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Manual Transmission Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Remove the bolt and separate the wire harness clamp.
      Fig 1: Separating Wire Harness Clamp
      G04046434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the back-up light switch and gasket.

      SST 09817-16011

      Fig 2: Removing Back-Up Light Switch & Gasket Using SST
      G04046435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY 
    1. Remove the floor shift control shift lever retainer sub-assembly.
      Fig 3: Identifying Floor Shift Control Shift Lever Retainer Sub-Assembly
      G04046436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER 
    1. Pull up the locks of the shift lever pins, and remove the 2 shift lever pins.
    2. Remove the floor shift control shift lever retainer.
    Fig 4: Identifying Floor Shift Control Shift Lever Retainer
    G04046437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE SHIFT AND SELECT LEVER BOOT 
    1. Remove the shift and select lever boot.
  5. REMOVE SHIFT LEVER RETAINER BUSHING 
    1. Remove the 4 shift lever retainer bushings.
      Fig 5: Identifying Shift Lever Retainer Bushings
      G04046438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CONTROL SHAFT 
    1. Using a screwdriver, remove the E-ring and control shaft.
    2. Remove the 2 collars from the floor shift control shaft.
      Fig 6: Removing Control Shaft
      G04046439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FLOOR SHIFT CONTROL SHAFT 
    1. Using a hammer and a screwdriver, cut off the control shaft collar and remove it from the shaft.
    2. Remove the shaft pin and floor shift control shaft.
    3. Remove the shift lever damper from the floor shift control shaft.
    Fig 7: Removing Floor Shift Control Shaft
    G04046440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE EXTENSION HOUSING DUST DEFLECTOR 
    1. Using a plastic hammer, remove the extension housing dust deflector.
  9. REMOVE EXTENSION HOUSING SUB-ASSEMBLY 
    1. Remove the 8 bolts.
      Fig 8: Identifying Extension Housing Sub-Assembly Bolts
      G04046441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, carefully tap out the extension housing.
    3. Remove the extension housing.
      Fig 9: Identifying Extension Housing
      G04046442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE EXTENSION HOUSING REAR OIL SEAL 
    1. Using SST, remove the extension housing rear oil seal.

      SST 09612-70100 (09612-07210) 

      Fig 10: Identifying Extension Housing Rear Oil Seal
      G04046443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL 
    1. Using SST, remove the extension housing oil seal.

      SST 09308-00010 

      Fig 11: Removing Manual Transmission Extension Housing Oil Seal
      G04046444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE 
    1. Using a snap ring expander, remove the snap ring.
      Fig 12: Removing Snap Ring Using Snap Ring Expander
      G04046445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the oil receiver pipe.
      Fig 13: Identifying Oil Receiver Pipe
      G04046446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE SHIFT DETENT BALL PLUG 
    1. Using a socket hexagon wrench (10 mm), remove the shift detent ball plug from the transmission rear case.
    2. Remove the ball and compression spring from the transmission rear case.
      Fig 14: Removing Shift Detent Ball Plug
      G04046447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE OUTPUT SHAFT ADJUST NUT 
    1. Using a belt and wooden block, fasten the transmission to the workbench.
    2. Using a chisel and hammer, unstake the nut.
      Fig 15: Unstaking Nut Using Chisel & Hammer
      G04046448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place the gearshift into 5th gear, and then fix the input shaft using SST.

      SST 09556-16030 

      Fig 16: Fixing Input Shaft Using SST
      G04046449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, remove the nut from the output shaft.

      SST 09922-10010 

    5. Remove the belt and wooden block from the transmission.
      Fig 17: Removing Nut From Output Shaft
      G04046450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the No. 2 taper roller bearing and spacer.
      Fig 18: Identifying No. 2 Taper Roller Bearing & Spacer
      G04046451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSMISSION REAR CASE 
    1. Remove the 10 bolts and bracket.
      Fig 19: Identifying Bracket
      G04046452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, carefully tap out the rear case.
    3. Remove the rear case.
      Fig 20: Identifying Transmission Rear Case
      G04046453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the 2 transmission filler plugs and 2 gaskets from the transmission rear case.
      Fig 21: Removing Transmission Filler Plugs & Gaskets From Transmission Rear Case
      G04046454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE 
    1. Remove the extension housing oil receiver pipe from the transmission rear case.
      Fig 22: Removing Extension Housing Oil Receiver Pipe From Transmission Rear Case
      G04046455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE OIL SEPARATOR PACKING SEAL 
    1. Remove the oil separator packing seal from the transmission rear case.
      Fig 23: Removing Oil Separator Packing Seal From Transmission Rear Case
      G04046456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE 
    1. Using SST, remove the 2 bearing outer races.

      SST 09308-00010 

      Fig 24: Identifying Bearing Outer Races
      G04046457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING 
    1. Remove the bolt, then remove the bearing lock plate.
      Fig 25: Identifying Bearing Lock Plate Bolt
      G04046458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the counter gear rear cylindrical roller bearing from the transmission rear case.

      SST 09308-00010 

      Fig 26: Removing Counter Gear Rear Cylindrical Roller Bearing From Transmission Rear Case
      G04046459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSMISSION REAR CASE BEARING 
    1. Using SST and a press, remove the transmission rear case bearing from the transmission rear case.

      SST 09950-60010 (09951-00230) 

      Fig 27: Removing Transmission Rear Case Bearing From Transmission Rear Case
      G04046460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE TRANSMISSION OIL SEPARATOR 
    1. Remove the 2 bolts, then remove the oil separator.
      Fig 28: Identifying Transmission Oil Separator Bolts
      G04046461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    1. Remove the reverse idler gear shaft bolt and gasket from the transmission middle case.
      Fig 29: Removing Reverse Idler Gear Shaft Bolt & Gasket From Transmission Middle Case
      G04046462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSMISSION MIDDLE CASE 
    1. Remove the 11 bolts, then remove the transmission middle case.
      Fig 30: Identifying Transmission Middle Case Bolts
      G04046463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, carefully tap out the transmission middle case.
      Fig 31: Tapping Out Transmission Middle Case Using Plastic Hammer
      G04046464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSMISSION DRAIN PLUG 
    1. Remove the drain plug and gasket from the transmission middle case.
      Fig 32: Identifying Transmission Drain Plug
      G04046465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 OIL RECEIVER PIPE 
    1. Remove the No. 2 oil receiver pipe from the transmission middle case.
      Fig 33: Removing No. 2 Oil Receiver Pipe From Transmission Middle Case
      G04046466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE TRANSMISSION MIDDLE CASE BEARING 
    1. Using SST and a press, remove the transmission middle case bearing from the transmission middle case.

      SST 09950-60010 (09951-00230) 

      Fig 34: Removing Transmission Middle Case Bearing From Transmission Middle Case
      G04046467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE SHIFT AND SELECT LEVER SHAFT 
    1. Remove the shift and select lever shaft.
      Fig 35: Identifying Shift & Select Lever Shaft
      G04046468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE SHIFT AND SELECT LEVER 
    1. Remove the bolt, then remove the shift and select lever.
    2. Remove the lock ball pin and spring from the shift and select lever.
      Fig 36: Identifying Shift & Select Lever
      G04046469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE SHIFT AND SELECT LEVER CAM 
    1. Using a screwdriver, remove the E-ring and the shift and select lever cam from the shift and select lever shaft.
      Fig 37: Identifying Shift & Select Lever Cam
      G04046470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the thrust clearance.

      Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 in.) 

      Maximum clearance: 0.25 (0.0098 in.) 

      If the clearance exceeds the maximum, replace the reverse idler gear shaft, reverse idler gear or transmission front case.

      Fig 38: Measuring Reverse Idler Gear Thrust Clearance Using Feeler Gauge
      G04046471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REVERSE IDLER GEAR 
    1. Remove the reverse idle gear shaft, reverse idler gear bearing and reverse idler gear.
      Fig 39: Identifying Reverse Idle Gear
      G04046472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE 
    1. Install the reverse idler gear and reverse idler gear bearing to the reverse idler gear shaft.
    2. Using a dial indicator, measure the radial clearance.

      Standard clearance: 0.015 to 0.050 mm (0.0006 to 0.0020 in.) 

      Maximum clearance: 0.050 mm (0.0020 in.) 

      If the clearance exceeds the maximum, replace the reverse idler gear bearing, reverse idler gear shaft or reverse idler gear.

      Fig 40: Measuring Radial Clearance Using Dial Indicator
      G04046473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSMISSION FRONT CASE 
    1. Using a hexagon wrench (24 mm), remove the plug from the transmission front case.
      Fig 41: Removing Plug From Transmission Front Case Using Hexagon Wrench
      G04046474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts from the shift interlock bracket.
      Fig 42: Identifying Shift Interlock Bracket Bolts
      G04046475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tie the input shaft, counter gear and control assembly with a rope or string.
      Fig 43: Tying Input Shaft, Counter Gear & Control Assembly With Rope Or String
      G04046476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Expand the 2 snap rings, and lift up the output shaft, input shaft, counter gear and control assembly.
      Fig 44: Expanding Snap Rings & Lifting Up Output Shaft, Input Shaft, Counter Gear & Control Assembly
      G04046477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the output shaft, input shaft, counter gear shaft and control assembly while gently tapping the front case with a plastic hammer.
      NOTE: Take care not to subject the output shaft, input shaft, counter gear shaft and control assembly to any impact. This may cause the ball and spring to come out.
    6. Separate the output shaft, input shaft, counter gear shaft and control assembly.
      Fig 45: Identifying Output Shaft, Input Shaft, Counter Gear Shaft & Control Assembly
      G04046478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE NO. 1 OIL RECEIVER PIPE 
    1. Remove the No. 1 oil receiver pipe from the transmission front case.
      Fig 46: Removing No. 1 Oil Receiver Pipe From Transmission Front Case
      G04046479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT BEARING SHAFT SNAP RING 
    1. Using snap ring pliers, remove the 2 snap rings.
      Fig 47: Removing Snap Rings Using Snap Ring Pliers
      G04046480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE TRANSMISSION CASE OIL SEAL 
    1. Using SST, remove the transmission case oil seal from the transmission front case.

      SST 09308-00010 

      Fig 48: Removing Transmission Case Oil Seal From Transmission Front Case
      G04046481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 3 GEAR SHIFT FORK 
    1. Using 2 screwdrivers, remove the 4 snap rings.
      Fig 49: Removing Snap Rings Using Screwdrivers
      G04046482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, then remove the No. 3 gear shift fork.
      Fig 50: Removing No. 3 Gear Shift Fork
      G04046483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 1 GEAR SHIFT HEAD 
    1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
      Fig 51: Tapping Out Slotted Spring Pin Using Pin Punch & Hammer
      G04046484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 1 GEAR SHIFT FORK SHAFT 
    1. Remove the No. 1 gear shift fork shaft, No. 1 gear shift head, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.
      Fig 52: Identifying No. 1 Gear Shift Fork Shaft
      G04046485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 2 GEAR SHIFT FORK 
    1. Remove the bolt, then remove the No. 2 gear shift fork.
      Fig 53: Identifying No. 2 Gear Shift Fork
      G04046486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 2 GEAR SHIFT FORK SHAFT 
    1. Remove the No. 2 gear shift fork shaft, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.
      Fig 54: Identifying No. 2 Gear Shift Fork Shaft
      G04046487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 3 GEAR SHIFT HEAD 
    1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
      Fig 55: Tapping Out Slotted Spring Pin
      G04046488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 3 GEAR SHIFT FORK SHAFT 
    1. Remove the No. 3 gear shift fork shaft, ball, spring, No. 3 gear shift head and No. 1 shift interlock pin.
      Fig 56: Identifying No. 3 Gear Shift Fork Shaft
      G04046489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE NO. 1 GEAR SHIFT FORK 
    1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
      Fig 57: Tapping Out Slotted Spring Pin
      G04046490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 gear shift head and No. 1 gear shift fork.
      Fig 58: Identifying No. 2 Gear Shift Head & No. 1 Gear Shift Fork
      G04046491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE NO. 4 GEAR SHIFT FORK 
    1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
    2. Remove the No. 4 gear shift fork.
      Fig 59: Tapping Out Slotted Spring Pin
      G04046492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE NO. 4 GEAR SHIFT FORK SHAFT 
    1. Remove the No. 4 gear shift fork shaft, ball and spring.
      Fig 60: Identifying No. 4 Gear Shift Fork Shaft, Ball & Spring
      G04046493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE SHIFT ARM 
    1. Using a screwdriver, remove the E-ring.
      Fig 61: Removing E-Ring Using Screwdriver
      G04046494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the shift arm pivot and shift arm.
      Fig 62: Identifying Shift Arm Pivot & Shift Arm
      G04046495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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