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Manual Transaxle Unit: Reassembly

  1. INSTALL SYNCHRONIZER PULL RING 
    1. Install the No. 5 synchronizer middle ring, No. 5 synchronizer ring outer, and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, fix them with the snap ring.
      Fig 1: Installing Synchronizer Pull Ring Using Screwdriver
      G04977298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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 No. 3 hole of the clutch hub.
    2. Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.
      Fig 2: Installing Synchronizer Ring Set And Synchromesh Shifting Key Spring No. 3 To Transmission Clutch Hub No. 3
      G04977299Courtesy 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.
  3. 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) 

      Oil seal installation depth: - 0.5 to 0.5 mm (-0.020 to 0.020 in.) 

    2. Coat the front transaxle case cover oil seal lip with MP grease.
      Fig 3: Installing Front Transaxle Case Cover Oil Seal
      G04977300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a hammer, install the front differential case front tapered roller bearing (outer race) to the front transaxle case.

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

      Fig 4: Installing FR Differential Case Front Tapered Roller Bearing (Outer Race) To Front Transaxle Case
      G04977301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the front differential case front tapered roller bearing (inner race) to the front differential case.

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

      Fig 5: Installing FR Differential Case Front Tapered Roller Bearing To Front Differential Case
      G04977302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Install the front differential case shim rear.
    2. Using SST and a hammer, install the front differential case rear tapered roller bearing (outer race).

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

      Fig 6: Installing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
      G04977303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the front differential case rear tapered roller bearing (inner race).

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

      Fig 7: Installing FR Differential Case Rear Tapered Roller Bearing (Inner Race)
      G04977304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, install a transmission case oil seal to the manual transmission case.

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

      Oil seal installation depth: 3.0 to 4.0 mm (0.1181 to 0.1575 in.) 

    2. Coat the transmission case oil seal lip with MP grease.
      Fig 8: Installing Transmission Case Oil Seal To Manual Transmission Case
      G04977305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL OUTPUT SHAFT REAR BEARING 
    1. Using SST and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case.

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

      Clearance: 3.8 to 4.4 mm (0.150 to 0.173 in.) 

      Fig 9: Using SST And Hammer To Install Output Shaft Rear Bearing (Outer Race) To Manual Transmission Case
      G04977306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL OUTPUT SHAFT COVER 
    1. Coat the output shaft cover with MP grease, and install it to the manual transaxle case.
      NOTE: Align the projection of the output shaft with the transmission groove.
      Fig 10: Coating Output Shaft (MTM) Cover With MP Grease And Installing It To Manual Transaxle Case
      G04977307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL OUTPUT SHAFT FRONT BEARING 
    1. Using SST and a hammer, install the output shaft front bearing (outer race).

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

      Fig 11: Installing Output Shaft Front Bearing (Outer Race)
      G04977308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. ADJUST OUTPUT SHAFT BEARING PRELOAD 
    1. Install the output shaft to the manual transaxle case.
      Fig 12: Installing Output Shaft To Manual Transaxle Case
      G04977309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission case to the manual transaxle case with the 14 bolts.

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

      Fig 13: Locating Bolts And Manual Transmission Case To Manual Transaxle Case
      G04977251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts to the manual transaxle case.

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

      Fig 14: Locating Bolts To Manual Transaxle Case
      G04977250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the output shaft rear bearing case shim to the output shaft.
      Fig 15: Installing Output Shaft Rear Bearing Case Shim To Output Shaft
      G04977312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a "TORX" socket wrench (T45), install the bearing retainer rear to the manual transmission case with the 7 screws.

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

      Fig 16: Installing Bearing Retainer Rear With Screws To Manual Transmission Case
      G04977313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
    7. Using a socket wrench and torque wrench, inspect the preload.
      Fig 17: Using Socket Wrench And Torque Wrench To Inspect Preload
      G04977314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload: N*m (kgf*cm, in.*lbf) 

      BEARING PRELOAD

      Bearing Preload
      New 0.8 to 1.6 (8.16 to 16.32, 7.1 to 14.2)
      Used 0.5 to 1.0 (5.10 to 10.20, 4.4 to 8.9)
    8. 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 shim varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.35 to 0.53 in.*lbf).

      Shim 

      SHIM THICKNESS

      Part No. Thickness: mm (in.) Mark
      90564-59001 1.30 (0.0512) 0
      90564-59002 1.35 (0.0531) 1
      90564-59003 1.40 (0.0551) 2
      90564-59004 1.45 (0.0571) 3
      90564-59005 1.50 (0.0591) 4
      90564-59006 1.55 (0.0610) 5
      90564-59007 1.60 (0.0630) 6
      90564-59008 1.65 (0.0650) 7
      90564-59009 1.70 (0.0669) 8
      90564-59010 1.75 (0.0689) 9
      90564-59011 1.80 (0.0709) A
      90564-59012 1.85 (0.0728) B
      90564-59013 1.90 (0.0748) C
      90564-59014 1.95 (0.0768) D
      90564-59015 2.00 (0.0787) E
      90564-59016 2.05 (0.0807) F
      90564-59017 2.10 (0.0827) G
      90564-59018 2.15 (0.0846) H
      90564-59019 2.20 (0.0866) J
      90564-59020 2.25 (0.0886) K
      90564-59021 2.30 (0.0906) L
      90564-59022 2.35 (0.0925) M
      90564-59023 2.40 (0.0945) N
      90564-59024 2.45 (0.0965) P
      90564-59025 2.50 (0.0984) Q
    9. Remove the output shaft rear set nut from the output shaft.
    10. Using a "TORX" socket wrench (T45), remove the 7 screws and bearing retainer rear from the manual transmission case.
      Fig 18: Removing Screws And Bearing Retainer Rear From Manual Transmission Case
      G04977315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the output shaft rear bearing shim from the output shaft.
      Fig 19: Installing Output Shaft Rear Bearing Case Shim To Output Shaft
      G04977312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Remove the 3 bolts.
      Fig 20: Locating Bolts On Front Manual Transaxle Case Side
      G04977250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the 14 bolts and manual transmission case from the manual transaxle case.
      Fig 21: Locating Bolts And Manual Transmission Case To Manual Transaxle Case
      G04977251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the output shaft assembly from the front manual transaxle case.
      Fig 22: Installing Output Shaft To Manual Transaxle Case
      G04977309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. ADJUST TAPERED ROLLER BEARING PRELOAD 
    1. Install the differential case assembly to the manual transaxle case.
      Fig 23: Installing Differential Case Assembly To Manual Transaxle Case
      G04977273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 14 bolts and manual transmission case to the manual transaxle case.

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

      Fig 24: Locating Bolts And Manual Transmission Case To Manual Transaxle Case
      G04977251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts to the front manual transaxle case.

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

      Fig 25: Locating Bolts On Front Manual Transaxle Case Side
      G04977250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the differential case in both directions to make sure that it starts to turn smoothly.
    5. Using SST and a torque wrench, inspect preload.

      SST 09564-32011 

      Fig 26: Using SST And Torque Wrench To Inspect Preload
      G04977323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload: N*m (kgf*cm, in.*lbf) 

      BEARING PRELOAD

      Bearing Preload
      New 0.8 to 1.6 (8.16 to 16.32, 7.1 to 14.2)
      Used 0.5 to 1.0(5.10 to 10.2, 4.4 to 8.9)

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

      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, 0.35 to 0.53 in.*lbf).

      Shim 

      SHIM THICKNESS

      Part No. Thickness: mm (In.) Mark
      90564-56055 2.00 (0.0787) 0
      90564-56056 2.05 (0.0807) 1
      90564-56057 2.10 (0.0827) 2
      90564-56058 2.15 (0.0846) 3
      90564-56059 2.20 (0.0866) 4
      90564-56060 2.25 (0.0886) 5
      90564-56061 2.30 (0.0906) 6
      90564-56062 2.35 (0.0925) 7
      90564-56063 2.40 (0.0945) 8
      90564-56064 2.45 (0.0965) 9
      90564-56065 2.50 (0.0984) A
      90564-56066 2.55 (0.1004) B
      90564-56067 2.60 (0.1024) C
      90564-56068 2.65 (0.1043) D
      90564-56069 2.70 (0.1063) E
      90564-56070 2.75 (0.1083) F
      90564-56071 2.80 (0.1102) G
      90564-56072 2.85 (0.1122) H
    6. Remove the 3 bolts.
      Fig 27: Locating Bolts On Front Manual Transaxle Case Side
      G04977250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 14 bolts and manual transmission case from the manual transaxle case.
      Fig 28: Locating Bolts And Manual Transmission Case To Manual Transaxle Case
      G04977251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the differential case assembly from the manual transaxle case.
      Fig 29: Removing Differential Case Assembly From Manual Transaxle Case
      G04977273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new front transaxle case oil seal to the manual transaxle case.

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

      Fig 30: Installing Front Transaxle Case Oil Seal No. 1 To Manual Transaxle Case
      G04977327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of the front transaxle case oil seal with MP grease.

    Clearance: 1.0 to 2.0 mm (0.0394 to 0.0787 in.) 

  13. INSTALL INPUT SHAFT FRONT BEARING 
    1. Coat the input shaft front bearing with gear oil.
    2. Using SST and a hammer, install the oil seal to the manual transaxle case.

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

      Clearance: 4.28 to 4.60 mm (0.1685 to 0.1811 in.) 

      Fig 31: Installing Oil Seal To Manual Transaxle Case
      G04977328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    1. Install the manual transaxle case receiver to the manual transaxle case with the 3 bolts.

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

      Fig 32: Locating Bolts And Manual Transaxle Case Receiver To Manual Transaxle Case
      G04977274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case.
      Fig 33: Coating Differential Case Tapered Roller Bearing With Gear Oil
      G04977273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL OUTPUT SHAFT ASSEMBLY 
    1. Apply gear oil to each sliding part of the output shaft assembly.
    2. Lift the differential case assembly with the output shaft assembly leaned, and install it to the manual transaxle case.
      Fig 34: Lifting Differential Case Assembly Up With Output Shaft Assembly
      G04977331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL INPUT SHAFT ASSEMBLY 
    1. Apply gear oil to each sliding part of the input shaft assembly.
    2. Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.
      Fig 35: Installing Input Shaft Assembly To Manual Transaxle Case While Tilting Output Shaft Assembly
      G04977271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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 36: Installing No. 2 Gear Shift Fork
      G00411968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL NO. 3 GEAR SHIFT FORK 
    1. Install the No. 3 gear 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 gear shift fork shaft.
      Fig 37: Using Brass Bar And Hammer To Install Shift Fork Shaft Snap Rings To Gear Shift Fork Shaft
      G04977334Courtesy 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 manual transaxle case.
      Fig 38: Installing No. 3 Gear Shift Fork Shaft To Manual Transaxle Case
      G00411966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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 39: Installing No. 1 Gear Shift Fork
      G00411967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL NO. 2 GEAR SHIFT FORK SHAFT 
    1. Install the No. 1 gear shift head to the No. 2 gear shift fork shaft.
    2. Apply gear oil to each sliding part of the No. 2 gear shift fork shaft, and install it to the manual transaxle case.
      Fig 40: Installing No. 2 Gear Shift Fork Shaft
      G00411965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift fork set bolt and shift head set bolt to the No. 1 gear shift head.

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

      Fig 41: Installing Shift Fork Set Bolt And Shift Head Set Bolt To Gear Shift Head No. 1
      G04977338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL REVERSE SHIFT FORK ROLLER 
    1. Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.
      Fig 42: Using Magnetic Finger To Install Reverse Shift Fork Roller To Reverse Shift Fork
      G04977264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL NO. 1 GEAR SHIFT FORK SHAFT 
    1. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 shift fork shaft.
      Fig 43: Using Brass Bar And Hammer To Install Shift Fork Shaft Snap Ring To Shift Fork Shaft No. 1
      G04977340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 gear shift fork shaft to the manual transaxle case.
      Fig 44: Installing No. 1 Gear Shift Fork Shaft To Manual Transaxle Case
      G04977341Courtesy 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 45: Installing Shift Fork Set Bolt To Gear Shift Fork No. 1
      G00411971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Install the reverse shift arm bracket assembly to the manual transaxle case with the 2 bolts.

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

      Fig 46: Locating Bolts And Reverse Shift Arm Bracket Assembly To Manual Transaxle Case
      G04977260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Coat the reverse idler gear and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.
      Fig 47: Installing Reverse Idler Gear And Reverse Idler Thrust To Reverse Idler Gear Shaft
      G04977259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the reverse idler gear to the manual transaxle case.

      HINT:

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

      Fig 48: Aligning Mark Of Reverse Idler Gear Shaft With Hole Of Bolt
      G04977345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet and install it to the manual transaxle case.
      Fig 49: Installing Transmission Magnet
      G04977346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 1 OIL RECEIVER PIPE 
    1. Install the No. 1 oil receiver pipe to the manual transmission case with the bolt.

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

    NOTE: Do not damage the pipe.
    Fig 50: Locating No. 1 Oil Receiver Pipe
    G04977256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL NO. 2 OIL RECEIVER PIPE 
    1. Install the No. 2 oil receiver pipe to the manual transmission case with the bolt.

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

      NOTE: Do not damage the pipe.
      Fig 51: Locating No. 2 Oil Receiver Pipe
      G04977255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    1. Install the transmission oil baffle and reverse restrict pin with the bolt.

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

      Fig 52: Installing Reverse Restrict Pin Assembly
      G04977254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (ø 5 mm), install the slotted pin to the reverse restrict pin assembly.

      Clearance: 12.5 to 13.5 mm (0.492 to 0.531 in.) 

      Fig 53: Installing Slotted Pin To Reverse Restrict Pin Assembly
      G04977350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the reverse restrict pin plug with adhesive. Using a hexagon wrench (6 mm), install the manual transmission case.

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

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 54: Locating Manual Transmission Case
      G04977252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL MANUAL TRANSMISSION CASE 
    1. Apply a bead of FIPG to the manual transmission case as shown in the illustration.

      HINT:

      Install the manual transmission case within 10 minutes after applying FIPG.

      Fig 55: Applying Unbroken Bead Of FIPG To Manual Transmission Case
      G04977352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case to the manual transaxle case with the 14 bolts.

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

      Fig 56: Locating Bolts And Manual Transmission Case To Manual Transaxle Case
      G04977251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 3 bolts with adhesive.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 57: Installing Bolts On Front Manual Transaxle Case Side
      G04977250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 3 bolts to the manual transaxle case.

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

  31. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the bolt with adhesive. Install a new gasket to the manual transmission case with the bolt.

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

      Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 58: Coating Bolt With Sealant And Installing New Gasket To Manual Transmission Case With Bolt
      G04977249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL SHIFT FORK SHAFT, SHAFT SNAP RING 
    1. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 1 gear shift fork shaft.
      Fig 59: Using Brass Bar And Hammer To Install Shift Fork Shaft Snap Ring To Gear Shift Fork Shaft No. 1
      G04977356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, install the shift fork shaft snap ring to the No. 2 gear shift fork shaft.
      Fig 60: Using Brass Bar And Hammer To Install Shift Fork Shaft Snap Ring To Gear Shift Fork Shaft No. 2
      G04977357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    1. Using a snap ring expander, install the input shaft rear bearing shaft snap ring.
      Fig 61: Using Snap Ring Expander To Install Input Shaft Rear Bearing Shaft Snap Ring
      G04977358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL OUTPUT SHAFT REAR BEARING SHIM 
    1. Install the output shaft rear bearing shim to the output shaft.
      Fig 62: Installing Output Shaft Rear Bearing Shim To Output Shaft
      G04977245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL REAR BEARING RETAINER 
    1. Coat the rear bearing retainer with sealant and install it with a "TORX" wrench (T45).
    2. Install a new output rear set nut to the output shaft.

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

      Fig 63: locating New Output Rear Set Nut To Output Shaft
      G04977360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL 5TH DRIVEN GEAR 
    1. Using SST, install the 5th driven gear to the output shaft.

      SST 09309-12020 

      Fig 64: Using SST To Install 5Th Driven Gear To Output Shaft
      G04977361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL 5TH GEAR NEEDLE ROLLER BEARING 
    1. Coat the 5th gear needle roller bearing with gear oil and install it to the input shaft.
      Fig 65: Coating 5Th Gear Needle Roller Bearing With Gear Oil And Installing It To Input Shaft
      G04977242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL 5TH GEAR 
    1. Coat the 5th gear with gear oil and install it to the input shaft.
      Fig 66: Installing 5Th Gear
      G04977241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. 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.
      Fig 67: Using SST To Install Transmission Clutch Hub No. 3 To Input Shaft
      G04977364Courtesy 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 68: Installing Transmission Hub Sleeve No. 3 And Gear Shift Fork No. 3 To Transmission Clutch Hub No. 3
      G04977365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the shift fork set bolt with adhesive and install it to the No. 3 gear shift fork.

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

      Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 69: Coating Shift Fork Set Bolt With Sealant And Installing It To Gear Shift Fork No. 3
      G04977366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, install the shaft snap ring.

      Clearance: 0.1 mm (0.004 in.) or less Snap ring 

      Fig 70: Using Brass Bar And Hammer To Installing Shaft Snap Ring
      G04977367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    SHIM THICKNESS

    Part No. Thickness: mm (in.) Mark
    90520-27061 1.75 to 1.80 (0.0689 to 0.0709) a
    90520-27062 1.80 to 1.85 (0.0709 to 0.0728) b
    90520-27063 1.85 to 1.90 (0.0728 to 0.0748) c
    90520-27064 1.90 to 1.95 (0.0748 to 0.0768) d
    90520-27065 1.95 to 2.00 (0.0768 to 0.0787) e
    90520-27066 2.00 to 2.05 (0.0787 to 0.0807) f
    90520-27067 2.05 to 2.10 (0.0807 to 0.0827) g
    90520-27068 2.10 to 2.15 (0.0827 to 0.0846) h
    90520-27069 2.15 to 2.20 (0.0846 to 0.0886) j
  40. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Engage the 1st and 2nd gears simultaneously.
      Fig 71: Engaging 1st And 2nd Gears Simultaneously
      G04977235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new manual transmission output shaft rear set nut.

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

      Fig 72: Installing Manual Transmission Output Shaft Rear Set Nut
      G04977369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
      Fig 73: Staking Manual Transmission Output Shaft Rear Set Nut
      G04977370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the gears.
  41. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Apply FIPG to the transaxle case cover sub-assembly as shown in the installation.

      FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      NOTE: Install the part within 10 minutes after applying the packing material (FIPG).
      Fig 74: Applying FIPG To Transaxle Case Cover Sub-Assembly
      G04977371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission case cover sub-assembly to the manual transaxle case with the 10 bolts.
      Fig 75: Locating Transmission Case Cover Sub-Assembly With Bolts To Manual Transaxle Case
      G04977234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL DRAIN PLUG SUB-ASSEMBLY 
    1. Install the drain plug sub-assembly to the manual transmission case with a new gasket.

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

      Fig 76: Installing Drain Plug Sub-Assembly With New Gasket To Manual Transmission Case
      G04977233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install the manual transmission filler plug to the transaxle case with a new gasket.

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

      Fig 77: Locating Manual Transmission Filler Plug With New Gasket To Oil Seal
      G04977374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Coat the shift and select lever shaft assembly with gear oil, and install it to the manual transmission case.
      Fig 78: Installing Shift And Select Lever Shaft Assembly
      G04977230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Install the back-up light switch assembly to the manual transmission case with a new gasket.

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

      Fig 79: Locating Back Up Light Switch Assembly To Manual Transmission Case
      G04977231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL MANUAL TRANSMISSION BREATHER PLUG 
    1. Install the manual transmission breather plug to the manual transmission case.
      Fig 80: Locating Manual Transmission Breather Plug
      G04977229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL SHIFT GATE PIN 
    1. Install the shift gate pin to the manual transmission case.

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

      Fig 81: Locating Shift Gate Pin
      G04977228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL NO. 1 LOCK BALL ASSEMBLY 
    1. Install the lock ball assembly No. 1 to the manual transmission case.

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

      Fig 82: Locating No. 1 Lock Ball Assembly
      G04977227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL NO. 2 CLUTCH TUBE BRACKET 
    1. Install the bolt and No. 2 clutch tube bracket.
      Fig 83: Identifying No. 2 Clutch Tube Bracket
      G00411964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL CONTROL SHAFT COVER 
    1. Coat the 4 bolts with adhesive. Install a new gasket and the control shaft cover with the bolts.

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

      Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 84: Install Gasket And Control Shaft Cover With Bolts
      G04977225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL CONTROL SHIFT LEVER 
    1. Install the control shift lever with the shift outer 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 85: Locating Control Shift Lever
      G04977223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL SELECTING BELLCRANK ASSEMBLY 
    1. Coat the 2 bolts with adhesive. Install the selecting bellcrank assembly to the manual transmission case with the bolts.

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

      Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 86: Locating Selecting Bellcrank Assembly
      G04977222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Install a new O-ring and the speedometer driven hole cover sub-assembly to the transmission case with the bolt.

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

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

      Torque: 47 N*m (480 kgf*cm, 36 ft.*lbf) 

  56. 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.

      Sealant: Part No. 08887-01806, Release Hub Grease or equivalent 

      Fig 87: Locating Clutch Release Bearing Assembly
      G04977161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply clutch spline grease to the input shaft spline.
  57. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY 
    1. Install the clutch release fork sub-assembly to the input shaft.
      Fig 88: Installing Clutch Release Fork Sub-Assembly To Input Shaft
      G04977150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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