Manual Transaxle ASSY (C59): Overhaul

1. Remove the manual transmission filler plug and gasket from the manual transmission case.

Fig 2: Removing Drain Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.

1. Remove the bolt and speedometer sensor from the transaxle case.
2. Remove the O-ring from the speedometer sensor.

1. Remove the clip and speedometer driven (MTM) gear sub-assy from the speedometer sensor.

1. Remove the bolt and speedometer driven hole cover sub-assy from the transaxle case.
2. Remove the O-ring from the speedometer driven hole cover.

Fig 3: Removing Clutch Release Fork Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release fork sub-assy with the clutch release bearing assy from the transaxle case.

1. Remove the clutch release bearing clip and clutch release bearing assy from the clutch release fork sub-assy.

Fig 4: Removing Clutch Release Bearing Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release fork support from the transaxle case.

Fig 5: Removing Clutch Release Fork Support

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release fork boot from the transaxle case.

Fig 6: Removing Clutch Release Fork Boot

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the back up lamp switch assy and gasket from the manual transmission case.

Fig 7: Removing Back Up Lamp Switch Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.

Fig 8: Removing Bolts Floor Shift Control Lever Housing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and selecting bell crank assy from the manual transmission case.
2. Remove the control shift lever bush.

Fig 9: Removing Control Shift Lever Bush

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place the manual transaxle assy on wooden blocks.

Fig 10: Placing Manual Transaxle Assy On Wooden Blocks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the lock ball assy No.1 from the manual transmission case.

Fig 11: Removing Lock Ball Assy No.1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts, shift & select lever shaft assy and gasket from the manual transmission case.

Fig 12: Removing Shift & Select Lever Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 9 bolts.
   Fig 13: Removing Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assy to remove it from the manual transmission case.

Fig 14: Taping Projection Of Manual Transmission Case Cover Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
   Fig 15: Loosening Staked Part Of Manual Transmission Output Shaft Rear Set Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage two gears simultaneously to lock the transmission.
3. Remove the manual transmission output shaft rear set nut.
4. Disengage the two gears.

Fig 16: Removing Manual Transmission Output Shaft Rear Set Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the gear shift fork lock bolt from the gear shift fork No.3.
   Fig 17: Removing Gear Shift Fork Lock Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the transmission hub sleeve No.3 with the gear shift fork No.3 from the transmission clutch hub No.3.

Fig 18: Removing Transmission Hub Sleeve No. 3

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the 5th gear thrust clearance.

Fig 19: Measuring 5th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the 5th gear radial clearance.

Fig 20: Measuring 5th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

1. Using 2 screwdrivers and a hammer, tap out the snap ring.

   HINT:

   Use a shop rag to keep the snap ring from flying.

   Fig 21: Taping Out Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the transmission clutch hub No.3, 5th gear and synchronizer ring No.3 from the input shaft.

   SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010), 09950-60010 (09951-00200)

   Fig 22: Removing Transmission Clutch Hub No. 3, 5th Gear And Synchronizer Ring No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No.3.

Fig 23: Removing Synchromesh Shifting Keys And Synchromesh Shifting Key Springs

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.

Fig 24: Removing 5th Gear Needle Roller Bearing And 5th Gear Bearing Spacer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the 5th driven gear from the output shaft.

SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190)

Fig 25: Removing 5th Driven Gear From Output Shaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.

Fig 26: Removing Bolts And Bearing Retainer Rear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.

Fig 27: Removing Output Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.

Fig 28: Removing Input Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.

Fig 29: Removing Reverse Idler Gear Shaft Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No.2.

HINT:

Use a shop rag to keep the snap ring from flying.

Fig 30: Taping Out Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
   Fig 31: Removing Shift Detent Ball Plugs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the 2 seats, 2 springs and 2 shift detent balls from the manual transmission case.
   Fig 32: Removing Seats, Springs And Shift Detent Balls

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.
   Fig 33: Removing Shift Detent Ball Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a magnetic finger, remove the seat, spring and shift detent ball from the transaxle case.

Fig 34: Removing Seat, Spring And Shift Detent Ball

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a hexagon wench, remove the lock ball assy No.1 from the manual transmission case.

Fig 35: Removing Lock Ball Assy No.1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts from the transaxle case side.
   Fig 36: Removing Bolts From Transaxle Case Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the manual transmission case side.
   Fig 37: Removing Bolts From Manual Transmission Case Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, carefully tap the projection of the manual transmission case to remove it from the transaxle case.

Fig 38: Taping Projection Of Manual Transmission Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft from the transaxle case.

Fig 39: Removing Reverse Idler Gear Sub-Assy, Thrust Washer And Reverse Idler Gear Shaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and reverse shift arm bracket assy from the transaxle case.

Fig 40: Removing Bolts And Reverse Shift Arm Bracket Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts from the gear shift fork No. 2 and gear shift head No.1.
   Fig 41: Removing Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork shaft No.2 and gear shift head No.1 from the transaxle case.

Fig 42: Removing Gear Shift Fork Shaft And Gear Shift Head

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap out the snap ring.

   HINT:

   Use a shop rag to keep the snap ring from flying.

   Fig 43: Taping Out Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assy No.1 from the gear shift fork No.1.
   Fig 44: Removing Gear Shift Fork Lock Bolt And Gear Shift Fork Shaft Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the gear shift fork No.1.

Fig 45: Removing Gear Shift Fork

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No.3.

   HINT:

   Use a shop rag to keep the snap ring from flying.

   Fig 46: Taping Out Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift fork shaft No.3 with the reverse shift fork and gear shift fork No.2 from the transaxle case.
   Fig 47: Removing Shift Fork Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
   Fig 48: Removing Balls

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using 2 screwdrivers and a hammer, tap out the snap ring.

   HINT:

   Use a shop rag to keep the snap ring from flying.

5. Remove the reverse shift fork from the gear shift fork shaft No.3.

Fig 49: Taping Out Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the input and output shaft assy from the transaxle case.

Fig 50: Removing Input And Output Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the differential case assy from the transaxle case.

Fig 51: Removing Differential Case Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and manual transaxle case receiver from the transaxle case.

Fig 52: Removing Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
   Fig 53: Removing Reverse Restrict Pin Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (phi 5 mm) and a hammer, drive out the slotted pin and remove the reverse restrict pin assy from the manual transmission case.

Fig 54: Removing Slotted Pin

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and oil receiver pipe No.1 (MTM) from the manual transmission case.

Fig 55: Removing Bolt And Oil Receiver Pipe

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and oil receiver pipe No.2 (MTM) from the manual transmission case.

Fig 56: Removing Bolt And Oil Receiver Pipe

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and bearing lock plate from the transaxle case.

Fig 57: Removing Bolt And Bearing Lock Plate

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the transmission magnet from the transaxle case.

Fig 58: Removing Transmission Magnet

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the input shaft front bearing from the transaxle case.

   SST 09612-65014 (09612-01050, 09612-01060)

Fig 59: Removing Input Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.

Fig 60: Removing Front Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the output shaft front bearing from the transaxle case.

   SST 09308-00010

Fig 61: Removing Output Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the output shaft (MTM) cover from the transaxle case.

Fig 62: Removing Output Shaft Cover From Transaxle Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the FR differential case front tapered roller bearing (outer race) and shim from the transaxle case.

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

   Fig 63: Removing FR Differential Case Front Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case.

SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360) NOTICE: Be careful not to damage the bearing.

Fig 64: Removing FR Differential Case Front Tapered Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, drive out the transaxle case oil seal from the transaxle case.

   SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)

Fig 65: Removing Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the FR differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.

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

   Fig 66: Removing FR Differential Case Rear Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.

SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)

Fig 67: Removing FR Differential Case Rear Tapered Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.

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

Fig 68: Removing Transmission Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check for wear or damage.
2. Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks.

   If the synchronizer ring does not lock, replace the ring or the 5th gear.

   Fig 69: Inspecting Locks Synchronizer Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

   Minimum clearance: 0.75 mm (0.0295 in.) 

If the clearance is less than the minimum, replace the synchronizer ring and gear.

Fig 70: Measuring Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the sliding condition between the transmission hub sleeve No.3 and transmission clutch hub No.3.
2. Check that the tip of the spline gear of the transmission hub sleeve No.3 is not worn down.
   Fig 71: Checking Sliding Condition

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (A) and the thickness of the claw part on the gear shift fork No.3 (B), and calculate the clearance.

   Standard clearance (A - B): 

   0.3 to 0.5 mm (0.012 to 0.0197 in.) 

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

Fig 72: Measuring Width Of Transmission Hub Sleeve

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a caliper gauge, inspect the 5th gear as shown in the illustration.

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

Fig 73: Inspecting Gear Inner Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a caliper gauge, inspect the reverse idler gear sub-assy as shown in the illustration.
   INNER DIAMETER REFERENCE
   
   

   Standard inner diameter: mm (in.)	Maximum inner diameter: mm (in.)
   18.040 to 18.058 (0.7102 to 0.7109)	18.058 (0.7109)

   If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assy

2. Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.

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

Fig 74: Inspecting Gear Inner Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.

Fig 75: Installing Output Shaft (MTM) Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new output shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.

   SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)

Fig 76: Installing Output Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)

   Drive in depth: 15.6 to 16.0 mm (0.6142 to 0.6299 in.) 

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

Fig 77: Installing Front Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new input shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.

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

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

Fig 78: Installing Input Shaft Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install a new FR differential case front tapered roller bearing (inner race) to the front differential case.

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

   Fig 79: Installing FR Differential Case Front Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new FR differential case front tapered roller bearing (outer race) with the shim to the transaxle case.

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

Fig 80: Installing FR Differential Case Front Tapered Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install a new FR differential case rear tapered roller bearing (inner race) to the front differential case.

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

   Fig 81: Installing FR Differential Case Rear Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, install a new FR differential case rear tapered roller bearing (outer race) with the shim to the manual transmission case.

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

Fig 82: Installing FR Differential Case Rear Tapered Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the differential case assy with gear oil, and install it to the transaxle case.
2. Install the manual transmission case with the 16 bolts.

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

   Fig 83: Installing Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a torque wrench, turn the differential case assy to the right and left 2 or 3 times to allow the bearings to settle.

   SST 09564-32011

   Fig 84: Turning Differential Case Assy To Right And Left

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a torque wrench, measure the preload.

   SST 09564-32011

   Preload (at starting): 

   New bearing: 

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

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

   SHIM THICKNESS REFERENCE
   
   

   Mark	Thickness: mm (in.)	Mark	Thickness: mm (in.)
   AA	2.10 (0.0827)	LL	2.60 (0.1024)
   BB	2.15 (0.0846)	MM	2.65 (0.1043)
   CC	2.20 (0.0866)	NN	2.70 (0.1063)
   DD	2.25 (0.0886)	PP	2.75 (0.1083)
   EE	2.30 (0.0906)	QQ	2.80 (0.1102)
   FF	2.35 (0.0925)	RR	2.85 (0.1122)
   GG	2.40 (0.0945)	SS	2.90 (0.1142)
   HH	2.45 (0.0965)	TT	2.95 (0.1161)
   JJ	2.50 (0.0984)	UU	3.00 (0.1181)
   KK	2.55 (0.1004)	-	-

   Fig 85: Measuring Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   The preload will change by about 0.3 to 0.4 Nm (3 to 4 kgfcm, 2.6 to 3.5 in.lbf) corresponding to a change of 0.05 mm (0.0020 in.) in shim thickness.

5. Remove the 16 bolts and manual transmission case from the transaxle case.
6. Remove the differential case assy from the transaxle case.

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

   SST 09316-60011 (09316-00011)

   Drive in depth: 9.6 to 10.2 mm (0.378 to 0.402 in.) 

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

Fig 86: Installing Transmission Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

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

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

Fig 87: Installing Transaxle Case Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the transmission magnet, and install it to the transmission case.

Fig 88: Installing Transmission Magnet

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the bearing lock plate with the bolt.

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

Fig 89: Installing Bearing Lock Plate Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil receiver pipe No.1 (MTM) with the bolt to the manual transmission case.

Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

Fig 90: Installing Oil Receiver Pipe Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil receiver pipe No.2 (MTM) with the bolt to the manual transmission case.

   Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

Fig 91: Installing Oil Receiver Pipe Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the reverse restrict pin assy to the manual transmission case.
   NOTE: Do not set the reverse restrict pin assy in an incorrect orientation.
   Fig 92: Installing Reverse Restrict Pin Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (phi 5 mm) and hammer, install the slotted pin to the reverse restrict pin assy.

   Standard clearance (A): 

   15.5 to 16.5 mm (0.6102 to 0.6496 in.) 

3. Apply sealant to the reverse restrict pin plug.

   Sealant: 

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

   Fig 93: Installing Slotted Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.

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

Fig 94: Installing Reverse Restrict Pin Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the manual transaxle case receiver with the bolt to the transaxle case.

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

Fig 95: Installing Manual Transaxle Case Receiver Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the differential case tapered roller bearing with gear oil, and install the differential case assy to the transaxle case.

Fig 96: Installing Differential Case Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the sliding and rotating surfaces of the input and output shafts with gear oil, and install them to the transaxle case.

Fig 97: Installing Input Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

HINT:

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

Fig 98: Installing Reverse Idler Gear Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the gear shift fork No.1 and gear shift fork No.2 with gear oil, and install them.
   Fig 99: Installing Gear Shift Fork Shaft Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift fork shaft sub-assy No. 1 with gear oil, and install it.
3. Apply sealant to the shift fork lock bolt.

   Sealant: 

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

4. Install the gear shift fork lock bolt.

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

   Fig 100: Installing Gear Shift Fork Lock Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No.1.

Fig 101: Installing Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 2 balls with MP grease, and install them to the reverse shift fork.
2. Install the reverse shift fork to the gear shift fork shaft No.3.
   Fig 102: Installing Gear Shift Fork Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft No.3.
   Fig 103: Installing Shift Fork Shaft Snap Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the gear shift fork shaft No.3 with gear oil, and install it.

Fig 104: Installing Gear Shift Fork Shaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the gear shift head No.1 and gear shift fork shaft No.2 with gear oil, and install them.
   Fig 105: Installing Gear Shift Fork Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: To avoid the interference of the 2 shift fork balls, lift up the gear shift fork shaft No.3 to the position shown in the illustration.
   Fig 106: Lifting Up Gear Shift Fork Shaft No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No.2 and gear shift head No.1.

   Sealant: 

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

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

Fig 107: Installing Shift Lock Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

Fig 108: Installing Reverse Shift Arm Bracket Assy Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
   Fig 109: Applying FIPG

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 13 bolts with sealant, and install them to the manual transmission case.

   Sealant: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 

   242 or equivalent 

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

   Fig 110: Installing Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 3 bolts with sealant, and install them to the transaxle case.

   Sealant: 

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

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

Fig 111: Installing Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket.

   Sealant: 

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

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

Fig 112: Installing Reverse Idler Gear Shaft Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the lock ball assy No.1 with sealant, and install it using a hexagon wrench.

   Sealant: 

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

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

Fig 113: Installing Lock Ball Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 shift detent balls, 2 springs, and 2 seats to the manual transmission case.
   Fig 114: Installing Shift Detent Ball

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 2 shift detent ball plugs with sealant, and install them using a hexagon wrench.

   Sealant: 

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

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

   Fig 115: Installing Shift Detent Ball Plugs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the shift detent ball, spring and seat to the transaxle case.
   Fig 116: Installing Shift Detent Ball, Spring And Seat

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the shift detent ball plug with sealant, and install it using a hexagon wrench.

   Sealant: 

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

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

Fig 117: Installing Shift Detent Ball Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.

Fig 118: Installing Input Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.

Fig 119: Installing Output Shaft Rear Bearing Hole Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No.2.

Fig 120: Installing Shift Fork Shaft Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 5 bolts with sealant, and install them and bearing retainer rear (MTM) to the manual transmission case.

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

Fig 121: Installing Bearing Retainer Rear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the 5th driven gear to the output shaft.

   SST 09309-12020

Fig 122: Installing 5th Driven Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them to the input shaft.

Fig 123: Installing 5th Gear Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 5th gear with gear oil, and install it to the input shaft.

Fig 124: Installing 5th Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the synchronizer ring No.3 with gear oil, and install it to the 5th gear.

Fig 125: Installing Synchronizer Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 3 synchromesh shifting keys and 2 synchro-mesh shifting key springs to the transmission clutch hub No.3.

   HINT:

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

   Fig 126: Installing Transmission Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, install the transmission clutch hub No.3 to the input shaft.

   SST 09636-20010

   NOTE:

   • Before driving in the No.3 clutch hub assy, place the suitable sized wooden block under the rear side of the input shaft, as shown in the illustration.
   • When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded and might be damaged.
   Fig 127: Installing Transmission Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No.3 below 0.1 mm (0.004 in.).
   SNAP RING THICKNESS SPECIFICATION
   
   

   Mark	Thickness: mm (in.)	Mark	Thickness: mm (in.)
   A	2.25 (0.0886)	E	2.49 (0.0980)
   B	2.31 (0.0909)	F	2.55 (0.1004)
   C	2.37 (0.0933)	G	2.61 (0.1028)
   D	2.43 (0.0957)	-	-

   Fig 128: Checking Snap Ring Thickness

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a brass bar and a hammer, install the snap ring to the input shaft.

1. Using a dial indicator, measure the 5th gear thrust clearance.

Fig 129: Measuring 5th Gear Thrust Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, measure the 5th gear radial clearance.

If the clearance exceeds the maximum value, replace the gear, needle roller bearing or shaft.

Fig 130: Measuring 5th Gear Radial Clearance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the transmission clutch hub sleeve No.3 with gear oil, and install it and gear shift fork No.3 to the transmission clutch hub No.3.

   HINT:

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

   Fig 131: Installing Gear Shift Fork

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the gear shift lock fork ball with sealant, and install it to the gear shift fork No.3.

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

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

Fig 132: Installing Gear Shift Lock Fork Ball

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Engage two gears simultaneously to lock the transmission.
2. Install a new manual transmission output shaft rear set nut.

   Torque: 118 Nm (1,200 kgf.cm, 87 ft.lbf) 

   Fig 133: Installing Manual Transmission Output Shaft Rear Set Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
4. Disengage the two gears.

Fig 134: Staking Manual Transmission Output Shaft Rear Set Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply FIPG to the manual transmission case cover sub-assy as shown in the illustration.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
   Fig 135: Applying FIPG

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the manual transmission case cover sub-assy with the 9 bolts to the manual transmission case.

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

Fig 136: Installing Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the 2 bolts with sealant, and install them, 2 bolts, a new gasket and the shift & select lever shaft assy to the manual transmission case.

   Sealant: 

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

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

Fig 137: Coating Bolts With Sealant

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the lock ball assy No.1 with sealant, and install it to the manual transmission case.

   Sealant: 

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

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

Fig 138: Installing Lock Ball Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the selecting bell crank assy and the control shift lever bush with the 2 bolts to the manual transmission case.

   Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

Fig 139: Installing Selecting Bell Crank Assy And Control Shift Lever Bush Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case.

   Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

Fig 140: Installing Floor Shift Control Lever Housing Support Bracket Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the back up lamp switch assy with a new gasket to the manual transmission case.

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

   SST 09817-16011

Fig 141: Installing Back Up Lamp Switch Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring to the speedometer driver hole cover sub-assy.
2. Install the speedometer driver hole cover sub-assy with the bolt.

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

1. Install the speedometer driven (MTM) gear sub-assy with the clip to the speedometer sensor.

1. Install a new O-ring to the speedometer sensor.
2. Install the speedometer sensor with the bolt.

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

1. Install the clutch release fork support to the transaxle case.

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

Fig 142: Installing Release Fork Support

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clutch release fork boot to the transaxle case.

Fig 143: Installing Clutch Release Fork Boot

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the clutch release bearing assy with release hub grease, and install it to the clutch release fork sub-assy with the release bearing clip.

   Sealant: 

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

Fig 144: Installing Clutch Release Bearing Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clutch release fork sub-assy to the input shaft.
2. Apply clutch spline grease to the spline of the input shaft.

   Sealant: 

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

Fig 145: Installing Clutch Release Fork Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

Fig 146: Installing Manual Transmission Filler Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the drain (MTM) plug sub-assy with a new gasket.

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

Fig 147: Installing Drain Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002