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Manual Transaxle Unit: Reassembly

  1. INSPECT SYNCHRONIZER RING NO. 3 (See INSPECTION  )
  2. INSPECT TRANSMISSION HUB SLEEVE NO. 3 (See INSPECTION  )
  3. INSPECT 5TH GEAR (See INSPECTION  )
  4. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY (See INSPECTION  )
  5. INSTALL OUTPUT SHAFT (MTM) COVER 
    1. Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.
      NOTE: Fit the output shaft (MTM) cover projection into the case side hollow.
      Fig 1: Installing Output Shaft (MTM) Cover
      G04464019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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) 

      NOTE:
      • Be sure to install a new bearing in the correct direction, as shown in the illustration.
      • When replacing the output shaft front bearing, replace the output shaft front bearing inner race along with it.
        Fig 2: Installing Output Shaft Front Bearing
        G04464020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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) 

      Drive 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 3: Installing Front Transaxle Case Oil Seal
      G04464021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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) 

      Drive in depth: 0 to 0.3 mm (0 to 0.012 in.) 

      Fig 4: Installing Input Shaft Front Bearing
      G04464022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new FR differential case front tapered roller bearing (inner race) to the front differential case.

      SST 09350-32014 (09351-32120), 09950-60010 (09951-00530) 

      Fig 5: Installing FR Differential Case Front Tapered Roller Bearing (Inner Race)
      G04464023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install a new FR differential case front tapered roller bearing (outer race) with the shim to the transaxle case.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07150) 

      Fig 6: Installing FR Differential Case Front Tapered Roller Bearing (Outer Race)
      G04464024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new FR differential case rear tapered roller bearing (inner race) to the front differential case.

      SST 09350-32014 (09351-32120), 09950-60010 (09951-00530) 

      Fig 7: Installing FR Differential Case Rear Tapered Roller Bearing (Inner Race)
      G04464025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install a new FR differential case rear tapered roller bearing (outer race) with the shim to the manual transmission case.

      SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150) 

      Fig 8: Installing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
      G04464026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Coat the differential case assembly with gear oil, and install it to the transaxle case.
    2. 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
      G04464027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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 10: Adjusting Differential Side Bearing Preload
      G04464028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a torque wrench, measure the preload.

      SST 09564-32011 

      Torque: New bearing preload (at starting) 

      0.78 to 1.57 N*m (8 to 16 kgf*cm, 6.9 to 13.9 in.*lbf) 

      If the preload is out of specification, select another shim.

      Fig 11: Measuring Differential Side Bearing Preload
      G04464029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Shim thickness 

      SHIM THICKNESS

      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 will change by about 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) corresponding to a change of 0.05mm(0.0020 in.) in shim thickness.

    5. Remove the 16 bolts and manual transmission case from the transaxle case.
    6. Remove the differential case assembly from the transaxle case.
  12. INSTALL TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, install a new transmission case oil seal to 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 transmission case oil seal with MP grease.
      Fig 12: Installing Transmission Case Oil Seal
      G04464030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new transaxle case oil seal in the transaxle case.

      SST 09710-20011 (09710-06071), 09950-70010 (09951-07150) 

      Drive in depth: 1.6 to 2.2 mm (0.063 to 0.087 in.) 

    2. Coat the lip of the transaxle case oil seal with MP grease.
      Fig 13: Installing Transaxle Case Oil Seal
      G04464031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet, and install it to the transmission case.
      Fig 14: Installing Transmission Magnet
      G04464032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL BEARING LOCK PLATE 
    1. Install the bearing lock plate with the bolt.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

      Fig 15: Installing Bearing Lock Plate
      G04464033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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) 

      NOTE:
      • Prevent the oil receiver pipe No. 1 (MTM) from being deformed.
      • Install the oil receiver pipe No. 1 (MTM) while placing it against the manual transmission case, as shown in the illustration.
        Fig 16: Installing Oil Receiver Pipe No. 1 (MTM)
        G04464034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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) 

      NOTE:
      • Prevent the oil receiver pipe No. 2 (MTM) from being deformed.
      • Install the oil receiver pipe No. 2 (MTM) while placing it against the manual transmission case, as shown in the illustration.
        Fig 17: Installing Oil Receiver Pipe No. 2 (MTM)
        G04464035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    1. Install the reverse restrict pin assembly to the manual transmission case.
      NOTE: Do not set the reverse restrict pin assembly in an incorrect orientation.
      Fig 18: Installing Reverse Restrict Pin Assembly To Manual Transmission Case
      G04464036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch ( 5 mm) and hammer, install the slotted pin to the reverse restrict pin assembly.

      Standard clearance (A): 15.5 to 16.5 mm (0.6102 to 0.6496 in.) 

    3. Apply sealant to the reverse restrict pin plug.

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

      Fig 19: Identifying Clearance Between Slotted Pin And Restrict Pin
      G04464037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Fig 20: Installing Reverse Restrict Pin Plug To Manual Transmission Case
      G04464038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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 21: Installing Manual Transaxle Case Receiver
      G04464039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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 22: Installing Differential Case Assembly
      G04464040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. 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 23: Installing Input Shaft Assembly
      G04464041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 as shown in the illustration.

      HINT:

      Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.

      Fig 24: Aligning Mark On Reverse Idler Gear Shaft With Bolt Hole
      G04464042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL GEAR SHIFT FORK SHAFT SUBASSEMBLY NO. 1 
    1. Coat the gear shift fork No. 1 and gear shift fork No. 2 with gear oil, and install them.
      Fig 25: Installing Gear Shift Fork No. 1 And Gear Shift Fork No. 2
      G04464043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the gear shift fork shaft sub-assembly No. 1 with gear oil, and install it.
    3. Apply sealant to the shift fork lock bolt.

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

    4. Install the gear shift fork lock bolt.

      Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) 

      Fig 26: Installing Gear Shift Fork Shaft Sub-Assembly No. 1
      G04464044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a brass bar and a hammer, install the snap ring to the gear shift fork shaft No. 1.
      Fig 27: Installing Snap Ring To Gear Shift Fork Shaft No. 1
      G04464045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL GEAR SHIFT FORK SHAFT NO. 3 
    1. Coat the 2 balls with MP grease, and install them to the reverse shift fork.
    2. Install the reverse shift fork to the gear shift fork shaft No. 3.
      Fig 28: Installing Balls To Reverse Shift Fork
      G04464046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, install the 2 shift fork haft snap rings to the gear shift fork shaft No. 3.
      Fig 29: Installing Shift Fork Haft Snap Rings To Gear Shift Fork Shaft No. 3
      G04464047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the gear shift fork shaft No. 3 with gear oil, and install it.
      Fig 30: Installing Gear Shift Fork Shaft No. 3
      G04464048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL GEAR SHIFT FORK SHAFT NO. 2 
    1. Coat the gear shift head No. 1 and gear shift fork shaft No. 2 with gear oil, and install them.
      NOTE: To avoid the interference of the 2 shift fork balls, lift up the gear shift fork shaft No. 3 to the position shown in the illustration.
      Fig 31: Installing Gear Shift Head No. 1 And Gear Shift Fork Shaft No. 2
      G04464049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 32: Installing Shift Lock Bolts
      G04464050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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 33: Installing Reverse Shift Arm Bracket Assembly
      G04464051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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 34: Applying FIPG To Manual Transmission Case
      G04464052Courtesy 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 35: Installing Bolts To Manual Transmission Side
      G04464053Courtesy 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 36: Installing Bolts To Transaxle Case Side
      G04464054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket.

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

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

      Fig 37: Installing Reverse Idler Gear Shaft Bolt
      G04464055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL LOCK BALL ASSEMBLY NO. 1 
    1. Coat the lock ball assembly No. 1 with sealant, and install it using a hexagon wrench.

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

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

      Fig 38: Installing Lock Ball Assembly No. 1
      G04464056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL SHIFT DETENT BALL 
    1. Install the 2 shift detent balls, 2 springs, and 2 seats to the manual transmission case.
      Fig 39: Installing Shift Detent Balls, Springs, And Seats To Manual Transmission Case
      G04464057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 2 shift detent ball plugs with sealant, and install them using a hexagon wrench.

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

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

      Fig 40: Installing Shift Detent Ball Plugs
      G04464058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift detent ball, spring and seat to the transaxle case.
      Fig 41: Installing Shift Detent Ball, Spring And Seat To Transaxle Case
      G04464059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the shift detent ball plug with sealant, and install it using a hexagon wrench.

      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 Plug
      G04464060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. 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 43: Installing Input Shaft Rear Bearing Hole Snap Ring
      G04464061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. 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 44: Installing Output Shaft Rear Bearing Hole Snap Ring
      G04464062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. 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 45: Installing Shift Fork Shaft Snap Ring
      G04464063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL BEARING RETAINER REAR (MTM) 
    1. Coat the 5 bolts with sealant, and install them and bearing retainer rear (MTM) to the manual transmission case.

      Torque: 27 N*m (279 kgf*cm, 20 ft.*lbf) 

      Fig 46: Installing Bearing Retainer Rear (MTM)
      G04464064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL 5TH DRIVEN GEAR 
    1. Using SST, install the 5th driven gear to the output shaft.

      SST 09309-12020 

      Fig 47: Installing 5th Driven Gear
      G04464065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. 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 to the input shaft.
      Fig 48: Installing 5th Gear Needle Roller Bearing
      G04464066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL 5TH GEAR 
    1. Coat the 5th gear with gear oil, and install it to the input shaft.
      Fig 49: Installing 5th Gear
      G04464067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL SYNCHRONIZER RING NO. 3 
    1. Coat the synchronizer ring No. 3 with gear oil, and install it to the 5th gear.
      Fig 50: Installing Synchronizer Ring No. 3
      G04464068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL TRANSMISSION CLUTCH HUB NO. 3 
    1. Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs to the transmission clutch hub No. 3.

      HINT:

      Do not set the openings of the shifting key springs in the same position.

      Fig 51: Installing Synchromesh Shifting Keys And Synchromesh Shifting Key Springs
      G04464069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the transmission clutch hub No. 3 to the input shaft.

      SST 09636-20010 

      NOTE:
      • Before driving in the No. 3 clutch hub assembly, 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 52: Installing Transmission Clutch Hub No. 3 To Input Shaft
        G04464070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 3 below 0.1 mm (0.004 in.).

      Snap ring thickness 

      SNAP RING THICKNESS

      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) - -
      Fig 53: Installing Snap Ring
      G04464071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brass bar and a hammer, install the snap ring to the input shaft.
  40. INSPECT 5TH GEAR THRUST CLEARANCE (See INSPECTION  )
  41. INSPECT 5TH GEAR RADIAL CLEARANCE (See INSPECTION  )
  42. INSTALL GEAR SHIFT FORK NO. 3 
    1. Coat the transmission clutch hub sleeve No. 3 with gear oil, and install it and gear shift fork No. 3 to the transmission clutch hub No. 3.

      HINT:

      Do not set the transmission clutch hub No. 3 in an incorrect orientation.

      Fig 54: Installing Gear Shift Fork No. 3
      G04464072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the gear shift lock fork ball with sealant, and install it to the gear shift fork No. 3.

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

      Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) 

      Fig 55: Installing Gear Shift Lock Fork Ball
      G04464073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Engage two gears simultaneously to lock the transmission.
    2. Install a new manual transmission output shaft rear set nut.

      Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf) 

      Fig 56: Installing Manual Transmission Output Shaft Rear Set Nut
      G04464074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
    4. Disengage the two gears.
      Fig 57: Staking Manual Transmission Output Shaft Rear Set Nut
      G04464075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Apply FIPG to the manual transmission case cover sub-assembly 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 58: Applying FIPG To Manual Transmission Case Cover Sub-Assembly
      G04464076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case cover subassembly with the 9 bolts to the manual transmission case.

      Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 

      Fig 59: Installing Manual Transmission Case Cover Subassembly
      G04464077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. 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 

      Fig 60: Installing Shift And Select Lever Shaft Assembly
      G04464078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      NOTE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
  46. INSTALL LOCK BALL ASSEMBLY NO. 1 
    1. Coat the lock ball assembly No. 1 with sealant, and install it 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 61: Installing Lock Ball Assembly No. 1
      G04464079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL SELECTING BELL CRANK ASSEMBLY 
    1. Install the selecting bell crank assembly and the 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 62: Installing Selecting Bell Crank Assembly
      G04464080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. 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 63: Installing Floor Shift Control Lever Housing Support Bracket
      G04464081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. 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.

      Torque: 40 N*m (411 kgf*cm, 30 ft.*lbf) 

      SST 09817-16011 

  50. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Install a new O-ring to the speedometer driver hole cover sub-assembly.
    2. Install the speedometer driver hole cover subassembly with the bolt.
      Fig 64: Installing Back Up Light Switch Assembly
      G04464082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

  51. INSTALL SPEEDOMETER SENSOR 
    1. Install a new O-ring to the speedometer sensor.
    2. Install the speedometer sensor with the bolt.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

  52. INSTALL RELEASE FORK SUPPORT 
    1. Install the clutch release fork support to the transaxle case.

      Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) 

      Fig 65: Installing Release Fork Support
      G04464083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL CLUTCH RELEASE FORK BOOT 
    1. Install the clutch release fork boot to the transaxle case.
      Fig 66: Installing Clutch Release Fork Boot
      G04464084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. 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 release bearing clip.

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

      Fig 67: Installing Clutch Release Bearing Assembly
      G04464085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY 
    1. Install the clutch release fork sub-assembly to the input shaft.
    2. Apply clutch spline grease to the spline of the input shaft.

      Sealant: Part No. 08887-01806, CLUTCH SPLINE GREASE or equivalent 

      Fig 68: Installing Clutch Release Fork Sub-Assembly
      G04464086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install the manual transmission filler plug with a new gasket.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

      Fig 69: Installing Manual Transmission Filler Plug
      G04464087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY 
    1. Install the drain (MTM) plug sub-assembly with a new gasket.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

      Fig 70: Installing Drain (MTM) Plug Sub-Assembly
      G04464088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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