БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ ПОВТОРНАЯ СБОРКА

PROCEDURE

  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

    1. Using SST and a press, install a new front differential case front tapered roller bearing to the differential case assembly.

      A012IUPN09
      SST
      09309-37010
      09506-35010
    2. Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer to the front transaxle case.

      A012IOXN09
      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07200 )
  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

    1. Using SST and a press, install a new front differential case rear tapered roller bearing to the differential case assembly.

      A012K83N09
      SST
      09636-20010
      09726-40010
    2. Using SST and a press, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer to the manual transmission case.

      A012NCZN09
      SST
      09309-36010
      09950-60020   ( 09951-00730 )
      09950-70010   ( 09951-07100 )
      Tip:

      Use a plate washer of the same thickness as the removed one.

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

    1. Coat the differential case assembly with gear oil and install it to the front transaxle case.

      A012HH4
    2. Install the manual transmission case with the 16 bolts.

      Момент затяжки
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    3. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      A012I81C03
      *1 Front Differential Case Rear Plate Washer
      SST
      09564-32011
    4. Using SST and a torque wrench, measure the preload.

      SST
      09564-32011
      Preload (at starting)
      New Bearing
      1.0 to 1.6 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf)
      Used Bearing
      0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 11 in.*lbf)

      If the preload is out of specification, replace the front differential case rear plate washer with one of a different thickness. Use the table below to select a front differential case rear plate washer which will ensure that the preload is within the specification.

      Front Differential Case Rear Plate Washer Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      10 2.100 (0.0827) 26 2.500 (0.0984)
      11 2.125 (0.0837) 27 2.525 (0.0994)
      12 2.150 (0.0846) 28 2.550 (0.100)
      13 2.175 (0.0856) 29 2.575 (0.101)
      14 2.200 (0.0866) 30 2.600 (0.102)
      15 2.225 (0.0876) 31 2.625 (0.103)
      16 2.250 (0.0886) 32 2.650 (0.104)
      17 2.275 (0.0896) 33 2.675 (0.105)
      18 2.300 (0.0906) 34 2.700 (0.106)
      19 2.325 (0.0915) 35 2.725 (0.107)
      20 2.350 (0.0925) 36 2.750 (0.108)
      21 2.375 (0.0935) 37 2.775 (0.109)
      22 2.400 (0.0945) 38 2.800 (0.110)
      23 2.425 (0.0955) 39 2.825 (0.111)
      24 2.450 (0.0965) 40 2.850 (0.112)
      25 2.475 (0.0974) - -
      Tip:
      • Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

      • Make a memo as the torque values will be needed to adjust output shaft bearing preload.

    5. Remove the 16 bolts and manual transmission case.

    6. Remove the differential case assembly from the front transaxle case.

  4. INSTALL FRONT OUTPUT SHAFT BEARING (OUTER RACE)

    1. Install the output shaft cover to the front transaxle case.

      Note:

      Insert the key of the output shaft cover into the case groove.

      A012HFDC01
      *a Key
    2. Using SST and a press, install the front output shaft bearing (outer race) to the front transaxle case.

      A012HK9N01
      SST
      09950-60010   ( 09951-00630 )
      09950-70010
  5. INSTALL REAR OUTPUT SHAFT BEARING (OUTER RACE)

    1. Using SST and a press, install the rear output shaft bearing (outer race) with the rear output shaft bearing shim to the manual transmission case.

      A012GF5N09
      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07200 )
      Tip:

      Use a plate washer of the same thickness as the removed one.

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD

    1. Coat the differential case assembly with gear oil and install it to the front transaxle case.

      A012HH4
    2. Coat the output shaft assembly with gear oil and install it to the front transaxle case.

      A012LA8
    3. Install the manual transmission case with the 16 bolts.

      Момент затяжки
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
    4. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      A012GLQC03
      *1 Rear Output Shaft Bearing Shim
      SST
      09564-32011
    5. Using SST and a torque wrench, measure the preload. Calculate the rear output shaft bearing preload using the following formula.

      SST
      09564-32011
      Formula
      Measured preload - Differential side bearing preload = Output shaft bearing preload
      Bearing Differential gear ratio Preload (at starting)
      New bearing 3.944 4.0 to 6.9 N*m (41 to 70 kgf*cm, 35 to 61 in.*lbf)
      Used bearing 2.6 to 4.4 N*m (27 to 45 kgf*cm, 23 to 39 in.*lbf)
      New bearing 3.736 3.8 to 6.5 N*m (39 to 66 kgf*cm, 34 to 58 in.*lbf)
      Used bearing 2.5 to 4.2 N*m (25 to 43 kgf*cm, 22 to 37 in.*lbf)

      If the preload is out of specification, replace the rear output shaft bearing shim with one of a different thickness. Use the table below to select a rear output shaft bearing shim which will ensure that the preload is within the specification.

      Rear Output Shaft Bearing Shim Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      50 1.750 (0.0689) 72 2.300 (0.0906)
      51 1.775 (0.0699) 73 2.325 (0.0915)
      52 1.800 (0.0709) 74 2.350 (0.0925)
      53 1.825 (0.0719) 75 2.375 (0.0935)
      54 1.850 (0.0728) 76 2.400 (0.0945)
      55 1.875 (0.0738) 77 2.425 (0.0955)
      56 1.900 (0.0748) 78 2.450 (0.0965)
      57 1.925 (0.0758) 79 2.475 (0.0974)
      58 1.950 (0.0768) 80 2.500 (0.0984)
      59 1.975 (0.0778) 81 2.525 (0.0994)
      60 2.000 (0.0787) 82 2.550 (0.100)
      61 2.025 (0.0797) 83 2.575 (0.101)
      62 2.050 (0.0807) 84 2.600 (0.102)
      63 2.075 (0.0817) 85 2.625 (0.103)
      64 2.100 (0.0827) 86 2.650 (0.104)
      65 2.125 (0.0837) 87 2.675 (0.105)
      66 2.150 (0.0846) 88 2.700 (0.106)
      67 2.175 (0.0856) 89 2.725 (0.107)
      68 2.200 (0.0866) 90 2.750 (0.108)
      69 2.225 (0.0876) 91 2.775 (0.109)
      70 2.250 (0.0886) 92 2.800 (0.110)
      71 2.275 (0.0896) - -
      Tip:

      Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

    6. Remove the 16 bolts and manual transmission case.

    7. Remove the output shaft assembly from the front transaxle case.

    8. Remove the differential case assembly from the front transaxle case.

  7. INSTALL OUTER SHIFT LEVER OIL SEAL

    1. Using SST and a hammer, install a new outer shift lever oil seal to the manual transmission case.

      A012MO4C02
      *a Depth
      SST
      09950-60010   ( 09951-00260 )
      09950-70010   ( 09951-07100 )
      Standard Depth
      0.5 to 1.0 mm (0.0197 to 0.0394 in.)
    2. Coat the lip of the outer shaft lever oil seal with MP grease.

  8. INSTALL OUTER NO. 1 SHIFT LEVER

    1. Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.

      A012G5ZC02
      *a Mark
      *b Depth
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
      Tip:

      Install the lever with its mark facing the outside of the manual transmission case.

    2. Using a 5 mm pin punch and a hammer, install the inner shift lever slotted spring pin to the inner No. 1 shift lever.

  9. INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY

    1. Install the manual transmission oil separator sub-assembly to the manual transmission case with the 4 bolts.

      A012FZS
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
      Tip:

      Make sure that the end tabs of the manual transmission oil separator sub-assembly are inserted into the grooves of the manual transmission case.

  10. INSTALL TRANSMISSION OIL SEPARATOR

    1. Install the transmission oil separator to the manual transmission case with the 2 bolts.

      A012L7G
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
      Tip:

      Make sure that the tip of the transmission oil separator is inserted into the groove of the transmission case.

  11. INSTALL NO. 1 OIL RECEIVER PIPE

    1. Install the No. 1 oil receiver pipe to the manual transmission case.

      A012LWP
      Tip:

      Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

  12. INSTALL STRAIGHT PIN

    1. Using a plastic hammer, install 5 new straight pins to the specified protrusion height.

      A012HB1C01
      *a Protrusion Height
      Protrusion Height
      8.5 to 9.5 mm (0.335 to 0.374 in.)
  13. INSTALL REVERSE RESTRICT PIN ASSEMBLY

    1. Install the reverse restrict pin assembly to the front transaxle case.

      A012HA5
  14. INSTALL BREATHER PLUG

    1. Using SST and a hammer, install the breather plug to the front transaxle case.

      A012IO1N07
      SST
      09350-30020   ( 09350-07110 )
  15. INSTALL TRANSMISSION OIL SEPARATOR

    1. Install the transmission oil separator to the front transaxle case with the 4 bolts.

      A012N01
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
  16. INSTALL FRONT TRANSAXLE CASE OIL SEAL

    1. Using SST and a hammer, install a new front transaxle case oil seal to the front transaxle case.

      A012MONC03
      *a Depth
      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )
      Standard Depth
      0.9 to 1.9 mm (0.0354 to 0.0748 in.)
    2. Coat the lip of the front transaxle case oil seal with MP grease.

  17. INSTALL TRANSMISSION MAGNET

    1. Clean the transmission magnet and install it to the front transaxle case.

      A012H1T
  18. INSTALL INPUT SHAFT COVER

    1. Install the input shaft cover to the manual transmission case.

      Note:

      Insert the key of the input shaft cover into the manual transmission case groove.

      A012HPJC01
      *a Key
  19. INSTALL REAR INPUT SHAFT BEARING SHIM

    1. Install the rear input shaft bearing shim to the manual transmission case.

      Note:

      Apply grease to the shim to prevent it from falling out of the case during reassembly.

    2. Measure the area between the end of the manual transmission case and the rear input shaft bearing shim (Dimension A).

      A012IN4C02
      *1 Manual Transmission Case *2 Input Shaft Assembly
      *3 Front Transaxle Case - -
      *a Dimension A *b Dimension B
      *c Dimension C - -
    3. Measure the area between the end of the front transaxle case and the installation surface of the front input shaft bearing (Dimension B).

    4. Measure the area between both input shaft bearing outer races (Dimension C).

      Note:

      Measure Dimension C with each bearing having no axial clearance.

    5. Calculate the rear input shaft bearing shim value using the following formula.

      Formula
      (Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = 0.02 mm (0.000787 in.) to 0.14 mm (0.00551 in.)

      If the preload is out of specification, replace the rear input shaft bearing shim with one of a different thickness. Use the table below to select a rear input shaft bearing shim which will ensure that the preload is within the specification.

      Rear Input Shaft Bearing Shim Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      08 1.30 (0.0512) 14 1.60 (0.0630)
      09 1.35 (0.0531) 15 1.65 (0.0650)
      10 1.40 (0.0551) 16 1.70 (0.0669)
      11 1.45 (0.0571) 17 1.75 (0.0689)
      12 1.50 (0.0591) 18 1.80 (0.0709)
      13 1.55 (0.0610) 19 1.85 (0.0728)
    6. Coat the rear input shaft bearing shim with MP grease and install it to the manual transmission case.

      Note:

      Do not apply MP grease to the oil grooves.

  20. INSTALL DIFFERENTIAL CASE ASSEMBLY

    1. Coat the differential case assembly with gear oil and install it to the front transaxle case.

      A012HH4
  21. INSTALL INPUT SHAFT ASSEMBLY

    1. Apply gear oil to all sliding and rotating parts.

    2. Coat the No. 1 gear shift fork shaft assembly with gear oil and install it.

      A012ND1C02
      *1 No. 1 Gear Shift Fork Shaft Assembly
      *2 Output Shaft Assembly
    3. Coat the No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly with gear oil and install them.

      A012INEC02
      *1 No. 2 Gear Shift Fork Shaft Assembly
      *2 No. 3 Gear Shift Fork Shaft Assembly
      *3 Input Shaft Assembly
    4. Temporarily install the output shaft assembly, input shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly, and tie them with a rope or string.

    5. Install the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly to the front transaxle case.

      A012HRD
  22. INSTALL OUTER SELECT LEVER OIL SEAL

    1. Using SST and a hammer, install a new outer select lever oil seal to the front transaxle case.

      A012IPRC01
      *a Depth
      SST
      09950-60010   ( 09951-00240 )
      09950-70010   ( 09951-07100 )
      Standard Depth
      0.5 to 1.0 mm (0.0197 to 0.0393 in.)
    2. Coat the lip of the outer select lever oil seal with MP grease.

  23. INSTALL OUTER SELECT LEVER

    1. Install the outer select lever and inner select lever to the front transaxle case.

      A012HX3C02
      *a Mark
      Tip:

      Install the lever with its mark facing the outside of the front transaxle case.

  24. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY

    1. Turn the shift and select lever shaft assembly and inner select lever counterclockwise, and install them to the front transaxle case.

      Tip:

      When installing the inner select lever, make sure to engage it with the shift inter lock plate.

      A012FOXC01
      *1 Shift and Select Lever Shaft Assembly
      *2 Shift Inter Lock Plate
      *3 Inner Select Lever
    2. Coat the threads of the inner select lever set bolt with adhesive and install the bolt using a 6 mm hexagon socket wrench.

      A012G9Y
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Момент затяжки
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
  25. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. Install the reverse shift arm bracket assembly to the front transaxle case with the 2 bolts.

      A012HFG
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
  26. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY

    1. Coat the reverse shift fork shaft assembly with gear oil and install it.

      A012M73
  27. 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.

      Note:

      Make sure that the reverse idler gear shaft bolt installation surface of the reverse idler gear is parallel to the screw hole on the front transaxle case.

      Tip:

      Raise the edge of the reverse shift arm bracket assembly and install it to the reverse shift fork shaft assembly.

      A012JXUC05
      *a Parallel
      *b Reverse Idler Gear Shaft Bolt Installation Surface
      *c Screw Hole
  28. INSTALL MANUAL TRANSMISSION CASE

    1. Apply FIPG to the manual transmission case as shown in the illustration.

      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Note:
      • Remove any oil from the contact surfaces.

      • Install the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

      A012F2RC04
      *a

      FIPG

      (Seal Diameter 1.2 mm (0.0472 in.))

    2. Push the outer No. 1 shift lever and install the manual transmission case.

      A012MVM
      Tip:

      Pushing on the outer No. 1 shift lever allows the manual transmission case to be installed.

    3. Pull the outer No. 1 shift lever out and turn it counterclockwise.

      A012GBI
    4. Install the manual transmission case with the 16 bolts.

      A012LQT
      Момент затяжки
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
  29. INSTALL OUTER SHIFT LEVER E-RING

    1. Install the outer shift lever E-ring to the outer No. 1 shift lever.

      A012KNH
  30. INSTALL TRANSMISSION CASE OIL SEAL

    1. for LH Side

      A012HK3N03
      1. Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.

        SST
        09316-60011   ( 09316-00011 )
        Standard Depth
        10.6 to 11.6 mm (0.417 to 0.457 in.)
        Note:

        Do not damage the oil seal lip.

      2. Coat the lip of the transmission case oil seal with MP grease.

    2. for RH Side

      A012KHQN03
      1. Using SST and a hammer, install a new transmission case oil seal to the front transaxle case.

        SST
        09630-24014   ( 09620-24051 )
        09950-60010   ( 09951-00410, 09951-00530, 09952-06010 )
        09950-70010   ( 09951-07100 )
        Standard Depth
        1.2 to 2.2 mm (0.0472 to 0.0866 in.)
        Note:

        Do not damage the oil seal lip.

      2. Coat the lip of the transmission case oil seal with MP grease.

  31. INSTALL SHIFT DETENT BALL

    1. Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.

      A012I5R
    2. Coat the threads of the 2 shift detent ball plugs with adhesive and install them using a 6 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Момент затяжки
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
      Note:

      Be careful not to drop the shift detent balls into the manual transmission case.

    3. Install the shift detent ball and shift detent ball compression spring to the manual transmission case.

      A012LF4
    4. Coat the threads of the shift detent ball plug with adhesive and install it using a 6 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Момент затяжки
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
      Note:

      Be careful not to drop the shift detent ball into the manual transmission case.

  32. INSTALL LOCK BALL PIN

    1. Install the lock ball pin and shift and select lever shaft compression spring to the manual transmission case.

      A012LQX
    2. Coat the threads of the plug with adhesive and install it using a 10 mm hexagon socket wrench.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Момент затяжки
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }
  33. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    1. Coat the threads of the reverse idler gear shaft bolt with adhesive and install it to the manual transmission case with a new gasket.

      A012IK9
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Момент затяжки
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
  34. INSTALL NO. 1 LOCK BALL ASSEMBLY

    1. Coat the threads of the No. 1 lock ball assembly with adhesive and install it to the manual transmission case.

      A012FQB
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Момент затяжки
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
  35. INSTALL TRANSMISSION CASE PLUG

    1. Install the transmission case plug to the manual transmission case with a new gasket.

      A012MAG
      Момент затяжки
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
  36. INSTALL NO. 1 CLUTCH HOUSING COVER

    1. Install the No. 1 clutch housing cover to the front transaxle case.

      A012IJH
  37. INSTALL RELEASE CYLINDER BLEEDER PLUG

    1. Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.

      Момент затяжки
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
  38. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP

    1. Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.

  39. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

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  40. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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  41. INSPECT CLUTCH PIPE LINE

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  42. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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  43. INSTALL WIRE HARNESS CLAMP BRACKET (w/ Stop And Start System)

    1. Install the wire harness clamp bracket onto the manual transmission case with the bolt.

      A012J3D
      Момент затяжки
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
  44. INSTALL CONTROL CABLE BRACKET ASSEMBLY

    1. Hook the outer select lever to the reverse restrict pin to secure it.

      A012I8Q
    2. Install the control cable bracket assembly to the manual transmission case with the 3 bolts.

      A012M0J
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
  45. INSTALL NEUTRAL POSITION SWITCH (w/ Stop And Start System)

    1. Using a 27 mm deep socket wrench, install the neutral position switch and a new gasket to the manual transmission case.

      A012G42
      Момент затяжки
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }
  46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    1. Using a 27 mm deep socket wrench, install the back-up light switch and a new gasket to the manual transmission case.

      A012JJD
      Момент затяжки
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }
  47. INSTALL MANUAL TRANSMISSION FILLER PLUG

    1. Install the manual transmission filler plug to the manual transmission case with a new gasket.

      A012L7L
      Момент затяжки
      39.2 N*m  { 400 kgf*cm, 29 ft.*lbf }
  48. INSTALL MANUAL TRANSMISSION DRAIN PLUG

    1. Using a 10 mm hexagon socket wrench, install the manual transmission drain plug to the front transaxle case with a new gasket.

      A012GAK
      Момент затяжки
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }