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Manual Transaxle Unit: Installation

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL SYNCHRONIZER PULL RING 
    1. Install the No. 5 synchronizer ring middle, No. 5 synchronizer ring outer and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, fix them in place with the synchronizer pull ring snap ring.
    Fig 1: Removing No 5 Synchronizer Ring Middle, No 5 Synchronizer Ring Outer
    G04222589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 5 SYNCHRONIZER RING MIDDLE 
    1. Check that the No. 5 synchronizer ring middle rotates smoothly.
      Fig 2: Checking No. 5 Synchronizer Ring Middle
      G04222590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub.
      Fig 3: Checking No. 5 Synchronizer Ring Middle
      G04222591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY SPRING 
    1. Install the No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.
      NOTE: Align the projection of the shifting key spring with the hole of the No. 3 clutch hub and install it.
    2. Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.
    Fig 4: Installing No 3 Synchromesh Shifting Key Spring To No 3 Transmission Clutch Hub
    G04222592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.
    • Align the projection of the shifting key spring with the hole of the No. 3 clutch hub and install it.
  4. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL 
    1. Using SST and a hammer, install a new front transaxle case cover oil seal.

      SST 09316-20011, 09950-60020 (09951-00910), 09950-70010 (09951-07150) 

      Standard depth: 

      -0.5 to 0.5 mm (-0.020 to 0.020 in.) 

    2. Coat the lip of the oil seal with MP grease.
    Fig 5: Installing Front Transaxle Case Cover Oil Seal
    G04222593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a hammer, tap in the front tapered roller bearing (outer race) to the front transaxle case.

      SST 09950-60020 (09951-00910), 09950-70010 (09951-07100, 09951-07150) 

      Fig 6: Taping In Front Tapered Roller Bearing
      G04222594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the front tapered roller bearing (inner race) to the front differential case.

      SST 09950-70010 (09951-07100, 09951-07150), 09608-10010 

    Fig 7: Pressing In Front Tapered Roller Bearing
    G04222595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Install the rear shim.
    2. Using SST and a hammer, tap in the rear tapered roller bearing (outer race).

      SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) 

      Fig 8: Taping In Rear Tapered Roller Bearing
      G04222596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press in the rear tapered roller bearing (inner race).

      SST 09631-12090, 09950-60010 (09951-00600), 09950-70010 (09951-07100) 

    Fig 9: Pressing In Rear Tapered Roller Bearing
    G04222597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal to the transmission case.

      SST 09608-32010, 09950-70010 (09951-07150) 

      Standard depth: 

      3.0 to 4.0 mm (0.118 to 0.158 in.) 

    2. Coat the oil seal lip with MP grease.
    Fig 10: Taping Oil Seal To Transmission Case
    G04222598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL REAR OUTPUT SHAFT BEARING 
    1. Using SST and a hammer, tap in the rear bearing (outer race) to the transmission case.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07100) 

      Standard clearance: 

      3.8 to 4.4 mm (0.150 to 0.173 in.) 

    Fig 11: Taping Rear Bearing To Transmission Case
    G04222599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL OUTPUT SHAFT COVER 
    1. Coat the shaft cover with MP grease, and install it to the transaxle case.
      NOTE: Align the projection of the output shaft with the transaxle groove and install it.
    Fig 12: Installing Output Shaft Cover
    G04222600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT OUTPUT SHAFT BEARING 
    1. Using SST and a hammer, tap in the front bearing (outer race).

      SST 09950-60020 (09951-00730), 09950-70010 (09951-07100) 

    Fig 13: Taping Front Bearing
    G04222601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. ADJUST OUTPUT SHAFT BEARING PRELOAD 
    1. Install the output shaft to the transaxle case.
      Fig 14: Installing Output Shaft To Transaxle Case
      G04222602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission case to the transaxle case with the 14 bolts.

      Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

      Fig 15: Installing Transmission Case To Transaxle Case With Bolts
      G04222603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts on the transaxle side.

      Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

      Fig 16: Installing Bolts On Transaxle Side
      G04222604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the output shaft rear bearing shim to the output shaft.
      Fig 17: Installing Output Shaft Rear Bearing Shim To Output Shaft
      G04222605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a T45 "torx" socket, install the rear bearing retainer with the 7 "torx" screws to the transmission case.

      Torque: 43 N.m (438 kgf.cm, 32 ft. lbf) 

      Fig 18: Installing Rear Bearing Retainer
      G04222606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
    7. Temporarily install the output shaft rear set nut.
    8. Using a socket wrench and torque wrench, inspect the preload.

      Standard preload 

      Bearing Torque
      New 0.8 to 1.6 N.m (8.16 to 16,32 kgf.cm 7,1 to 14.2 in.lbf)
      Used 0.5 to 1.0 N.m (5.10 to 10.20 kgf.cm 4.4 to 8.9 in.lbf)
      Fig 19: Checking Preload
      G04222607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. If preload is out of specification, select a proper output shaft rear bearing shim and adjust it.

      HINT:

      The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 N.m (0.408 to 0.612 kgf.cm, 0.354 to 0.531 in. lbf)

      STANDARD SHIM THICKNESS SPECIFICATION

      Part No Mark Thickness
      90564-59001 0 1.30 mm (0.0512 in.)
      90564-59002 1 1.35 mm (0.0531 in.)
      90564-59003 2 1.40 mm (0.0551 in.)
      90564-59004 3 1.45 mm (0.0571 in.)
      90564-59005 4 1.50 mm (0.0591 in.)
      90564-59006 5 1.55 mm (0.0610 in.)
      90564-59007 6 1.60 mm (0.0630 in.)
      90564-59008 7 1.65 mm (0.0650 in.)
      90564-59009 8 1.70 mm (0.0669 in.)
      90564-59010 9 1.75 mm (0.0689 in.)
      90564-59011 A 1.80 mm (0.0669 in.)
      90564-59012 B 1.85 mm (0.0728 in.)
      90564-59013 C 1.90 mm (0.0748 in.)
      90564-59014 D 1.95 mm (0.0768 in.)
      90564-59015 E 2.00 mm (0.787 in.)
      90564-59016 F 2.05 mm (0.0807 in.)
      90564-59017 G 2.10 mm (0.0827 in.)
      90564-59018 H 2.15 mm (0.0846 in.)
      90564-59019 J 2.20 mm (0.0866 in.)
      90564-59020 K 2.25 mm (0.0886 in.)
      90564-59021 L 2.30 mm (0.0906 in.)
      90564-59022 M 2.35 mm (0.0925 in.)
      90564-59023 N 2.40 mm (0.0945 in.)
      90564-59024 O 2.45 mm (0.0965 in.)
      90564-59025 P 2.50 mm (0.0984 in.)
    10. Remove the output shaft rear set nut from the output shaft.
    11. Using a T45 "torx" socket, remove the 7 "torx" screws and rear bearing retainer from the manual transmission case.
      Fig 20: Removing Torx Screws
      G04222608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Remove the output shaft rear bearing shim from the output shaft.
      Fig 21: Removing Output Shaft Rear Bearing Shim From Output Shaft
      G04222609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the 3 bolts.
      Fig 22: Removing Front Transaxle Case Bolts
      G04222610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the 14 bolts and transmission case from the transaxle case.
      Fig 23: Removing Bolts And Transmission Case From Transaxle Case
      G04222611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Remove the output shaft assembly from the front transaxle case.
    Fig 24: Removing Output Shaft Assembly From Front Transaxle Case
    G04222612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. ADJUST TAPERED ROLLER BEARING PRELOAD 
    1. Install the differential case assembly to the transaxle case.
      Fig 25: Installing Differential Case Assembly To Transaxle Case
      G04222613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 14 bolts and transmission case to the transaxle case.

      Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

      Fig 26: Installing Bolts And Transmission Case To Transaxle Case
      G04222614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts on the front transaxle case side.

      Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

    4. Turn the differential case in both directions to make sure that it starts to turn smoothly.
      Fig 27: Installing Bolts On Front Transaxle Case Side
      G04222615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a torque wrench, measure the preload.

      Standard preload 

      Bearing Torque
      New 0.8 to 1.6 N.m (8.16 to 16.32 kgf.cm, 7.1 to 14.2 in. lbf)
      Used 0.5 to 1.0 N.m (5.10 to 10.2 kgf.cm, 4.4 to 8.9 in. lbf)

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

      Fig 28: Measuring Preload
      G04222616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 N.m (0.408 to 0.612 kgf.cm, 0.354 to 0.531 in. lbf).

      SHIM THICKNESS SPECIFICATION

      Part No. Mark Thickness
      90564-56055 0 2.00 mm (0.0787 in.)
      90564-56056 1 2.05 mm (0.0807 in.)
      90564-56057 2 2.10 mm (0.0827 in.)
      90564-56058 3 2.15 mm (0.0846 in.)
      90564-56059 4 2.20 mm (0.0866 in.)
      90564-56060 5 2.25 mm (0.0886 in.)
      90564-56061 6 2.30 mm (0.0906 in.)
      90564-56062 7 2.35 mm (0.0925 in.)
      90564-56063 8 2.40 mm (0.0945 in.)
      90564-56064 9 2.45 mm (0.0965 in.)
      90564-56065 A 2.50 mm (0.00984 in.)
      90564-56066 B 2.55 mm (0.1004 in.)
      90564-56067 C 2.60 mm (0.1024 in.)
      90564-56068 D 2.65 mm (0.1043 in.)
      90564-56069 E 2.70 mm (0.1063 in.)
      90564-56070 F 2.75 mm (0.1083 in.)
      90564-56071 G 2.80 mm (0.1102 in.)
      90564-56072 H 2.85 mm (0.1122 in.)
    6. Remove the 3 bolts.
      Fig 29: Removing Front Transaxle Case Bolts
      G04222617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 14 bolts and transmission case from the transaxle case.
      Fig 30: Removing Bolts And Transmission Case From Transaxle Case
      G04222618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the differential case assembly from the transaxle case.
    Fig 31: Removing Differential Case Assembly From Transaxle Case
    G04222619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal to the transaxle case.

      SST 09950-60010 (09951-00420), 09950-70010 (09951-07150) 

      Standard distance: 

      1 to 2 mm (0.04 to 0.08 in.) 

    2. Coat the lip of the oil seal with MP grease.
    Fig 32: Installing Oil Seal To Transaxle Case
    G04222620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT INPUT SHAFT BEARING 
    1. Coat the input shaft front bearing with gear oil, and using SST, install it to the transaxle case.

      SST 09950-60010 (09951-00570), 09950-70010 (09951-07150) 

      Standard distance: 

      4.28 to 4.60 mm (0.1685 to 0.1811 in.) 

    Fig 33: Installing Front Input Shaft Bearing
    G04222621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    1. Install the 3 bolts and the receiver to the transaxle case.

    Torque: 7.0 N.m (71 kgf.cm, 62 in. lbf) 

    Fig 34: Installing Bolts And Receiver To Transaxle Case
    G04222622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. Coat the differential case tapered roller bearing with gear oil, and install the differential case to the transaxle case.
    Fig 35: Installing Differential Case Assembly
    G04222623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL OUTPUT SHAFT ASSEMBLY 
    1. Apply gear oil to each sliding part of the output shaft.
    2. Slightly lift up on the differential case at an angle, and install the output shaft to the transaxle case.
    Fig 36: Installing Output Shaft Assembly
    G04222624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL INPUT SHAFT ASSEMBLY 
    1. Apply gear oil to each sliding part of the input shaft.
    2. Install the input shaft to the transaxle case while tilting the output shaft.
    Fig 37: Installing Input Shaft To Transaxle Case
    G04222625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL NO. 2 GEAR SHIFT FORK 
    1. Coat the No. 2 gear shift fork with gear oil, and install it to the input shaft assembly.
    Fig 38: Installing No. 2 Gear Shift Fork
    G04222626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL NO. 3 GEAR SHIFT FORK 
    1. Install the reverse shift fork to the No. 3 gear shift fork shaft.
    2. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the No. 3 gear shift fork shaft.
      Fig 39: Installing Reverse Shift Fork To No. 3 Gear Shift Fork Shaft
      G04222627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply gear oil to each sliding part of the No. 3 gear shift fork shaft, and install it to the transaxle case.
    Fig 40: Installing No. 3 Gear Shift Fork Shaft
    G04222628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL NO. 1 GEAR SHIFT FORK 
    1. Apply gear oil to each sliding part of the No. 1 gear shift fork, and install it to the output shaft assembly.
    Fig 41: Installing No. 1 Gear Shift Fork
    G04222629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 2 GEAR SHIFT FORK 
    1. Apply gear oil to each sliding part of the No. 2 gear shift fork shaft and No. 1 gear shift head, and install them to the transaxle case.
      Fig 42: Installing No. 2 Gear Shift Fork
      G04222630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the shift fork set bolt and shift head set bolt to the No. 1 gear shift head and No. 2 gear shift fork.
    Fig 43: Installing Shift Fork Set Bolt And Shift Head Set Bolt
    G04222631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL REVERSE SHIFT FORK ROLLER 
    1. Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.
    Fig 44: Installing Reverse Shift Fork Roller
    G04222632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 1 GEAR SHIFT FORK SHAFT 
    1. Using a brass bar and hammer, tap in the shaft snap ring to the No. 1 shift fork shaft.
      Fig 45: Installing No. 1 Gear Shift Fork Shaft
      G04222633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 gear shift fork shaft to the transaxle case.
      Fig 46: Installing No. 1 Gear Shift Fork Shaft To Transaxle Case
      G04222634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift fork set bolt to the No. 1 gear shift fork.

    Torque: 24 N.m (245 kgf.cm, 18 ft. lbf) 

    Fig 47: Installing Shift Fork Set Bolt To No. 1 Gear Shift Fork
    G04222635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Install the reverse shift arm bracket to the transaxle case with the 2 bolts.

    Torque: 17 N.m (173 kgf.cm, 13 ft. lbf) 

    Fig 48: Installing Reverse Shift Arm Bracket To Transaxle Case
    G04222636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Coat the reverse idler gear and thrust washer with gear oil, and install them to the reverse idler gear shaft.
      Fig 49: Installing Reverse Idler Gear Sub-Assembly
      G04222637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the reverse idler gear with the reverse idler gear shaft to the transaxle case.

      HINT:

      Align the mark of the reverse idler gear shaft with the hole of the bolts.

    Fig 50: Installing Reverse Idler Gear With Reverse Idler Gear Shaft To Transaxle Case
    G04222638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet, and install it to the transaxle case.
    Fig 51: Installing Transmission Magnet
    G04222639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    1. Install the reverse restrict pin to the transaxle case.
    2. Using a 5 mm pin punch, install the slotted spring pin.

      Standard clearance: 

      12.5 to 13.5 mm (0.492 to 0.531 in.) 

      Fig 52: Installing Slotted Spring Pin
      G04222640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the reverse restrict pin plug with adhesive 1324, and using a 6 mm hexagon wrench, install it to the manual transmission case.

    Torque: 13 N.m (133 kgf.cm, 9.6 ft. lbf) 

    Fig 53: Installing Manual Transmission Case
    G04222641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL NO. 1 OIL RECEIVER PIPE 
    1. Install the oil receiver pipe to the transmission case with the bolt.

    Torque: 17 N.m (173 kgf.cm, 13 ft. lbf) 

    NOTE: Do not damage the pipe.
    Fig 54: Installing Oil Receiver Pipe To Transmission Case
    G04222642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL NO. 2 OIL RECEIVER PIPE 
    1. Install the oil receiver pipe to the transmission case with the bolt.

      Torque: 17 N.m (173 kgf.cm, 13 ft. lbf) 

      NOTE: Do not damage the pipe.
    Fig 55: Installing Oil Receiver Pipe To Transmission Case
    G04222643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL MANUAL TRANSMISSION CASE 
    1. Apply FIPG to the transmission case in a continuous line, as shown in the illustration.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 

      NOTE: Install the part within 10 minutes after applying the packing material (FIPG).
      Fig 56: Applying FIPG To Transmission Case
      G04222644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission case to the transaxle case with the 14 bolts.

      Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

      Fig 57: Installing Transmission Case To Transaxle Case With Bolts
      G04222645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 3 bolts with sealant, and install them on the transaxle case side.

    Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

    Sealant: 

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

    32. Fig 58: Installing Front Transaxle Case Bolts
    G04222646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL CLUTCH TUBE BRACKET 
    1. Install the clutch tube bracket with the bolt.

    Torque: 17 N.m (173 kgf.cm, 13 ft. lbf) 

  33. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the reverse idler gear shaft bolt with sealant, and install a new reverse idler gear shaft gasket and the reverse idler gear shaft bolt to the transmission case.

      Torque: 30 N.m (306 kgf.cm, 22 ft. lbf) 

      Sealant: 

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

    Fig 59: Installing Reverse Idler Gear Shaft Bolt
    G04222647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING 
    1. Using a brass bar and hammer, tap in the shaft snap ring to the No. 1 gear shift fork shaft.
      Fig 60: Installing Shift Fork Shaft Shaft Snap Ring
      G04222648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, tap in the shaft snap ring to the No. 2 gear shift fork shaft.
    Fig 61: Taping In Shaft Snap Ring To No No. 2 Gear Shift Fork Shaft
    G04222649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    1. Using a snap ring expander, install the shaft snap ring.
    Fig 62: Installing Shaft Snap Ring
    G04222650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL OUTPUT SHAFT REAR BEARING SHIM 
    1. Install the output shaft rear bearing shim to the output shaft.
    Fig 63: Installing Output Shaft Rear Bearing Shim To Output Shaft
    G04222651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL REAR BEARING RETAINER 
    1. Coat the 7 bolts with sealant, and using a T45 "torx" socket, install the bearing retainer with the bolts.

      Torque: 43 N.m (438 kgf.cm, 32 ft. lbf) 

      Sealant: 

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

    Fig 64: Installing Bearing Retainer With Bolts
    G04222652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL 5TH DRIVEN GEAR 
    1. Using SST, install the 5th driven gear to the output shaft.

    SST 09309-12020 

    Fig 65: Installing 5th Driven Gear To Output Shaft
    G04222653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL 5TH GEAR NEEDLE ROLLER BEARING 
    1. Coat the needle roller bearing with gear oil, and install it to the input shaft.
    Fig 66: Installing 5th Gear Needle Roller Bearing
    G04222654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL 5TH GEAR 
    1. Coat the 5th gear with gear oil, and install it to the input shaft.
    Fig 67: Installing 5th Gear
    G04222655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL NO. 3 TRANSMISSION CLUTCH HUB 
    1. Using SST, install the No. 3 transmission clutch hub to the input shaft.

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

      NOTE: Align the projection of the synchronizer ring with the hole of the 5th gear and install it.
      Fig 68: Installing No. 3 Transmission Clutch Hub To Input Shaft
      G04222656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 3 transmission hub sleeve and No. 3 gear shift fork to the No. 3 transmission clutch hub.
      Fig 69: Installing No. 3 Transmission Hub Sleeve And No. 3 Gear Shift Fork
      G04222657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the shift fork set bolt with sealant, and install it to the No. 3 gear shift fork.

      Torque: 24 N.m (245 kgf.cm, 18 ft. lbf) 

      Sealant: 

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

      Fig 70: Installing Gear Shift Fork
      G04222658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Select the No. 3 transmission clutch hub shaft snap ring that allows the minimum amount of axial play. Using a brass bar and hammer, tap in the No. 3 transmission clutch hub shaft snap ring.

    Standard clearance: 

    0.1 mm (0.004 in.) or less 

    Standard snap ring 

    Fig 71: Taping No 3 Transmission Clutch Hub Shaft Snap Ring
    G04222659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    SNAP RING THICKNESS SPECIFICATION

    Part No. Mark Thickness
    90520-27061 a 1.75 to 1.80mm (0.0689 to 0.0709 in.)
    90520-27062 b 1.80 to 1.85mm (0.0709 to 0.0728 in.)
    90520-27063 c 1.85 to 1.90mm (0.0728 to 0.0748 in.)
    90520-27064 d 1.90 to 1.95mm (0.0748 to 0.0768 in.)
    90520-27065 e 1.95 to 2.00mm (0.0768 to 0.0787 in.)
    90520-27066 f 2.00 to 2.05mm (0.0787 to 0.0807 in.)
    90520-27067 g 2.05 to 2.10mm (0.0807 to 0.0827 in.)
    90520-27068 h 2.10 to 2.15mm (0.0827 to 0.0846 in.)
    90520-27069 j 2.15 to 2.20mm (0.0846 to 0.0866 in.)
  42. INSPECT 5TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 5th gear radial clearance.

    Standard clearance: 

    0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

    If the clearance is out of specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.

    Fig 72: Measuring 5th Gear Radial Clearance
    G04222660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSPECT 5TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 5th gear thrust clearance.

    Standard clearance: 

    0.10 to 0.65 mm (0.0039 to 0.0260 in.) 

    If the clearance is out of specification, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

    Fig 73: Measuring 5th Gear Thrust Clearance
    G04222661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Engage the 2 gears simultaneously to lock the transmission.
      Fig 74: Engaging Gears Simultaneously To Lock Transmission
      G04222662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new transmission output shaft rear set nut.

      Torque: 123 N.m (1,254 kgf.cm, 90 ft. lbf) 

      Fig 75: Installing Transmission Output Shaft Rear Set Nut
      G04222663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a chisel and hammer, stake the rear set nut.
    4. Disengage the 2 gears.
    Fig 76: Staking Rear Set Nut
    G04222664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Apply FIPG to the transaxle case cover, as shown in the installation.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 

      NOTE: Install the part within 10 minutes after applying the packing material (FIPG).
      Fig 77: Applying FIPG To Transaxle Case Cover
      G04222665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission case cover to the transaxle case with the 10 bolts.

    Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

    Fig 78: Installing Transmission Case Cover To Transaxle Case
    G04222666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL DRAIN PLUG SUB-ASSEMBLY 
    1. Install a new gasket and the drain plug to the transmission case.

    Torque: 49 N.m (500 kgf.cm, 36 ft. lbf) 

    Fig 79: Installing Drain Plug Sub-Assembly
    G04222667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install a new gasket and the filler plug to the transaxle case.

    Torque: 49 N.m (500 kgf.cm, 36 ft. lbf) 

    Fig 80: Installing Gasket And Filler Plug To Transaxle Case
    G04222668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Coat the shift and select lever shaft with gear oil, and install it to the transmission case.
    Fig 81: Installing Shift And Select Lever Shaft Assembly
    G04222669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL CONTROL SHAFT COVER 
    1. Coat the 4 bolts with sealant, and install a new gasket and the control shaft cover with the 4 bolts.

    Sealant: 

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

    Torque: 20 N.m (204 kgf.cm, 15 ft. lbf) 

    Fig 82: Installing Control Shaft Cover
    G04222670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Install a new gasket and the back-up light switch to the manual transmission case.

    Torque: 40 N.m (408 kgf.cm, 30 ft. lbf) 

    Fig 83: Installing Back-Up Light Switch Assembly
    G04222671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL MANUAL TRANSMISSION BREATHER PLUG 
    1. Install a new gasket and the breather plug to the case.

    Torque: 49 N.m (500 kgf.cm, 36 ft. lbf) 

    Fig 84: Installing Breather Plug To Case
    G04222672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL NO. 1 LOCK BALL ASSEMBLY 
    1. Install the No. 1 lock ball to the transmission case.

    Torque: 29 N.m (296 kgf.cm, 21 ft. lbf) 

    Fig 85: Installing No. 1 Lock Ball To Transmission Case
    G04222673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL CONTROL SHIFT LEVER 
    1. Install the control shift lever with the shift outer lever lever lock pin to the shift and select lever shaft.
    2. Install the spring washer with the nut.

    Torque: 6.4 N.m (65 kgf.cm, 57 in. lbf) 

    Fig 86: Installing Spring Washer With Nut
    G04222674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL SELECTING BELLCRANK ASSEMBLY 
    1. Install the shift and select lever bush to the selecting bellcrank.
    2. Coat the 2 bolts with sealant, and install the selecting bellcrank to the transmission case with the 2 bolts.

    Sealant: 

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

    Torque: 20 N.m (204 kgf.cm, 15 ft. lbf) 

    Fig 87: Installing Selecting Bellcrank To Transmission Case With Bolts
    G04222675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Install a new O-ring to the hole cover.
    2. Install the hole cover to the transmission case with the bolt.

    Torque: 5.5 N.m (56 kgf.cm, 48 ft. lbf) 

  56. INSTALL CLUTCH RELEASE FORK BOOT 
    1. Install the clutch release fork boot to the transaxle case.
  57. INSTALL RELEASE FORK SUPPORT 
    1. Using a deep socket wrench, install the release fork support to the transaxle case.

    Torque: 47 N.m (480 kgf.cm, 35 in. lbf) 

  58. INSTALL CLUTCH RELEASE BEARING ASSEMBLY 
    1. Coat the clutch release bearing with release hub grease, and install it to the clutch release fork with the clutch release bearing clip.

    Sealant: 

    Part No. 08887-01806, RELEASE HUB GREASE or equivalent 

    Fig 88: Installing Release Fork Support
    G04222676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY 
    1. Apply clutch spline grease to the input shaft spline.
    2. Install the clutch release fork to the input shaft.
    Fig 89: Installing Clutch Release Fork To Input Shaft
    G04222677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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