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Manual Transaxle ASSY (E351): Overhaul

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE CLUTCH RELEASE FORK SUB-ASSY 
    1. Remove the clutch release fork sub-assy together with the clutch release bearing assy from the manual transaxle case.
      Fig 1: Removing Clutch Release Fork Sub-Assy
      G03552432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE CLUTCH RELEASE BEARING ASSY 
    1. Remove the clutch release bearing assy and release bearing hub clip from the clutch release fork subassy.
  3. REMOVE RELEASE FORK SUPPORT 
    1. Remove the release fork support from the manual transaxle case.
      Fig 2: Removing Release Fork Support
      G03552433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CLUTCH RELEASE FORK BOOT 
    1. Remove the clutch release fork boot from the manual transaxle case.
  5. REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY 
    1. Remove the bolt and speedometer driven (MTM) gear sub-assy.
    2. Remove the MTM speedometer shaft sleeve clip, and remove the speedometer driven gear from the speedometer sensor.
  6. REMOVE SELECTING BELL CRANK ASSY 
    1. Remove the 2 bolts and selecting bell crank assy from the manual transmission case.
      Fig 3: Removing Selecting Bell Crank Assy
      G03552434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CONTROL SHIFT LEVER 
    1. Remove the nut and spring washer.
      Fig 4: Removing Spring Washer
      G03552435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, remove the shift outer lever lock pin.
      Fig 5: Removing Shift Outer Lever Lock Pin
      G03552436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the control shift lever.
  8. REMOVE CONTROL SHAFT COVER 
    1. Remove the 4 bolts and control shaft cover from the manual transmission case.
      Fig 6: Removing Control Shaft Cover
      G03552437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. FIX MANUAL TRANSAXLE ASSY 
    1. Place the manual transaxle assy on wooden blocks.
      Fig 7: Fixing Manual Transaxle Assy
      G03552438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE LOCK BALL ASSY NO. 1 
    1. Remove the lock ball assy No. 1 from the manual transmission case.
      Fig 8: Removing Lock Ball Assembly No. 1
      G03552439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE MANUAL TRANSMISSION BREATHER PLUG 
    1. Remove the manual transmission breather plug and gasket.
      Fig 9: Removing Manual Transmission Breather Plug
      G03552440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE SHIFT & SELECT LEVER SHAFT ASSY 
    1. Remove the shift & select lever shaft assy from the manual transmission case.
      Fig 10: Removing Shift & Select Lever Shaft Assembly
      G03552441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE BACK UP LAMP SWITCH ASSY 
    1. Remove the back up lamp switch assy and gasket from the manual transmission case.
      Fig 11: Removing Back Up Lamp Switch Assembly
      G03552442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the manual transmission filler plug and gasket from the manual transmission case.
      Fig 12: Removing Manual Transmission Filler Plug
      G03552443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE DRAIN (MTM) PLUG SUB-ASSY 
    1. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.
      Fig 13: Removing Drain (MTM) Plug Sub-Assy
      G03552444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY 
    1. Remove the 10 bolts and manual transmission case cover from the manual transmission case.
      Fig 14: Removing Manual Transmission Case Cover Sub-Assy
      G03552445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Double mesh the gears. (Engage 1st and 2nd gears simultaneously.)
      Fig 15: Double Meshing Gears
      G03552446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, unstake the manual transmission output shaft rear set nut.

      SST 09930-00010

      Fig 16: Unstaking Manual Transmission Output Shaft Rear Set Nut
      G03552447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the manual transmission output shaft rear set nut from the output shaft.

      SST 09229-55010

      Fig 17: Removing Manual Transmission Output Shaft Rear Set Nut
      G03552448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the gears.
  18. INSPECT 5TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, inspect the 5th gear thrust clearance.

      Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0256 in.) 

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

      Fig 18: Inspecting 5th Gear Thrust Clearance
      G03552449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT 5TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, inspect the 5th gear radial clearance.

      Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

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

      Fig 19: Inspecting 5th Gear Radial Clearance
      G03552450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE TRANSMISSION CLUTCH HUB NO. 3 
    1. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
      Fig 20: Removing Transmission Clutch Hub No. 3
      G03552451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Cover with a shop rag to keep the snap ring from flying.

    2. Remove the shift fork set bolt from the gear shift fork No. 3.
      Fig 21: Removing Shift Fork Set Bolt
      G03552452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the transmission clutch hub No. 3 and gear shift fork No. 3 from the input shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951-00280)

      Fig 22: Removing Transmission Clutch Hub No. 3 & Gear Shift Fork No. 3
      G03552453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE 5TH GEAR 
    1. Remove the 5th gear from the input shaft.
      Fig 23: Removing 5th Gear
      G03552454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 5th gear needle roller bearing from the input shaft.
      Fig 24: Removing 5th Gear Needle Roller Bearing
      G03552455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE 5TH DRIVEN GEAR 
    1. Using SST, remove the 5th driven gear from the output shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013

      Fig 25: Removing 5th Driven Gear
      G03552456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE BEARING RETAINER REAR (MTM) 
    1. Using a torx socket wrench (T45), remove the 7 torx screws and bearing retainer rear (MTM) from the manual transmission case.
      Fig 26: Removing Bearing Retainer Rear (MTM)
      G03552457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE OUTPUT SHAFT REAR BEARING SHIM 
    1. Remove the output shaft rear bearing shim from the output shaft.
      Fig 27: Removing Output Shaft Rear Bearing Shim
      G03552458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    1. Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
      Fig 28: Removing Input Shaft Rear Bearing Shaft Snap Ring
      G03552459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE SHIFT FORK SHAFT SNAP RING 
    1. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 1.

      HINT:

      Cover with a shop rag to keep the snap ring from flying.

      Fig 29: Removing Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 1
      G03552460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 2.

      HINT:

      Cover with a shop rag to keep the snap ring from flying.

      Fig 30: Removing Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 2
      G03552461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    1. Remove the reverse idler gear shaft bolt and gasket.
      Fig 31: Removing Reverse Idler Gear Shaft Bolt
      G03552462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE CLUTCH TUBE BRACKET NO. 1 
    1. Remove the bolt and clutch tube bracket.
  30. REMOVE MANUAL TRANSMISSION CASE 
    1. Remove the 3 bolts from the manual transaxle case side.
      Fig 32: Removing Manual Transmission Case (1 Of 2)
      G03552463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 14 bolts from the manual transmission case side.
      Fig 33: Removing Manual Transmission Case (2 Of 2)
      G03552464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tapping with a plastic hammer, remove the manual transmission case.
  31. REMOVE OIL RECEIVER PIPE NO. 2 (MTM) 
    1. Remove the bolt and oil receiver pipe No. 2 (MTM) from the manual transmission case.
      NOTE: Do not damage the pipe. 
      Fig 34: Removing Oil Receiver Pipe No. 2 (MTM)
      G03552465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE OIL RECEIVER PIPE NO. 1 (MTM) 
    1. Remove the bolt and oil receiver pipe No. 1 (MTM) from the manual transmission case.
      NOTE: Do not damage the pipe. 
      Fig 35: Removing Oil Receiver Pipe No. 1 (MTM)
      G03552466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE REVERSE RESTRICT PIN ASSY 
    1. Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.
      Fig 36: Removing Reverse Restrict Pin Plug
      G03552467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (Formulator 5 mm), remove the slotted pin and reverse restrict pin assy.
      Fig 37: Removing Slotted Pin & Restrict Pin Assy
      G03552468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSMISSION MAGNET 
    1. Remove the transmission magnet from the manual transaxle case.
      Fig 38: Removing Transmission Magnet
      G03552469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE REVERSE IDLER GEAR SUB-ASSY 
    1. Remove the reverse idler gear sub-assy from the manual transaxle case.
      Fig 39: Removing Reverse Idler Gear Sub-Assembly
      G03552470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.
      Fig 40: Removing Reverse Gear & Reverse Idler Thrust Washer
      G03552471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE REVERSE SHIFT ARM BRACKET ASSY 
    1. Remove the 2 bolts and reverse shift arm bracket assy from the manual transaxle case.
      Fig 41: Removing Reverse Shift Arm Bracket Assy
      G03552472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE GEAR SHIFT FORK SHAFT NO. 1 
    1. Remove the shift fork set bolt from the gear shift fork No. 1.
      Fig 42: Removing Shift Fork Set Bolt
      G03552473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull out the gear shift fork shaft No. 1 while the gear shift fork shaft No. 3 is pulled up.
      Fig 43: Pulling Out Gear Shift Fork Shaft No. 1
      G03552474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No. 1.
      NOTE: Cover with a shop rag to keep the snap ring from flying. 
      Fig 44: Removing Shift Fork Shaft Snap Ring
      G03552475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE REVERSE SHIFT FORK ROLLER 
    1. Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
      Fig 45: Removing Reverse Shift Fork Roller
      G03552476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE GEAR SHIFT FORK SHAFT NO. 2 
    1. Remove the shift fork set bolt and shift head set bolt from the gear shift fork No. 2 and gear shift head No. 1.
      Fig 46: Removing Shift Fork Set & Shift Head Set Bolts
      G03552477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gear shift fork shaft No. 2 and gear shift head No. 1 from the manual transaxle case.
      Fig 47: Removing Gear Shift Fork Shaft No. 2 & Gear Shift Head No. 1
      G03552478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE GEAR SHIFT FORK NO. 1 
    Fig 48: Removing Gear Shift Fork No. 1
    G03552479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE GEAR SHIFT FORK SHAFT NO. 3 
    1. Remove the gear shift fork shaft No. 3 from the manual transaxle case.
      Fig 49: Removing Gear Shift Fork Shaft No. 3
      G03552480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the gear shift fork shaft No. 3.
      Fig 50: Removing Shift Fork Shaft Snap Rings
      G03552481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the reverse shift fork from the gear shift fork shaft No. 3.
  42. REMOVE GEAR SHIFT FORK NO. 2 
    1. Remove the gear shift fork No. 2 from the input shaft assy.
      Fig 51: Removing Gear Shift Fork No. 2
      G03552482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE INPUT SHAFT ASSY 
    1. Tilt the output shaft, then remove the input shaft from the manual transaxle case.
      Fig 52: Removing Input Shaft Assy
      G03552483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE OUTPUT SHAFT ASSY 
    1. Remove the output shaft assy from the manual transaxle case.
      Fig 53: Removing Output Shaft Assy
      G03552484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE DIFFERENTIAL CASE ASSY 
    1. Remove the differential case assy from the manual transaxle case.
      Fig 54: Removing Differential Case Assy
      G03552485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE MANUAL TRANSAXLE CASE RECEIVER 
    1. Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.
      Fig 55: Removing Bolts & Manual Transaxle Case Receiver
      G03552486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE INPUT SHAFT FRONT BEARING 
    1. Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case.

      SST 09612-65014 (09612-01040, 09612-01050)

      Fig 56: Removing Input Shaft Front Bearing (Outer Race)
      G03552487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST, remove the manual transaxle case oil seal from the manual transaxle case.

      SST 09612-65014 (09612-01040, 09612-01050)

      Fig 57: Removing Manual Transaxle Case Oil Seal
      G03552488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case.

      SST 09387-00040 (09387-02020, 09387-02010)

      Fig 58: Removing Output Shaft Front Bearing (Outer Race)
      G03552489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE OUTPUT SHAFT (MTM) COVER 
    1. Remove the output shaft (MTM) cover from the manual transaxle case.
      Fig 59: Removing Output Shaft (MTM) Cover
      G03552490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE OUTPUT SHAFT REAR BEARING 
    1. Using SST, remove the output shaft rear bearing from the manual transmission case (outer race).

      SST 09950-60010 (09951-00680), 09950-70010 (09951-07100)

      Fig 60: Removing Output Shaft Rear Bearing
      G03552491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE TRANSMISSION CASE OIL SEAL 
    1. Using SST, remove the transmission case oil seal from the manual transmission case.

      SST 09308-00010

      Fig 61: Removing Transmission Case Oil Seal
      G03552492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL 
    1. Using a screwdriver, remove the front transaxle case cover oil seal.

      HINT:

      Tape the screwdriver tip before use to avoid damage.

      Fig 62: Removing Front Transaxle Case Cover Oil Seal
      G03552493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using a brass bar and a hammer, remove the FR differential case front tapered roller bearing (outer race) from the manual transaxle case.
      Fig 63: Removing FR Differential Case Front Tapered Roller Bearing (Outer Race)
      G03552494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the front differential case front tapered roller bearing from the front differential case.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560)

      Fig 64: Removing Front Differential Case Front Tapered Roller Bearing
      G03552495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a hammer, remove the FR differential case rear tapered roller bearing (outer race) and FR differential case rear shim from the manual transmission case

      SST 09950-60020 (09951-00790), 09950-70010 (09951-07100)

      Fig 65: Removing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
      G03552496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490)

      Fig 66: Removing FR Differential Case Rear Tapered Roller Bearing (Inner Race)
      G03552497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSPECT REVERSE IDLER GEAR SUB-ASSY 
    1. Using a caliper gauge, measure the inside diameter of the reverse idler gear.

      Inside diameter: mm (in.) 

      INSIDE DIAMETER SPECIFICATION

      Standard inside diameter Maximum inside diameter
      20.056 to 20.074 (0.7896 to 0.7903) 20.074 (0.7903)

      If the inside diameter exceeds the maximum, replace the reverse idler gear.

      Fig 67: Measuring Inside Diameter Of Reverse Idler Gear
      G03552498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a micrometer, measure the outside diameter of the reverse idler gear shaft.

      Outside diameter: mm (in.) 

      OUTSIDE DIAMETER SPECIFICATION

      Standard outside diameter Minimum outside diameter
      19.984 to 20.000 (0.7868 to 0.7874) 19.984 (0.7868)

      If the outside diameter is less than the minimum, replace the reverse idler gear shaft.

      Fig 68: Measuring Outside Diameter Of Reverse Idler Gear Shaft
      G03552499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE TRANSMISSION HUB SLEEVE NO. 3 
    1. Remove the transmission hub sleeve No. 3 from the transmission clutch hub No. 3.
      Fig 69: Removing Transmission Hub Sleeve No. 3
      G03552500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE SYNCHROMESH SHIFTING KEY SPRING NO. 3 
    1. Remove the 2 synchromesh shifting key springs No. 3 from the transmission clutch hub No. 3 while pushing on the synchromesh shifting key spring No. 3.
      Fig 70: Removing Synchromesh Shifting Key Springs No. 3
      G03552501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE SYNCHRONIZER PULL RING 
    1. Using a screwdriver, remove the synchronizer pull ring snap ring.
    2. Remove the synchronizer pull ring, synchronizer outer ring No. 5, synchronizer inner ring No. 5 and synchronizer ring middle No. 5 from the synchronizer ring inner No. 5.
      Fig 71: Removing Synchronizer Pull Ring Snap Ring
      G03552502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSPECT TRANSMISSION CLUTCH HUB NO. 3 
    1. Inspect the sliding condition between the transmission clutch hub No. 3 and the transmission hub sleeve No. 3.
    2. Inspect the tip of the spline gear on the transmission hub sleeve No. 3 for wear.
      Fig 72: Inspecting Transmission Clutch Hub No. 3
      G03552503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSPECT TRANSMISSION HUB SLEEVE NO. 3 
    1. Using vernier calipers, measure the width of the transmission hub sleeve No. 3 groove and the thickness of the claw part on the gear shift fork No. 3, and calculate the clearance.

      Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 in.) {A - B} 

      If clearance is out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3 with new ones.

      Fig 73: Inspecting Transmission Hub Sleeve No. 3
      G03552504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSPECT 5TH GEAR 
    1. Using a caliper gauge, measure the inside diameter of the 5th gear.

      Inside diameter: mm (in.) 

      INSIDE DIAMETER SPECIFICATION

      Standard inside diameter Maximum inside diameter
      34.981 to 34.997 (1.3772 to 1.3778) 34.997 (1.3778)

      If the inside diameter exceeds the maximum, replace the 5th gear.

      Fig 74: Measuring Inside Diameter Of 5th Gear
      G03552505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL SYNCHRONIZER PULL RING 
    1. Install the synchronizer middle ring No. 5, synchronizer ring outer No. 5 and synchronizer pull ring to the synchronizer ring inner No. 5 Using a screwdriver, fix them with the snap ring.
      Fig 75: Installing Synchronizer Middle Ring
      G03552506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSPECT SYNCHRONIZER RING MIDDLE NO. 5 
    1. Check that the synchronizer ring middle No. 5 rotates smoothly.
      Fig 76: Chekcing Synchronizer Ring Middle No. 5 Rotates
      G03552507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the synchronizer ring middle No. 5 does not rotate while being pushed against the clutch hub No. 3.
      Fig 77: Checking Synchronizer Ring Middle No. 5 Does Not Rotate
      G03552508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL SYNCHROMESH SHIFTING KEY SPRING NO. 3 
    1. Install the synchromesh shifting key spring No. 3 to the transmission clutch hub No. 3.
      Fig 78: Installing Synchromesh Shifting Key Spring No. 3
      G03552509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align the projection of the shifting key spring with the hole of the clutch hub No. 3 and install. 
    2. Install the synchronizer ring set and synchromesh shifting key spring No. 3 to the transmission clutch hub No. 3.
      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 clutch hub No. 3 and install. 
  66. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL 
    1. Using SST and a hammer, install the front transaxle case cover oil seal.

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

      Oil seal driven in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.) 

      Fig 79: Installing Front Transaxle Case Cover Oil Seal
      G03552510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the front transaxle case cover oil seal lip with MP grease.
  67. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a hammer, install the FR differential case front tapered roller bearing (outer race) to the front transaxle case.

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

      Fig 80: Installing FR Differential Case Front Tapered Roller Bearing (Outer Race)
      G03552511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case.

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

      Fig 81: Installing FR Differential Case Front Tapered Roller Bearing (Inner Race)
      G03552512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Install the front differential case shim rear.
    2. Using SST and a hammer, install the FR differential case rear tapered roller bearing (outer race).

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

      Fig 82: Installing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
      G03552513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the FR differential case rear tapered roller bearing (inner race).

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

      Fig 83: Removing FR Differential Case Rear Tapered Roller Bearing
      G03552514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. INSTALL TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, install the transmission case oil seal to the manual transmission case.

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

      Fig 84: Installing Transmission Case Oil Seal
      G03552515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Oil seal driven in depth: 3.5 +/- 0.5 mm (0.138 +/- 0.020 in.) 

    2. Coat the transmission case oil seal lip with MP grease.
  70. 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 85: Installing Output Shaft Rear Bearing
      G03552516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL OUTPUT SHAFT (MTM) COVER 
    1. Coat the output shaft (MTM) cover with MP grease, and install it to the manual transaxle case.
      NOTE: Align the projection of the output shaft with the transmission groove and install. 
      Fig 86: Installing Output Shaft (MTM) Cover
      G03552517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. 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 87: Installing Output Shaft Front Bearing
      G03552518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. ADJUST OUTPUT SHAFT BEARING PRELOAD 
    1. Install the output shaft to the manual transaxle case.
      Fig 88: Installing Output Shaft To Manual Transaxle Case
      G03552519Courtesy 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 89: Installing Transmission Case (1 Of 2)
      G03552520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts on the manual transaxle side.

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

      Fig 90: Installing Transmission Case (2 Of 2)
      G03552521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the output shaft rear bearing case shim to the output shaft.
      Fig 91: Installing Output Shaft Rear Bearing Case Shim
      G03552522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a torx socket wrench (T45), install the bearing retainer rear with the 7 screws to the manual transmission case.

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

    6. Install a new output rear set nut to the output shaft.
      Fig 92: Installing Bearing Retainer Rear
      G03552523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Turn the output shaft in both directions to make sure that it starts to turn smoothly.
    8. Using a socket wrench and torque wrench, inspect the preload.
      Fig 93: Inspecting Preload
      G03552524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload: N.m (kgf.cm, in.lbf) 

      PRELOAD SPECIFICATION

      Bearing Torque
      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)
    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.

      Shim: mm (in.) 

      SHIM THICKNESS SPECIFICATION

      Part No. Thickness: mm (in.) Make
      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
    10. Remove the output shaft rear set nut from the output shaft.
    11. Using a torx socket wrench (T45), remove the 7 screws and bearing retainer rear from the manual transmission case.
      Fig 94: Removing Bearing Retainer Rear
      G03552525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Remove the output shaft rear bearing shim from the output shaft.
      Fig 95: Removing Output Shaft Rear Bearing Shim
      G03552526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Remove the 3 bolts.
      Fig 96: Removing Front Manual Transaxle Side
      G03552527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the 14 bolts and manual transmission case from the manual transaxle case.
      Fig 97: Removing Manual Transmission Case
      G03552528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Remove the output shaft assy from the front manual transaxle case.
      Fig 98: Removing Output Shaft Assembly
      G03552529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. ADJUST TAPERED POLLER BEARING PRELOAD 
    1. Install the differential case assy to the manual transaxle case.
      Fig 99: Installing Differential Case Assembly
      G03552530Courtesy 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 100: Installing Manual Transmission Case
      G03552531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts on the front manual transaxle case side.

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

      Fig 101: Installing Front Manual Transaxle Case Side
      G03552532Courtesy 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

      Preload: N.m (kgf.cm, in.lbf) 

      Fig 102: Inspecting Preload
      G03552533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      PRELOAD SPECIFICATION

      Bearing Torque
      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.

      Shim: mm (in.) 

      SHIM THICKNESS SPECIFICATION

      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 103: Removing Front Manual Transaxle Case Side
      G03552534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 14 bolts and manual transmission case from the manual transaxle case.
      Fig 104: Removing Manual Transmission Case
      G03552535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the differential case assy from the manual transaxle case.
      Fig 105: Removing Differential Case Assembly
      G03552536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install the front transaxle case oil seal No. 1 to the manual transaxle case.

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

      Fig 106: Installing Front Transaxle Case Oil Seal No. 1
      G03552537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of the front transaxle case oil seal No. 1 with MP grease.

      Clearance: 1 to 2 mm (0.0394 to 0.0787 in.) 

  76. INSTALL INPUT SHAFT FRONT BEARING 
    1. Coat the input shaft front bearing with gear oil, and install it 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 107: Installing Input Shaft Front Bearing
      G03552538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    1. Install the 3 bolts and manual transaxle case receiver to the manual transaxle case.

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

      Fig 108: Installing Manual Transaxle Case Receiver
      G03552539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL DIFFERENTIAL CASE ASSY 
    1. Coat the differential case tapered roller bearing with gear oil, and install the differential case assy to the manual transaxle case.
      Fig 109: Installing Differential Case Assembly
      G03552540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. INSTALL OUTPUT SHAFT ASSY 
    1. Apply gear oil to each sliding part of the output shaft assy.
    2. Lift the differential case assy up with the output shaft assy leaned, and install it to the manual transaxle case.
      Fig 110: Installing Output Shaft Assy
      G03552541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL INPUT SHAFT ASSY 
    1. Apply gear oil to each sliding part of the input shaft assy.
    2. Install the input shaft assy to the manual transaxle case while tilting the output shaft assy.
      Fig 111: Installing Input Shaft Assy
      G03552542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL GEAR SHIFT FORK NO. 2 
    1. Coat the gear shift fork No. 2 with gear oil, and install it to the input shaft assy.
      Fig 112: Installing Gear Shift Fork No. 2
      G03552543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. INSTALL GEAR SHIFT FORK NO. 3 
    1. Install the gear shift fork No. 3 to the gear shift fork shaft No. 3.
    2. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft.
      Fig 113: Installing Shift Fork Shaft Snap Rings
      G03552544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply gear oil to each sliding part of the gear shift fork shaft No. 3, and install it to the manual transaxle case.
      Fig 114: Applying Gear Oil To Gear Shift Fork Shaft No. 3
      G03552545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSTALL GEAR SHIFT FORK NO. 1 
    1. Apply gear oil to each sliding part of the gear shift fork No. 1, and install it to the output shaft assy.
      Fig 115: Installing Gear Shift Fork No. 1
      G03552546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL GEAR SHIFT FORK SHAFT NO. 2 
    1. Install the gear shift head No. 1 to the gear shift fork shaft No. 2.
      Fig 116: Installing Gear Shift Head No. 1 To Gear Shift Fork Shaft No. 2
      G03552547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply gear oil to each sliding part of the gear shift fork shaft No. 2, and install it to the manual transaxle case.
    3. Install the shift fork set bolt and shift head set bolt to the gear shift head No. 1.

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

      Fig 117: Installing Shift Fork Set & Shift Head Set Bolts
      G03552548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL REVERSE SHIFT FORK ROLLER 
    1. Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.
      Fig 118: Installing Reverse Shift Fork Roller
      G03552549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL GEAR SHIFT FORK SHAFT NO. 1 
    1. Using a brass bar and hammer, install the shift fork shaft snap ring to the shift fork shaft No. 1.
      Fig 119: Installing Shift Fork Shaft Snap Ring
      G03552550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the gear shift fork shaft No. 1 to the manual transaxle case.
      Fig 120: Installing Gear Shift Fork Shaft No. 1
      G03552551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift fork set bolt to the gear shift fork No. 1.

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

      Fig 121: Installing Shift Fork Set Bolt
      G03552552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. INSTALL REVERSE SHIFT ARM BRACKET ASSY 
    1. Install the 2 bolts and reverse shift arm bracket assy to the manual transaxle case.

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

      Fig 122: Installing Reverse Shift Arm Bracket Assy
      G03552553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. INSTALL REVERSE IDLER GEAR SUB-ASSY 
    1. Coat the reverse idler gear and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.
      Fig 123: Applying Reverse Idler Gear & Idler Thrust Washer With Grease
      G03552554Courtesy 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 124: Aligning Mark Of Reverse Idler Gear Shaft
      G03552555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet, and install it to the manual transaxle case.
      Fig 125: Installing Transmission Magnet
      G03552556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL REVERSE RESTRICT PIN ASSY 
    1. Using a pin punch (Formulator 5 mm), install the reverse restrict pin and reverse restrict pin assy.

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

      Fig 126: Installing Reverse Restrict Pin Assy
      G03552557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the reverse restrict pin plug with adhesive 1324, and using a hexagon wrench (6 mm), install the manual transmission case.

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

      Fig 127: Installing Manual Transmission Case
      G03552558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSTALL OIL RECEIVER PIPE NO. 1 (MTM) 
    1. Install the bolt and oil receiver pipe No. 1 (MTM) to the manual transmission case.

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

      HINT:

      Tighten the oil receiver pipe No. 1 with the bolt.

      Fig 128: Installing Oil Receiver Pipe No. 1 (MTM)
      G03552559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. INSTALL OIL RECEIVER PIPE NO. 2 (MTM) 
    1. Install the bolt and oil receiver pipe No. 2 (MTM) to the manual transmission case.

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

      Fig 129: Installing Oil Receiver Pipe No. 2 (MTM)
      G03552560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. INSTALL MANUAL TRANSMISSION CASE 
    1. Apply an unbroken bead of FIPG, as shown in Fig 130 , to the manual transmission case.
      Fig 130: Applying Unbroken Bead Of FIPG
      G03552561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Install within 10 minutes after applying FIPG.

    2. Install the manual transmission case with the 14 bolts to the manual transaxle case.

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

      Fig 131: Installing Manual Transmission Case Bolts
      G03552562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts on the manual transaxle case side.

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

      Fig 132: Installing Manual Transaxle Case Side
      G03552563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. INSTALL CLUTCH TUBE BRACKET NO. 1 
    1. Install the clutch tube bracket with the bolt.

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

  95. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the bolt with sealant, and install a new gasket to the manual transmission case with the bolt.

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

      Sealant: 

      • Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
      Fig 133: Installing Reverse Idler Gear Shaft Bolt
      G03552564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. INSTALL SHIFT FORK SHAFT SNAP RING 
    1. Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No. 1.
      Fig 134: Installing Shift Fork Shaft Snap Ring To Gear Shift Fork Shaft No. 1
      G03552565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No. 2.
      Fig 135: Installing Shift Fork Shaft Snap Ring To Gear Shift Fork Shaft No. 2
      G03552566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    1. Using a snap ring expander, install the input shaft rear bearing shaft snap ring.
      Fig 136: Installing Input Shaft Rear Bearing Shaft Snap Ring
      G03552567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  98. INSTALL OUTPUT SHAFT REAR BEARING SHIM 
    1. Install the output shaft rear bearing shim to the output shaft.
      Fig 137: Installing Output Shaft Rear Bearing Shim
      G03552568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. INSTALL BEARING RETAINER REAR (MTM) 
    1. Coat the bearing retainer rear (MTM) with sealant, and install it with a torx wrench (T45).

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

      Fig 138: Installing Bearing Retainer Rear With Torx Wrench (T45)
      G03552569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  100. INSTALL 5TH DRIVEN GEAR 
    1. Using SST, install the 5th driven gear to the output shaft.

      SST 09309-12020

      Fig 139: Installing 5th Driven Gear Using SST
      G03552570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  101. 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 140: Installing 5th Gear Needle Roller Bearing
      G03552571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. INSTALL 5TH GEAR 
    1. Coat the 5th gear with gear oil, and install it to the input shaft.
      Fig 141: Coating 5th Gear With Gear Oil
      G03552572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. INSTALL TRANSMISSION CLUTCH HUB NO. 3 
    1. Using SST, install the transmission clutch hub No. 3 to the input shaft.

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

      Fig 142: Installing Transmission Clutch Hub No. 3
      G03552573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Align the projection of the synchronizer ring with the hole of the 5th gear and install. 
    2. Install the transmission hub sleeve No. 3 and gear shift fork No. 3 to the transmission clutch hub No. 3.
      Fig 143: Installing Transmission Hub Sleeve No. 3
      G03552574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the shift fork set bolt 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: 24 N.m (245 kgf.cm, 18 ft.lbf) 

      Fig 144: Installing Shift Fork Set Bolt
      G03552575Courtesy 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 or less 

      Fig 145: Installing Snap Ring
      G03552576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Snap ring: mm (in.) 

      SNAP RING THICKNESS SPECIFICATION

      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 0.0866) j
  104. INSPECT 5TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, inspect the 5th gear radial clearance.

      Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

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

      Fig 146: Inspecting 5th Gear Radial Clearance
      G03552577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  105. INSPECT 5TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, inspect the 5th gear thrust clearance.

      Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0260 in.) 

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

      Fig 147: Inspecting 5th Gear Thrust Clearance
      G03552578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  106. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Double mesh the gears. (Engage 1st and 2nd gears simultaneously.)
      Fig 148: Double Meshing Gears
      G03552579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new manual transmission output shaft rear set nut.

      Torque: 123 N.m (1, 254 kgf.cm, 91 ft.lbf) 

      Fig 149: Installing Manual Transmission Output Shaft Rear Set Nut
      G03552580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
      Fig 150: Staking Manual Transmission Output Shaft Rear Set Nut
      G03552581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the gears.
  107. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY 
    1. Apply FIPG to the transaxle case cover sub-assy, as shown in Fig 151 .

      FIPG: 

      • Part No. 08826-00090, THREE BOND 1281 
      Fig 151: Applying Sealant To Transaxle Case Cover Sub-Assy
      G03552582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the part within 10 minutes after applying the packing material (FIPG). 
    2. Install the transmission case cover sub-assy with the 10 bolts to the manual transaxle case.
      Fig 152: Installing Transmission Case Cover Sub-Assy Bolts
      G03552583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. INSTALL DRAIN (MTM) PLUG SUB-ASSY 
    1. Install the drain plug sub-assy with a new gasket to the manual transmission case.

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

      Fig 153: Installing Drain (MTM) Plug Sub-Assy
      G03552584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  109. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install the manual transmission filler plug with a new gasket to the oil seal.

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

      Fig 154: Installing Manual Transmission Filler Plug
      G03552585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  110. INSTALL SHIFT & SELECT LEVER SHAFT ASSY 
    1. Coat the shift & select lever shaft assy with gear oil, and install it to the manual transmission case.
      Fig 155: Installing Shift & Select Lever Shaft Assy
      G03552586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  111. INSTALL BACK UP LAMP SWITCH ASSY 
    1. Install the back up lamp switch assy to the manual transmission case.

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

      Fig 156: Installing Back Up Lamp Switch Assembly
      G03552587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  112. INSTALL MANUAL TRANSMISSION BREATHER PLUG 
    1. Install a new gasket with the manual transmission breather plug to the manual transmission case.

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

      Fig 157: Installing Manual Transmission Breather Plug
      G03552588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  113. INSTALL LOCK BALL ASSY NO. 1 
    1. Install the lock ball assy No. 1 to the manual transmission case.

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

      Fig 158: Installing Lock Ball Assembly No. 1
      G03552589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  114. INSTALL CONTROL SHAFT COVER 
    1. Coat the 4 bolts with sealant, and install a new gasket and the control shaft cover with the bolts.

      Sealant: 

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

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

      Fig 159: Installing Control Shaft Cover
      G03552590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  115. INSTALL CONTROL SHIFT LEVER 
    1. Install the control shift lever with the shift outer lever lock pin to the shift & select lever shaft.
    2. Install the spring washer with the nut.

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

      Fig 160: Installing Control Shift Lever
      G03552591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  116. INSTALL SELECTING BELL CRANK ASSY 
    1. Coat the 2 bolts with sealant, and install the selecting bell crank assy to the manual transmission case with the bolts.

      Sealant: 

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

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

      Fig 161: Installing Selecting Bell Crank Assembly
      G03552592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  117. INSTALL SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY 
    1. Install the speedometer driven gear to the speedometer sensor.
    2. Install the MTM speedometer shaft sleeve clip to the speedometer driven (MTM) gear sub-assy.
    3. Install the speedometer driven (MTM) gear sub-assy to the transmission case with the bolt.

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

  118. INSTALL CLUTCH RELEASE FORK BOOT 
    1. Install the clutch release fork boot to the manual transaxle case.
  119. 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, 35 ft.lbf) 

      Fig 162: Installing Release Fork Support
      G03552593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  120. INSTALL CLUTCH RELEASE BEARING ASSY 
    1. Coat the clutch release bearing assy with release hub grease, and install it to the clutch release fork sub-assy.

      Sealant: 

      • Part No. 08887-01806, RELEASE HUB GREASE or equivalent 
    2. Apply clutch spline grease to the input shaft spline.
  121. INSTALL CLUTCH RELEASE FORK SUB-ASSY 
    1. Install the clutch release fork sub-assy to the input shaft.
      Fig 163: Installing Clutch Release Fork Sub-Assy
      G03552594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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