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Reassembly [09/2022 - 11/2022]: Procedure

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  1. INSTALL SHIFT FORK SHAFT BEARING 
    1. Using SST and a press, press in 4 new shift fork shaft bearings to the front transaxle case.
      GTY1023028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09820-00031 

      Clearance

      0 to 0.5 mm (0 to 0.0197 in.)

  2. INSTALL OUTPUT SHAFT COVER 
    1. Align the protrusion on the output shaft cover with the groove on the front transaxle case as shown in the illustration, and install the output shaft cover to the front transaxle case.
      GTY1113055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Groove
  3. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING 
    1. Using SST and a hammer, install a new No. 2 output shaft front bearing (outer race) to the front transaxle case.
      GTY1023799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60021 
        1. 09951-00770
      • SST: 09950-70010 
        1. 09951-07100
  4. INSTALL OUTPUT SHAFT COVER 
    1. Align the protrusion on the output shaft cover with the groove on the front transaxle case as shown in the illustration, and install the output shaft cover to the front transaxle case.
      GTY1110254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Groove
  5. INSTALL OUTPUT SHAFT FRONT BEARING 
    1. Using SST and a hammer, install a new output shaft front bearing (outer race) to the front transaxle case.
      GTY1023383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60021 
        1. 09951-00790
      • SST: 09950-70010 
        1. 09951-07100
  6. 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.
      GTY1024026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00410
      • SST: 09950-70010 
        1. 09951-07200

      Drive in Depth

      14.2 to 15.2 mm (0.559 to 0.598 in.)

    2. Coat the front transaxle case oil seal lip with MP grease.
  7. INSTALL INPUT SHAFT FRONT BEARING 
    1. Using SST and a press, install a new input shaft front bearing to the front transaxle case.
      GTY1023431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-00010 
    2. Install the bearing lock plate to the front transaxle case with the bolt.
      GTY1023747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11.3 N.m (115 kgf/cm, 8 ft.lbf) 

  8. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    1. Using snap ring pliers, install a new input shaft rear bearing shaft snap ring to the manual transmission case.
      GTY1023737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL SHIFT AND SELECT LEVER SHAFT NEEDLE ROLLER BEARING 
    1. Using SST and a press, press in a new shift and select lever shaft needle roller bearing to the manual transmission case.
      GTY1022981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09285-76010 

      Clearance

      177.8 to 178.7 mm (7.00 to 7.04 in.)

  10. INSTALL SHIFT FORK SHAFT BEARING 
    1. Using SST and a press, press in 4 new shift fork shaft bearings to the manual transmission case.
      GTY1023689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09307-12010 
      • SST: 09820-00031 

      Clearance

      0 to 0.5 mm (0 to 0.0197 in.)

  11. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a hammer, install a new front differential case front tapered roller bearing (outer race) to the front transaxle case.
      GTY1023738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60021 
        1. 09951-00790
      • SST: 09950-70010 
        1. 09951-07200
    2. Temporarily install a new front differential case front tapered roller bearing (inner race) and the transmission sleeve yoke to the front No. 1 differential case sub-assembly.
      GTY1110344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transmission Sleeve Yoke
      *2 Front Differential Case Front Tapered Roller Bearing (Inner Race)
    3. Using SST and a press, install the transmission sleeve yoke and front differential case front tapered roller bearing (inner race) to the front No. 1 differential case sub-assembly.
      GTY1110531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transmission Sleeve Yoke
      *2 Front Differential Case Front Tapered Roller Bearing (Inner Race)
      • SST: 09950-60011 
        1. 09951-00550
      NOTE:

      Be sure to install the front differential case front tapered roller bearing (inner race) so that there is no clearance between the bearing inner race and front No. 1 differential case sub-assembly.

  12. INSTALL FRONT DRIVE SHAFT OIL SEAL RH 
    1. Coat the lip of a new front drive shaft oil seal RH with MP grease.
    2. Using SST and a hammer, tap in the front drive shaft oil seal RH to the transmission sleeve yoke.
      GTY1024521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00410
      • SST: 09950-70010 
        1. 09951-07200

      Drive in Depth

      23.9 to 24.9 mm (0.941 to 0.980 in.)

      NOTE:

      Do not damage the front drive shaft oil seal RH lip.

  13. INSTALL FRONT DIFFERENTIAL CASE REAR SHIM 
    1. Install the front differential case rear shim to the manual transmission case.
      GTY1024258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a hammer, install a new front differential case rear tapered roller bearing (outer race) to the manual transmission case.
      GTY1023987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-70010 
        1. 09951-07100
      • SST: 09951-00850 
    2. Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the front No. 1 differential case sub-assembly.
      GTY1024178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09554-22010 
      NOTE:

      Be sure to install the front differential case rear tapered roller bearing (inner race) so that there is no clearance between the bearing inner race and front No. 1 differential case sub-assembly.

  15. INSTALL MANUAL TRANSMISSION CASE STRAIGHT PIN 
    1. Using a plastic-faced hammer, tap in 3 new manual transmission case straight pins to the front transaxle case.
      GTY1023532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 10.5 to 11.5 mm (0.413 to 0.453 in.)

      Protrusion Height

      10.5 to 11.5 mm (0.413 to 0.453 in.)

  16. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Coat the differential gear assembly with gear oil and install it to the front transaxle case.
      GTY1023723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case to the front transaxle case with the 10 bolts.
      GTY1023717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

    3. Install the 8 bolts to the front transaxle case side.
      GTY1024255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

    4. w/o LSD:
      1. Turn the differential case in both directions to settle it.
        GTY1024234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using SST and a torque wrench, measure the starting preload.
        • SST: 09564-33010 

        Bearing Preload

        0.35 to 1.75 N.m (4 to 17 kgf/cm, 4 to 15 in.lbf)

      3. Select a front differential case rear shim.
        FRONT DIFFERENTIAL CASE REAR SHIM THICKNESS:

        Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
        0 1.99 to 2.01
        (0.0783 to 0.0791)        		 6 2.29 to 2.31
        (0.0902 to 0.0909)        		 C 2.59 to 2.61
        (0.1020 to 0.1028)
        1 2.04 to 2.06
        (0.0803 to 0.0811)        		 7 2.34 to 2.36
        (0.0921 to 0.0929)        		 D 2.64 to 2.66
        (0.1039 to 0.1047)
        2 2.09 to 2.11
        (0.0823 to 0.0831)        		 8 2.39 to 2.41
        (0.0941 to 0.0949)        		 E 2.69 to 2.71
        (0.1059 to 0.1067)
        3 2.14 to 2.16
        (0.0843 to 0.0850)        		 9 2.44 to 2.46
        (0.0961 to 0.0969)        		 F 2.74 to 2.76
        (0.1079 to 0.1087)
        4 2.19 to 2.21
        (0.0862 to 0.0870)        		 A 2.49 to 2.51
        (0.0980 to 0.0988)        		 G 2.79 to 2.81
        (0.1098 to 0.1106)
        5 2.24 to 2.26
        (0.0882 to 0.0890)        		 B 2.54 to 2.56
        (0.1000 to 0.1008)        		 H 2.84 to 2.86
        (0.1118 to 0.1126)
    5. w/ LSD:
      1. Insert the urethane portion of SST until it reaches portion A shown in the illustration.
        GTY1023208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Front Differential Case
        *a Urethane
        • SST: 09564-52020 
        • SST: 09564-52030 
      2. Hold the B portion of SST and rotate the C portion, and continue expanding until the urethane portion of SST contacts the differential case assembly.

        HINT: 

        If the urethane portion does not contact the differential case assembly, the rotation of SST and the differential case assembly will not be synchronized, and accurate measurement will be impossible.

      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.
        GTY1117741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09564-52020 
        • SST: 09564-52030 
      4. Using SST and a torque wrench, measure the differential side bearing preload.
        • SST: 09564-52020 
        • SST: 09564-52030 

        Bearing Preload

        0.35 to 1.75 N.m (4 to 17 kgf/cm, 4 to 15 in.lbf)

        HINT: 

        • If the preload is not as specified, select a front differential case rear shim to adjust it.
        • If the preload is higher than specified, select a thinner front differential case rear shim, and if the preload is lower than specified, select a thicker front differential case rear shim.
        • In order to adjust the output shaft bearing preload, make a memo of the differential side bearing preload in advance.
        FRONT DIFFERENTIAL CASE REAR SHIM THICKNESS:

        Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
        0 1.99 to 2.01
        (0.0783 to 0.0791)        		 6 2.29 to 2.31
        (0.0902 to 0.0909)        		 C 2.59 to 2.61
        (0.1020 to 0.1028)
        1 2.04 to 2.06
        (0.0803 to 0.0811)        		 7 2.34 to 2.36
        (0.0921 to 0.0929)        		 D 2.64 to 2.66
        (0.1039 to 0.1047)
        2 2.09 to 2.11
        (0.0823 to 0.0831)        		 8 2.39 to 2.41
        (0.0941 to 0.0949)        		 E 2.69 to 2.71
        (0.1059 to 0.1067)
        3 2.14 to 2.16
        (0.0843 to 0.0850)        		 9 2.44 to 2.46
        (0.0961 to 0.0969)        		 F 2.74 to 2.76
        (0.1079 to 0.1087)
        4 2.19 to 2.21
        (0.0862 to 0.0870)        		 A 2.49 to 2.51
        (0.0980 to 0.0988)        		 G 2.79 to 2.81
        (0.1098 to 0.1106)
        5 2.24 to 2.26
        (0.0882 to 0.0890)        		 B 2.54 to 2.56
        (0.1000 to 0.1008)        		 H 2.84 to 2.86
        (0.1118 to 0.1126)
    6. Remove the 8 bolts from the front transaxle case side.
    7. Remove the 10 bolts from the manual transmission case side.
    8. Remove the manual transmission case from the front transaxle case.
    9. Remove the differential gear assembly from the front transaxle case.
  17. INSTALL OUTPUT SHAFT COVER 
    1. Align the protrusion on the output shaft cover with the groove on the manual transmission case as shown in the illustration, and install the output shaft cover to the manual transmission case.
      GTY1024216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Groove
  18. INSTALL OUTPUT SHAFT REAR BEARING SHIM 
    1. Install the output shaft rear bearing shim to the manual transmission case.
      GTY1023605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark

      HINT: 

      When reusing the No. 2 output shaft rear bearing outer race, first install a output shaft rear bearing shim of the same thickness as the original. When installing a new No. 2 output shaft rear bearing outer race, first select and install a output shaft rear bearing shim which is thinner than the original.

  19. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING 
    1. Using SST and a hammer, install a new No. 2 output shaft rear bearing (outer race) to the manual transmission case.
      GTY1023937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00640
      • SST: 09950-70010 
        1. 09951-07200
  20. ADJUST NO. 2 OUTPUT SHAFT REAR BEARING PRELOAD 
    1. Install the No. 2 output shaft and differential gear assembly to the front transaxle case.
      GTY1024253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case to the front transaxle case with the 10 bolts.
      GTY1023717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

    3. Install the 8 bolts to the front transaxle case side.
      GTY1024255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

    4. w/o LSD:
      1. Using SST, measure the No. 2 output shaft rear bearing preload. Subtract the value of the differential side bearing preload from the measured No. 2 output shaft rear bearing preload. Select a output shaft rear bearing shim that will set the preload within the specified range below and install the output shaft rear bearing shim.
        GTY1024234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09564-33010 

        Bearing Preload

        1.22 to 6.05 N.m (13 to 61 kgf/cm, 11 to 53 in.lbf)

        HINT: 

        • If the preload is not as specified, select a output shaft rear bearing shim to adjust it.
        • If the preload is higher than specified, select a thinner output shaft rear bearing shim, and if the preload is lower than specified, select a thicker output shaft rear bearing shim.
        OUTPUT SHAFT REAR BEARING SHIM THICKNESS:

        Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
        A 1.79 to 1.81
        (0.0705 to 0.0713)        		 G 2.09 to 2.11
        (0.0823 to 0.0831)        		 N 2.39 to 2.41
        (0.0941 to 0.0949)
        B 1.84 to 1.86
        (0.0724 to 0.0732)        		 H 2.14 to 2.16
        (0.0843 to 0.0850)        		 P 2.44 to 2.46
        (0.0961 to 0.0969)
        C 1.89 to 1.91
        (0.0744 to 0.0752)        		 J 2.19 to 2.21
        (0.0862 to 0.0870)        		 Q 2.49 to 2.51
        (0.0980 to 0.0988)
        D 1.94 to 1.96
        (0.0764 to 0.0772)        		 K 2.24 to 2.26
        (0.0882 to 0.0890)        		 R 2.54 to 2.56
        (0.1000 to 0.1008)
        E 1.99 to 2.01
        (0.0783 to 0.0791)        		 L 2.29 to 2.31
        (0.0902 to 0.0909)        		 S 2.59 to 2.61
        (0.1020 to 0.1028)
        F 2.04 to 2.06
        (0.0803 to 0.0811)        		 M 2.34 to 2.36
        (0.0921 to 0.0929)        		 T 2.64 to 2.66
        (0.1039 to 0.1047)
    5. w/ LSD:
      1. Insert the urethane portion of SST until it reaches portion A shown in the illustration.
        GTY1023208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Front Differential Case
        *a Urethane
        • SST: 09564-52020 
        • SST: 09564-52030 
      2. Hold the B portion of SST and rotate the C portion, and continue expanding until the urethane portion of SST contacts the differential case assembly.

        HINT: 

        If the urethane portion does not contact the differential case assembly, the rotation of SST and the differential case assembly will not be synchronized, and accurate measurement will be impossible.

      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.
        GTY1117741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09564-52030 
        • SST: 09564-52030 
      4. Using SST and a torque wrench, measure the No. 2 output shaft rear bearing preload.
        • SST: 09564-52020 
        • SST: 09564-52030 

        Bearing Preload

        1.22 to 6.05 N.m (13 to 61 kgf/cm, 11 to 53 in.lbf)

        HINT: 

        • If the preload is not as specified, select a output shaft rear bearing shim to adjust it.
        • If the preload is higher than specified, select a thinner output shaft rear bearing shim, and if the preload is lower than specified, select a thicker output shaft rear bearing shim.
        OUTPUT SHAFT REAR BEARING SHIM THICKNESS:

        Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
        A 1.79 to 1.81
        (0.0705 to 0.0713)        		 G 2.09 to 2.11
        (0.0823 to 0.0831)        		 N 2.39 to 2.41
        (0.0941 to 0.0949)
        B 1.84 to 1.86
        (0.0724 to 0.0732)        		 H 2.14 to 2.16
        (0.0843 to 0.0850)        		 P 2.44 to 2.46
        (0.0961 to 0.0969)
        C 1.89 to 1.91
        (0.0744 to 0.0752)        		 J 2.19 to 2.21
        (0.0862 to 0.0870)        		 Q 2.49 to 2.51
        (0.0980 to 0.0988)
        D 1.94 to 1.96
        (0.0764 to 0.0772)        		 K 2.24 to 2.26
        (0.0882 to 0.0890)        		 R 2.54 to 2.56
        (0.1000 to 0.1008)
        E 1.99 to 2.01
        (0.0783 to 0.0791)        		 L 2.29 to 2.31
        (0.0902 to 0.0909)        		 S 2.59 to 2.61
        (0.1020 to 0.1028)
        F 2.04 to 2.06
        (0.0803 to 0.0811)        		 M 2.34 to 2.36
        (0.0921 to 0.0929)        		 T 2.64 to 2.66
        (0.1039 to 0.1047)
    6. Remove the 8 bolts from the front transaxle case side.
    7. Remove the 10 bolts from the manual transmission case side.
    8. Remove the manual transmission case from the front transaxle case.
    9. Remove the No. 2 output shaft from the front transaxle case.
    10. Remove the differential gear assembly from the front transaxle case.
  21. INSTALL OUTPUT SHAFT REAR BEARING SHIM 
    1. Install the output shaft rear bearing shim to the manual transmission case.
      GTY1023543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      When reusing the output shaft rear bearing (outer race), first install a output shaft rear bearing shim of the same thickness as the original. When installing a new output shaft rear bearing (outer race), first select and install a output shaft rear bearing shim which is thinner than the original.

  22. INSTALL OUTPUT SHAFT REAR BEARING 
    1. Using SST and a hammer, install a new output shaft rear bearing (outer race) to the manual transmission case.
      GTY1023259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00610
      • SST: 09950-70010 
        1. 09951-07200
  23. ADJUST OUTPUT SHAFT REAR BEARING PRELOAD 
    1. Install the No. 1 output shaft and differential gear assembly to the front transaxle case.
      GTY1023537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manual transmission case to the front transaxle case with the 10 bolts.
      GTY1023717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

    3. Install the 8 bolts to the front transaxle case side.
      GTY1024255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

    4. w/o LSD:
      1. Using SST, measure the output shaft rear bearing preload. Subtract the value of the differential side bearing preload from the measured output shaft rear bearing preload. Select an output shaft rear bearing shim that will set the preload within the specified range below and install the output shaft rear bearing shim.
        GTY1024234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09564-33010 

        Bearing Preload

        4.87 to 7.99 N.m (50 to 81 kgf/cm, 44 to 70 in.lbf)

        HINT: 

        • If the preload is not as specified, select a output shaft rear bearing shim to adjust it.
        • If the preload is higher than specified, select a thinner output shaft rear bearing shim, and if the preload is lower than specified, select a thicker output shaft rear bearing shim.
        OUTPUT SHAFT REAR BEARING SHIM THICKNESS:

        Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
        A 1.66 to 1.68
        (0.0654 to 0.0661)        		 G 1.96 to 1.98
        (0.0772 to 0.0780)        		 N 2.26 to 2.28
        (0.0890 to 0.0898)
        B 1.71 to 1.73
        (0.0673 to 0.0681)        		 H 2.01 to 2.03
        (0.0791 to 0.0799)        		 P 2.31 to 2.33
        (0.0909 to 0.0917)
        C 1.76 to 1.78
        (0.0693 to 0.0701)        		 J 2.06 to 2.08
        (0.0811 to 0.0819)        		 Q 2.36 to 2.38
        (0.0929 to 0.0937)
        D 1.81 to 1.83
        (0.0713 to 0.0720)        		 K 2.11 to 2.13
        (0.0831 to 0.0839)        		 R 2.41 to 2.43
        (0.0949 to 0.0957)
        E 1.86 to 1.88
        (0.0732 to 0.0740)        		 L 2.16 to 2.18
        (0.0850 to 0.0858)        		 S 2.46 to 2.48
        (0.0969 to 0.0976)
        F 1.91 to 1.93
        (0.0752 to 0.0760)        		 M 2.21 to 2.23
        (0.0870 to 0.0878)        		 T 2.51 to 2.53
        (0.0988 to 0.0996)
    5. w/ LSD:
      1. Insert the urethane portion of SST until it reaches portion A shown in the illustration.
        GTY1023208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Front Differential Case
        *a Urethane
        • SST: 09564-52020 
        • SST: 09564-52030 
      2. Hold the B portion of SST and rotate the C portion, and continue expanding until the urethane portion of SST contacts the differential case assembly.

        HINT: 

        If the urethane portion does not contact the differential case assembly, the rotation of SST and the differential case assembly will not be synchronized, and accurate measurement will be impossible.

      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.
        GTY1117741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09564-52020 
        • SST: 09564-52030 
      4. Using SST and a torque wrench, measure the output shaft rear bearing preload.
        • SST: 09564-52020 
        • SST: 09564-52030 

        Bearing Preload

        4.87 to 7.99 N.m (50 to 81 kgf/cm, 44 to 70 in.lbf)

        HINT: 

        • If the preload is not as specified, select a output shaft rear bearing shim to adjust it.
        • If the preload is higher than specified, select a thinner output shaft rear bearing shim, and if the preload is lower than specified, select a thicker output shaft rear bearing shim.
        OUTPUT SHAFT REAR BEARING SHIM THICKNESS:

        Mark Thickness mm (in.) Mark Thickness mm (in.) Mark Thickness mm (in.)
        A 1.66 to 1.68
        (0.0654 to 0.0661)        		 G 1.96 to 1.98
        (0.0772 to 0.0780)        		 N 2.26 to 2.28
        (0.0890 to 0.0898)
        B 1.71 to 1.73
        (0.0673 to 0.0681)        		 H 2.01 to 2.03
        (0.0791 to 0.0799)        		 P 2.31 to 2.33
        (0.0909 to 0.0917)
        C 1.76 to 1.78
        (0.0693 to 0.0701)        		 J 2.06 to 2.08
        (0.0811 to 0.0819)        		 Q 2.36 to 2.38
        (0.0929 to 0.0937)
        D 1.81 to 1.83
        (0.0713 to 0.0720)        		 K 2.11 to 2.13
        (0.0831 to 0.0839)        		 R 2.41 to 2.43
        (0.0949 to 0.0957)
        E 1.86 to 1.88
        (0.0732 to 0.0740)        		 L 2.16 to 2.18
        (0.0850 to 0.0858)        		 S 2.46 to 2.48
        (0.0969 to 0.0976)
        F 1.91 to 1.93
        (0.0752 to 0.0760)        		 M 2.21 to 2.23
        (0.0870 to 0.0878)        		 T 2.51 to 2.53
        (0.0988 to 0.0996)
    6. Remove the 8 bolts from the front transaxle case side.
    7. Remove the 10 bolts from the manual transmission case side.
    8. Remove the manual transmission case from the front transaxle case.
    9. Remove the No. 1 output shaft from the front transaxle case.
    10. Remove the differential gear assembly from the front transaxle case.
  24. INSTALL TRANSMISSION MAGNET 
    1. Clean and install the transmission magnet to the front transaxle case.
      GTY1023533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL DIFFERENTIAL GEAR ASSEMBLY 
    1. Coat the front differential case front tapered roller bearings with gear oil and install the differential gear assembly to the front transaxle case.
      GTY1023521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REVERSE SHIFT FORK 
    1. Install the reverse shift fork to the No. 3 gear shift fork.
      GTY1111746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 3 GEAR SHIFT FORK 
    1. Install the No. 3 gear shift fork to the No. 2 output shaft.
      GTY1024275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL NO. 2 GEAR SHIFT FORK 
    1. Install the No. 2 gear shift fork to the No. 1 gear shift fork.
      GTY1023806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL NO. 1 GEAR SHIFT FORK 
    1. Install the No. 1 gear shift fork to the No. 1 output shaft.
      GTY1023808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL INPUT SHAFT, NO. 1 OUTPUT SHAFT AND NO. 2 OUTPUT SHAFT 
    1. Bend left and right sides of SST in opposite directions.
      GTY1023801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09312-52010 
      NOTE:

      Do not bend SST more than necessary.

    2. Install SST to the top and bottom of the No. 3 transmission hub sleeve.
      GTY1116910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09312-52010 
      NOTE:

      Make sure that SST does not easily come loose.

      HINT: 

      Install SST in a tensioned state so that the No. 3 transmission hub sleeve does not shift out of position.

    3. Install the input shaft, No. 1 output shaft and No. 2 output shaft at the same time.
      GTY1023516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL REVERSE IDLER GEAR 
    1. Coat the reverse idler gear, needle roller bearing, and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.
      GTY1023513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure that the protruding part on the reverse idler thrust washer is fitted into the groove of the reverse idler gear shaft.

    2. Install the reverse idler gear shaft by sliding and lifting it.
      GTY1024212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the mark of the reverse idler gear shaft with the hole of the bolt.
      GTY1023027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30°
      *b Mark
      *c Bolt Hole
  32. INSTALL REVERSE SHIFT FORK SHAFT 
    1. Install the reverse shift fork shaft to the front transaxle case.
      GTY1023507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply adhesive to 2 or 3 threads on the end of the bolt.
      GTY1019142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      NOTE:

      Make sure to install the bolt immediately after applying adhesive to prevent foreign matter from attaching to it.

    3. Install the bolt to the reverse shift fork shaft.
      GTY1023504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 19.6 N.m (200 kgf/cm, 14 ft.lbf) 

  33. INSTALL SHIFT ARM 
    GTY1023829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the shift arm to the front transaxle case.
  34. INSTALL NO. 3 GEAR SHIFT HEAD 
    1. Install the No. 3 gear shift head to the No. 5 gear shift fork shaft.
      GTY1024210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 5 mm pin punch and a hammer, drive a new slotted spring pin into the No. 3 gear shift head.

      Drive in Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  35. INSTALL NO. 5 GEAR SHIFT FORK SHAFT 
    1. Install the No. 5 gear shift fork shaft to the front transaxle case.
      GTY1024207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the shift arm to the No. 5 gear shift fork shaft.
      GTY1023487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the shift arm pivot to the shift arm.
      GTY1023486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brass bar and a hammer, install a new E-ring to the shift arm pivot.
      GTY1024206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL 3RD AND 4TH SHIFT FORK SHAFT 
    1. Install the No. 2 gear shift head to the 3rd and 4th shift fork shaft.
      GTY1023482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3rd and 4th shift fork shaft to the front transaxle case.
    3. Using a 5 mm pin punch and a hammer, drive a new slotted spring pin into the No. 2 gear shift fork.
      GTY1023481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Drive in Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

    4. Using a 5 mm pin punch and a hammer, drive a new slotted spring pin into the No. 2 gear shift head.
      GTY1023103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape

      Drive in Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

    5. Remove the protective tape.
  37. INSTALL TRANSMISSION OIL SEPARATOR 
    1. Install the transmission oil separator to the front transaxle case with the 2 bolts.
      GTY1023812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

  38. INSTALL TRANSMISSION OIL SEPARATOR 
    1. Install the transmission oil separator to the manual transmission case with the 2 bolts.
      GTY1023843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

  39. INSTALL NO. 1 OIL RECEIVER PIPE 
    1. Install the No. 1 oil receiver pipe to the manual transmission case with the bolt.
      GTY1023844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

      NOTE:

      Do not damage the No. 1 oil receiver pipe.

  40. INSTALL MANUAL TRANSMISSION CASE 
    1. Clean the seal packing attached on the manual transmission case and front transaxle case using a scraper and wire brush. Then remove the oil with non-residue solvent.
      NOTE:

      Do not scratch the fitting surface.

    2. Apply seal packing to the manual transmission case as shown in the illustration.
      GTY1023614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      NOTE:

      Assemble parts within 10 minutes of application. Otherwise, the seal packing must be removed and reapplied.

    3. Using snap ring pliers, keep the snap ring stretched and install the manual transmission case.
      GTY1023472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Make sure that the snap ring is positioned correctly in the bearing groove by checking that the distance between the centers of the snap ring holes are as shown in the illustration.
      GTY1023400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 9.3 mm (0.366 in.)
    5. Install the manual transmission case to the front transaxle case with the 10 bolts.
      GTY1023717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

    6. Install the 8 bolts to the front transaxle case side.
      GTY1024255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

  41. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Apply adhesive to 2 or 3 threads on the end of the reverse idler gear shaft bolt.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      GTY1019142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
      NOTE:

      Make sure to install the bolt immediately after applying adhesive to prevent foreign matter from attaching to it.

    2. Install a new gasket and the reverse idler gear shaft bolt to the manual transmission case.
      GTY1023456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 80 N.m (816 kgf/cm, 59 ft.lbf) 

  42. INSTALL SHIFT DETENT BALL 
    1. Apply adhesive to 2 or 3 threads on the end of the detent ball plug.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      GTY1022643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
      NOTE:

      Make sure to install the plug immediately after applying adhesive to prevent foreign matter from attaching to it.

    2. Using a 6 mm hexagon wrench, install the 4 shift detent balls, 4 shift detent ball compression springs, 4 shift detent ball compression spring seats and 4 detent ball plugs to the front transaxle case.
      GTY1023455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 22.4 N.m (228 kgf/cm, 17 ft.lbf) 

  43. INSTALL MANUAL TRANSMISSION CASE PLUG 
    1. Clean the seal packing attached on the manual transmission case using a scraper and wire brush. Then remove the oil with non-residue solvent or equivalent.
      NOTE:

      Do not scratch the fitting surface.

    2. Apply seal packing to the manual transmission case as shown in the illustration.
      GTY1023236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing

      Seal packing

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      NOTE:

      Assemble parts within 10 minutes of application. Otherwise, the seal packing must be removed and reapplied.

    3. Apply adhesive to 2 or 3 threads on the end of the manual transmission case plug.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      NOTE:

      Make sure to install the plug immediately after applying adhesive to prevent foreign matter from attaching to it.

    4. Using SST and 27 mm straight hexagon, install the manual transmission case plug to the manual transmission case.

      Torque: 55 N.m (561 kgf/cm, 41 ft.lbf) 

  44. INSTALL SHIFT ARM PIVOT O-RING 
    1. Coat a new shift arm pivot O-ring with the MP grease, and install it to the shift and select lever shaft straight pin.
      GTY1023448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL SHIFT AND SELECT LEVER SHAFT STRAIGHT PIN 
    1. Install the spring and shift and select lever shaft straight pin.
      GTY1023698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Press and Hold
      *b Push in the shift and select lever shaft straight pin.
    2. While pressing in the shift and select lever shaft straight pin in as far as it will go, push in the shift and select lever shaft straight pin to install it.
  46. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install a new gasket and the manual transmission filler plug to the manual transmission case.

      Torque: 39.2 N.m (400 kgf/cm, 29 ft.lbf) 

      GTY1023865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL DRAIN PLUG 
    1. Install a new gasket and the drain plug to the manual transmission case.

      Torque: 39.2 N.m (400 kgf/cm, 29 ft.lbf) 

      GTY1024288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL FRONT DRIVE SHAFT OIL SEAL LH 

    Refer to PROCEDURE - Step 3

  49. INSTALL TRANSAXLE CASE OIL SEAL 

    Refer to PROCEDURE - Step 6

  50. INSTALL SHIFT AND SELECT LEVER ASSEMBLY 

    See step  7

  51. INSTALL SHIFT GATE PIN 
    1. Apply adhesive to 2 or 3 threads on the end of the shift gate pin.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      GTY1022673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
      NOTE:

      Make sure to install the pin immediately after applying adhesive to prevent foreign matter from attaching to it.

    2. Install the shift gate pin to the manual transmission case.
      GTY1024197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  52. INSTALL NO. 2 LOCK BALL ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads on the end of the No. 2 lock ball assembly.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      GTY1022667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
      NOTE:

      Make sure to install the lock ball assembly immediately after applying adhesive to prevent foreign matter from attaching to it.

    2. Install the No. 2 lock ball assembly to the manual transmission case.
      GTY1023441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

  53. INSTALL NO. 1 LOCK BALL ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads on the end of the No. 1 lock ball assembly.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      GTY1022667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
      NOTE:

      Make sure to install the lock ball assembly immediately after applying adhesive to prevent foreign matter from attaching to it.

    2. Install the No. 1 lock ball assembly to the manual transmission case.
      GTY1024193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39.2 N.m (400 kgf/cm, 29 ft.lbf) 

  54. INSTALL TRANSMISSION REVOLUTION SENSOR 

    Refer to PROCEDURE - Step 1

  55. INSTALL TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  56. INSTALL NEUTRAL POSITION SWITCH 
    1. Using SST, install a new gasket and the neutral position switch to the manual transmission case.
      • SST: 09816-30010 
      GTY1023905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 40.2 N.m (410 kgf/cm, 30 ft.lbf) 

  57. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Using SST, install a new gasket and the back-up light switch assembly to the manual transmission case.
      GTY1023239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09816-30010 

      Torque: 40.2 N.m (410 kgf/cm, 30 ft.lbf) 

  58. INSTALL SELECTING BELL CRANK ASSEMBLY 

    See step  15

  59. INSTALL CONTROL CABLE BRACKET ASSEMBLY 
    1. Install the control cable bracket assembly to the manual transmission case with the 3 bolts.

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

      GTY1023886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY 

    Refer to PROCEDURE - Step 3

  61. INSTALL CLUTCH RELEASE BEARING PLATE 

    Refer to PROCEDURE - Step 4

  62. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  63. INSPECT CLUTCH PIPE LINE 

    Refer to PROCEDURE - Step 6

  64. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  65. INSTALL RELEASE CYLINDER BLEEDER PLUG 
    1. Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.
      GTY1024293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP 
    1. Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.
      GTY1023888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. INSTALL NO. 1 CLUTCH HOUSING COVER 
    1. Install the No. 1 clutch housing cover to the front transaxle case.
      GTY1023890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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