Manual Transmission Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.

REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Remove the bolt and separate the wire harness clamp.
  
  Fig 1: Removing Wire Harness With Clamp And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the back-up light switch and gasket.
  SST 09817-16011
  
  Fig 2: Removing Back-Up Light Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY
1. Remove the floor shift control shift lever retainer sub-assembly.
  
  Fig 3: Removing Floor Shift Control Shift Lever Retainer Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER
1. Pull up the locks of the shift lever pins, and remove the 2 shift lever pins.
2. Remove the floor shift control shift lever retainer.
REMOVE SHIFT AND SELECT LEVER BOOT
1. Remove the shift and select lever boot.
  
  Fig 4: Removing Floor Shift Control Shift Lever Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT LEVER RETAINER BUSHING
1. Remove the 4 shift lever retainer bushings.
  
  Fig 5: Removing Shift Lever Retainer Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL SHAFT
1. Using a screwdriver, remove the E-ring and control shaft.
2. Remove the 2 collars from the floor shift control shaft.
  
  Fig 6: Removing E-Ring And Control Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SHIFT CONTROL SHAFT
1. Using a hammer and a screwdriver, cut off the control shaft collar and remove it from the shaft.
2. Remove the shaft pin and floor shift control shaft.
3. Remove the shift lever damper from the floor shift control shaft.
REMOVE EXTENSION HOUSING DUST DEFLECTOR
1. Using a plastic hammer, remove the extension housing dust deflector.
  
  Fig 7: Removing Extension Housing Dust Deflector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXTENSION HOUSING SUB-ASSEMBLY
1. Remove the 8 bolts.
  
  Fig 8: Removing Extension Housing With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap out the extension housing.
3. Remove the extension housing.
  
  Fig 9: Removing Extension Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXTENSION HOUSING REAR OIL SEAL
1. Using SST, remove the extension housing rear oil seal.
  SST 09612-70100 (09612-07210)
  
  Fig 10: Removing Extension Housing Rear Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL
1. Using SST, remove the extension housing oil seal.
  SST 09308-00010
  
  Fig 11: Removing Extension Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXTENSION HOUSING OIL RECEIVER PIPE
1. Using a snap ring expander, remove the snap ring.
  
  Fig 12: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the oil receiver pipe.
  
  Fig 13: Removing Extension Housing Oil Receiver Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT DETENT BALL PLUG
1. Using a socket hexagon wrench (10 mm), remove the shift detent ball plug from the transmission rear case.
2. Remove the ball and compression spring from the transmission rear case.
  
  Fig 14: Locating Shift Detent Ball Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT ADJUST NUT
1. Using a belt and wooden block, fasten the transmission to the workbench.
2. Using a chisel and hammer, unstake the nut.
  
  Fig 15: Removing Output Shaft Adjust Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the gearshift into 5th gear, and then fix the input shaft using SST.
  SST 09556-16030
  
  Fig 16: Fixing Input Shaft Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, remove the nut from the output shaft.
  SST 09922-10010
5. Remove the belt and wooden block from the transmission.
  
  Fig 17: Removing Nut From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the No. 2 taper roller bearing and spacer.
  
  Fig 18: Locating New Spacer And A New No. 2 Taper Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION REAR CASE
1. Remove the 10 bolts and bracket.
  
  Fig 19: Removing Transmission Rear Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap out the rear case.
3. Remove the rear case.
  
  Fig 20: Identifying Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION FILLER PLUG
1. Remove the 2 transmission filler plugs and 2 gaskets from the transmission rear case.
  
  Fig 21: Removing Transmission Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXTENSION HOUSING OIL RECEIVER PIPE
1. Remove the extension housing oil receiver pipe from the transmission rear case.
  
  Fig 22: Removing Transmission Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL SEPARATOR PACKING SEAL
1. Remove the oil separator packing seal from the transmission rear case.
  
  Fig 23: Identifying Oil Separator Packing Seal From Transmission Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE
1. Using SST, remove the 2 bearing outer races.
  SST 09308-00010
  
  Fig 24: Removing Bearing Outer Races
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING
1. Remove the bolt, then remove the bearing lock plate.
  
  Fig 25: Removing Bearing Lock Plate Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the counter gear rear cylindrical roller bearing from the transmission rear case.
  SST 09308-00010
  
  Fig 26: Removing Counter Gear Rear Cylindrical Roller Bearing From Transmission Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION REAR CASE BEARING
1. Using SST and a press, remove the transmission rear case bearing from the transmission rear case.
  SST 09950-60010 (09951-00230)
  
  Fig 27: Removing Transmission Rear Case Bearing From Transmission Rear Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION OIL SEPARATOR
1. Remove the 2 bolts, then remove the oil separator.
  
  Fig 28: Locating Transmission Oil Separator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the reverse idler gear shaft bolt and gasket from the transmission middle case.
  
  Fig 29: Locating Reverse Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION MIDDLE CASE
1. Remove the 11 bolts, then remove the transmission middle case.
  
  Fig 30: Locating Transmission Middle Case With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap out the transmission middle case.
  
  Fig 31: Tap Out Transmission Middle Case Using Plastic Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION DRAIN PLUG
1. Remove the drain plug and gasket from the transmission middle case.
  
  Fig 32: Locating Transmission Middle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL RECEIVER PIPE
1. Remove the No. 2 oil receiver pipe from the transmission middle case.
  
  Fig 33: Locating Transmission Middle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION MIDDLE CASE BEARING
1. Using SST and a press, remove the transmission middle case bearing from the transmission middle case.
  SST 09950-60010 (09951-00230)
  
  Fig 34: Removing Transmission Middle Case Bearing From Transmission Middle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT
1. Remove the shift and select lever shaft.
  
  Fig 35: Locating Shift And Select Lever Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER
1. Remove the bolt, then remove the shift and select lever.
2. Remove the lock ball pin and spring from the shift and select lever.
  
  Fig 36: Locating Shift And Select Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER CAM
1. Using a screwdriver, remove the E-ring and the shift and select lever cam from the shift and select lever shaft.
  
  Fig 37: Removing Shift And Select Lever Cam
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE IDLER GEAR THRUST CLEARANCE
1. Using a feeler gauge, measure the thrust clearance.
  Standard clearance:
  
  0.10 to 0.25 mm (0.0039 to 0.0098 in.)
  
  Maximum clearance:
  
  0.25 (0.0098 in.)
  
  If the clearance exceeds the maximum, replace the reverse idler gear shaft, reverse idler gear or transmission front case.
  
  Fig 38: Inspecting Reverse Idler Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR
1. Remove the reverse idle gear shaft, reverse idler gear bearing and reverse idler gear.
  
  Fig 39: Removing Reverse Idle Gear Shaft, Needle Roller Bearing And Reverse Idler Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE
1. Install the reverse idler gear and reverse idler gear bearing to the reverse idler gear shaft.
2. Using a dial indicator, measure the radial clearance.
  Standard clearance:
  
  0.015 to 0.050 mm (0.0006 to 0.0020 in.)
  
  Maximum clearance:
  
  0.050 mm (0.0020 in.)
  
  If the clearance exceeds the maximum, replace the reverse idler gear bearing, reverse idler gear shaft or reverse idler gear.
  
  Fig 40: Measuring Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION FRONT CASE
1. Using a hexagon wrench (24 mm), remove the plug from the transmission front case.
  
  Fig 41: Locating Plug Onto Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts from the shift interlock bracket.
  
  Fig 42: Locating Bolts From Shift Interlock Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tie the input shaft, counter gear and control assembly with a rope or string.
  
  Fig 43: Tying Input Shaft, Counter Gear And Control Assembly With String
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Expand the 2 snap rings, and lift up the output shaft, input shaft, counter gear and control assembly.
  
  Fig 44: Lifting Up Output Shaft, Input Shaft, Counter Gear And Control Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the output shaft, input shaft, counter gear shaft and control assembly while gently tapping the front case with a plastic hammer.
  NOTE: Take care not to subject the output shaft, input shaft, counter gear shaft and control assembly to any impact. This may cause the ball and spring to come out.
6. Separate the output shaft, input shaft, counter gear shaft and control assembly.
  
  Fig 45: Removing Output Shaft, Input Shaft, Counter Gear Shaft And Control Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL RECEIVER PIPE
1. Remove the No. 1 oil receiver pipe from the transmission front case.
  
  Fig 46: Locating Oil Receiver Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT BEARING SHAFT SNAP RING
1. Using snap ring pliers, remove the 2 snap rings.
  
  Fig 47: Removing Front Bearing Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CASE OIL SEAL
1. Using SST, remove the transmission case oil seal from the transmission front case.
  SST 09308-00010
  
  Fig 48: Removing Transmission Case Oil Seal From Transmission Front Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 GEAR SHIFT FORK
1. Using 2 screwdrivers, remove the 4 snap rings.
  
  Fig 49: Removing Snap Rings Using Screwdrivers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt, then remove the No. 3 gear shift fork.
  
  Fig 50: Removing No. 3 Gear Shift Fork With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 GEAR SHIFT HEAD
1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
  
  Fig 51: Taping Out Slotted Spring Pin Using Pin Punch And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 GEAR SHIFT FORK SHAFT
1. Remove the No. 1 gear shift fork shaft, No. 1 gear shift head, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.
  
  Fig 52: Removing No. 1 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 GEAR SHIFT FORK
1. Remove the bolt, then remove the No. 2 gear shift fork.
  
  Fig 53: Removing No. 2 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 GEAR SHIFT FORK SHAFT
1. Remove the No. 2 gear shift fork shaft, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.
  
  Fig 54: Removing No. 2 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 GEAR SHIFT HEAD
1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
  
  Fig 55: Removing No. 3 Gear Shift Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 GEAR SHIFT FORK SHAFT
1. Remove the No. 3 gear shift fork shaft, ball, spring, No. 3 gear shift head and No. 1 shift interlock pin.
  
  Fig 56: Removing No. 3 Gear Shift Head And No. 3 Gear Shift Fork Shaft Into Shift Interlock Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 GEAR SHIFT FORK
1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
  
  Fig 57: Removing No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 2 gear shift head and No. 1 gear shift fork.
  
  Fig 58: Removing No. 1 Gear Shift Fork And No. 2 Gear Shift Head Onto No. 4 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 4 GEAR SHIFT FORK
1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
2. Remove the No. 4 gear shift fork.
  
  Fig 59: Removing No. 4 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 4 GEAR SHIFT FORK SHAFT
1. Remove the No. 4 gear shift fork shaft, ball and spring.
  
  Fig 60: Removing No. 4 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT ARM
1. Using a screwdriver, remove the E-ring.
  
  Fig 61: Removing New E-Ring Onto Shift Arm Pivot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift arm pivot and shift arm.
  
  Fig 62: Removing Shift Arm And Shift Arm Pivot Onto Shift Interlock Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002