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Transmission Reassembly

NOTE: Coat all sliding or rotating parts with gear oil before assembly.
NOTE: Use Three Bond (1281) sealant. Assemble housing immediately after applying liquid gasket. Allow 30 minutes curing time before filing with oil.
  1. Before installing output shaft, remove countergear center bearing race from intermediate plate. Install outer race after installing countergear. Install output shaft into intermediate plate by pulling on output shaft and tapping on intermediate plate with plastic hammer.
  2. Install needle roller bearing into input shaft. Install input shaft, output shaft and countergear together. See Figure. Install countergear center bearing outer race. Ensure bearing rollers are not damaged.
  3. Mount intermediate plate in vise by installing 2 clutch housing bolts with nuts and washers in bottom holes of intermediate plate to prevent damage to sealing surface of intermediate plate. See Figure. Increase or decrease washers so that bolt tip does not protrude from nut. DO NOT apply pressure on intermediate plate.
  4. Install rear bearing retainer snap ring. Ensure snap ring is flush with intermediate plate surface. Install output shaft rear bearing retainer. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install reverse gear. Select and install snap ring that will allow minimum axial play. Select thickest snap ring that fits into groove. See REVERSE GEAR SNAP RING SPECIFICATIONS  table.
  5. Install 5th gear and rear bearing. See Figure. Select and install snap ring that will allow minimum axial play. Select thickest snap ring that fits into groove. See OUTPUT SHAFT REAR BEARING SNAP RING SPECIFICATIONS  table.
  6. Install rear magnet. Support countergear and install No. 3 clutch hub on countergear. Select and install snap ring that will allow minimum axial play. See NO. 3 CLUTCH HUB SNAP RING SPECIFICATIONS  table.
  7. Install bearing spacer on countergear shaft. Assemble counter 5th gear, synchronizer ring and needle bearings. See Figure. Install 5th gear with 5th gear gaps aligned with synchronizer cone ring pin. See Fig 1. Install spacer and bearing with bearing shield toward rear of shaft. Support front of countergear and drive on bearing with appropriate hammer and bearing installer. Select and install snap ring that will allow minimum axial play. Select thickest snap ring that fits into groove. See COUNTER 5TH GEAR SHAFT SNAP RING SPECIFICATIONS  table.
    Fig 1: Aligning 5th Gear Gaps With Ring Pin
    G00182357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    REVERSE GEAR SNAP RING SPECIFICATIONS

    ID Stamp Thickness - In. (mm)
    5 .089-.091 (2.25-2.30)
    11 .091-.093 (2.30-2.35)
    12 .093-.095 (2.35-2.40)
    13 .095-.097 (2.40-2.45)
    14 .097-.098 (2.45-2.50)
    15 .098-.100 (2.50-2.55)
    16 .100-.102 (2.55-2.60)
    17 .103-.105 (2.61-2.66)
    18 .105-.107 (2.67-2.72)
    19 .107-.109 (2.73-2.78)
    20 .110-.112 (2.79-2.84)
    21 .112-.114 (2.85-2.90)
    22 .115-.117 (2.91-2.96)
    23 .117-.119 (2.97-3.02)
    OUTPUT SHAFT REAR BEARING SNAP RING SPECIFICATIONS

    ID Stamp Thickness - In. (mm)
    8 .091-.093 (2.31-2.36)
    9 .093-.095 (2.37-2.42)
    10 .096-.098 (2.43-2.48)
    11 .098-.100 (2.49-2.54)
    12 .100-.102 (2.55-2.60)
    13 .103-.105 (2.61-2.66)
    14 .106-.107 (2.68-2.73)
    15 .108-.110 (2.74-2.79)
    NO. 3 CLUTCH HUB SNAP RING SPECIFICATIONS

    ID Stamp Thickness - In. (mm)
    2 .081-.083 (2.06-2.11)
    3 .083-.085 (2.12-2.17)
    4 .086-.088 (2.18-2.23)
    5 .088-.090 (2.24-2.29)
    COUNTER 5TH GEAR SHAFT SNAP RING SPECIFICATIONS

    ID Stamp Thickness - In. (mm)
    1 .075-.077 (1.90-1.95)
    2 .077-.079 (1.96-2.01)
    3 .080-.082 (2.02-2.07)
    4 .082-.084 (2.08-2.13)
    5 .085-.086 (2.14-2.19)
    6 .087-.089 (2.20-2.25)
    7 .089-.091 (2.26-2.31)
  8. Measure counter 5th gear thrust clearance. See Figure. Standard clearance is .004-.016" (.10-.41 mm). Service limit is .016" (.41 mm). Install vehicle speed sensor drive gear clip into slot on output shaft. Slide drive gear with clip and fit clip into holes. Install reverse idler gear and shaft. See Figure. Lubricate interlock pin and install into reverse shift head hole. Install No. 3 shift fork shaft with snap ring through No. 3 shift fork and reverse shift arm. Align No. 3 shift fork with No. 3 hub sleeve groove. See Figure. Install reverse shift arm into pivot of bearing retainer and align reverse shift arm shoe with reverse idler groove. Install No. 3 shift fork shaft to intermediate plate.
  9. Install No. 4 shift fork shaft into intermediate plate. Install ball and spring into reverse shift head. Install and tighten straight screw plug to specification. See TORQUE SPECIFICATIONS . Install slotted spring pin to No. 3 shift fork at a depth of 0-.020" (0-.50 mm). See Fig 2. Install snap ring to No. 3 shift fork shaft. Lubricate No. 2 and No. 3 interlock pins and install into intermediate plate hole. See Figure. Place No. 2 shift fork into groove of No. 2 hub sleeve. See Figure. Install No. 2 shift fork shaft through intermediate plate. Install snap ring to No. 2 shift fork shaft.
    Fig 2: Installing No. 3 Shift Fork Pin
    G00182358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Place No. 1 shift fork onto groove of No. 1 hub sleeve. See Figure. Install No. 1 shift fork shaft to No. 1 shift fork, then install through intermediate plate. Install 2 new set bolts to No. 1 and No. 2 shift fork. See Figure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
    NOTE: No gaskets are used between transmission housings. Use Three Bond (1281) sealant. Assemble housing immediately after applying liquid gasket. Allow 30 minutes curing time before filling with oil.
  11. Install 3 locking balls and springs to intermediate plate. Apply Loctite (242) or equivalent, to straight screw plugs and install. Note length and position of plugs. See Figure. Tighten plugs to specification. Install reverse idler gear shaft stopper. See Figure. Tighten bolt to specification. Install front magnet and oil separator. Tighten bolts to specification. Dismount intermediate plate from vise. Apply Three Bond (1281) or equivalent sealant to transmission case and install.
  12. Install snap rings on input shaft bearing and countergear. Install NEW oil seal to front bearing retainer. Drive oil seal to a depth of .460-.500" (11.68-12.70 mm). Apply Three Bond (1281), or equivalent sealant to front bearing retainer. Install retainer. Apply Loctite (242) or equivalent, to front bearing retainer bolts. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS . Apply Three Bond (1281) or equivalent sealant to extension housing. Align each bearing outer race and shift fork shaft end with housing holes. Install extension housing using plastic hammer. Install shift lever housing set bolt and tighten to specification. See Figure.
  13. Connect shift and select lever to inner lever. See Figure. Install control shift lever retainer with NEW oil deflector to shift and select lever shaft. Be sure to spline small ball portion of inner lever into shift lever housing. See Fig 3. Install NEW bolt and tighten to specification. Apply Loctite (242) or equivalent sealant, to control shift lever retainer bolts. Install and tighten bolts to specification.
  14. Ensure input and output shafts rotate smoothly and shifting is smooth in all positions. Install restrict pins with gaskets. Install Black restrict pin on reverse gear (5th gear side). See Figure. Tighten pins to specification. See TORQUE SPECIFICATIONS .
  15. Install clutch housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install vehicle speed sensor driven gear. Install back-up light switch to specification. Install wire clamp.
    Fig 3: Installing Small Ball Into Shift Lever Housing
    G00182359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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