
B	2.31 (0.0909)	F	2.55(0.1004)
C	2.37 (0.0933)	G	2.61 (0.1028)
D	2.43 (0.0957)	-	-

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

INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 5th gear thrust clearance.
  Standard clearance:
  
  0.1 to 0.55 mm (0.0039 to 0.0217 in.)
  
  Maximum clearance:
  
  0.55 mm (0.0217 in.)
  
  If the clearance exceeds the maximum, replace transmission clutch hub No. 3, the 5th gear or input shaft rear radial ball bearing.
  
  Fig 56: Measuring 5th Gear Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure 5th gear radial clearance.
  Standard clearance:
  
  KOYO made:
  
  0.015 to 0.058 mm (0.0006 to 0.0023 in.)
  
  NSK made:
  
  0.015 to 0.056 mm (0.0006 to 0.0022 in.)
  
  Maximum clearance:
  
  KOYO made:
  
  0.058 mm (0.0023 in.)
  
  NSK made:
  
  0.056 mm (0.0022 in.)
  
  If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.
  
  Fig 57: Measuring 5th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GEAR SHIFT FORK NO.3
1. Coat transmission clutch hub sleeve No. 3 with gear oil and install it together with gear shift fork No. 3 onto transmission clutch hub No. 3.
  HINT:
  
  Set the transmission clutch hub No. 3 in the correct orientation.
  
  Fig 58: Identifying Transmission Clutch Hub Sleeve No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift fork lock bolt with sealant, and install it onto gear shift fork No. 3.
  Sealant:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
  
  Fig 59: Tightening Gear Shift Fork Lock Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
1. Engage the 2 gears simultaneously to lock the transmission.
2. Coat a new manual transmission output shaft rear set nut with sealant.
  Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Fig 60: Tightening Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the new manual transmission output shaft rear set nut.
  Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf)
4. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
5. Disengage the 2 gears.
  
  Fig 61: Staking Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
1. Apply FIPG to the manual transaxle case cover sub-assembly as shown in Fig 62 .
  FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
  
  NOTE: Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
  
  Fig 62: Applying FIPG To Manual Transaxle Case Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.
  Torque: 18 N*m (185 kgf*cm, 14 ft.lbf)
  
  Fig 63: Identifying Manual Transmission Case Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Coat the shift and select lever shaft assembly with gear oil, and install it onto the transmission case.
  
  Fig 64: Identifying Shift & Select Lever Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONTROL SHAFT COVER OIL SEAL
1. Using SST and a hammer, install a new control shaft cover oil seal onto the control shaft cover.
  Drive in depth: 0.2 to 1.2 mm (0.0079 to 0.0472 in.)
  
  SST 09950-60010 (09951-00280), 09950-70010 (09951-07150)
2. Coat the control shaft cover oil seal with MP grease.
  
  Fig 65: Identifying SST, Hammer & New Control Shaft Cover Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONTROL SHAFT COVER
1. Coat the 4 bolts with sealant. Install a new gasket and control shaft cover onto the manual transmission case with the 4 bolts.
  Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
  
  Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  NOTE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
  
  Fig 66: Locating Bolts, Control Shaft Cover & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT GATE PIN
1. Coat the shift gate pin with sealant.
2. Install the washer and shift gate pin.
  Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf)
  
  Sealant:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Fig 67: Locating Shift Gate Pin & Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LOCK BALL ASSEMBLY NO.1
1. Coat lock ball assembly No. 1 with sealant, install it onto the manual transmission case.
  Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
  
  Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Fig 68: Locating Lock Ball Assembly No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SHIFT LEVER DAMPER
1. Install the dust boot onto the control shaft cover.
2. Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.
3. Install the spring washer with the nut.
  Torque: 12 N*m (120 kgf*cm, 8.7 ft.*lbf)
  
  Fig 69: Locating Nut & Spring Washer (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FLOOR SHIFT CONTROL SHIFT LEVER
1. Install the dust boot onto the shift and select lever shaft oil seal.
2. Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.
3. Install the spring washer with the nut.
  Torque: 12 N*m (120 kgf*cm, 8.7 ft.*lbf)
  
  Fig 70: Locating Nut & Spring Washer (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SELECTING BELL CRANK ASSEMBLY
1. Install the selecting bell crank assembly together with the control shift lever bush onto the manual transmission case with the 2 bolts and nut.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) for bolt
  
  12 N*m (120 kgf*cm, 8.7 ft.*lbf) for nut
  
  NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush.
  
  Fig 71: Locating Selecting Bell Crank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, install the back-up light switch assembly onto the manual transmission case with a new gasket.
  SST 09817-16011
  
  Torque: 40 N*m (410 kgf*cm, 30 ft.*lbf)
2. Install the back-up light switch wire harness into the 2 clamps.
  
  Fig 72: Identifying Back-Up Light Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEEDOMETER SENSOR (w/o ABS)
1. Install a new O-ring onto the speedometer sensor.
2. Install the speedometer sensor onto the transaxle case with the bolt.
  Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
1. Install a new O-ring onto the speedometer driven hole cover sub-assembly.
2. Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt.
  Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
INSTALL MANUAL TRANSMISSION FILLER PLUG
1. Install the manual transmission filler plug onto the manual transmission case with a new gasket.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 73: Identifying Manual Transmission Filler Plug & New Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN PLUG SUB-ASSEMBLY
1. Install the drain plug onto the manual transmission case with a new gasket.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  
  Fig 74: Identifying Drain Plug & New Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002