MANUAL TRANSAXLE UNIT > REASSEMBLY

for Preparation Click here



1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING


    C193768E01

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

    SST
    09309-37010  
    09506-35010  



    C198659E01

  1. Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer onto the front transaxle case.

    SST
    09950-60020   (09951-00680)
    09950-70010   (09951-07200)



2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING


    C193769E01

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

    SST
    09309-37010  
    09726-40010  



    C198670E01

  1. Using SST and a press, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer onto the manual transmission case.
    Text in Illustration 
    *1
    		Front differential case rear tapered roller bearing (outer race)
    *2
    		Front differential case rear plate washer

    SST
    09950-60020   (09951-00730)
    09950-70010   (09951-07100)

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



3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    C198656

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



    C198635

  1. Install the manual transmission case with the 16 bolts.

    Torque:
    29 N*m{ 300 kgf*cm , 22 ft.*lbf }



    C198688E01

  1. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
    Text in Illustration 
    *1
    		Front differential case rear plate washer

    SST
    09564-32011  

  1. Using SST and a torque wrench, measure the preload.

    SST
    09564-32011  

    Preload (at starting):
    New bearing:
    1.0 to 1.6 N*m (10 to 17 kgf*cm, 9 to 14 in.*lbf)
    Used bearing:
    0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 11 in.*lbf)

    If the preload is out of specification, select a front differential case rear plate washer.

    Plate Washer Thickness:
    Previous Version:
    Mark
    		Thickness
    mm (in.)
    		Mark
    		Thickness
    mm (in.)
    0
    		2.100 (0.0827)
    		G
    		2.500 (0.0984)
    1
    		2.125 (0.0837)
    		H
    		2.525 (0.0994)
    2
    		2.150 (0.0846)
    		J
    		2.550 (0.1004)
    3
    		2.175 (0.0856)
    		K
    		2.575 (0.1014)
    4
    		2.200 (0.0866)
    		L
    		2.600 (0.1024)
    5
    		2.225 (0.0876)
    		M
    		2.625 (0.1033)
    6
    		2.250 (0.0886)
    		N
    		2.650 (0.1043)
    7
    		2.275 (0.0896)
    		P
    		2.675 (0.1053)
    8
    		2.300 (0.0906)
    		Q
    		2.700 (0.1063)
    9
    		2.325 (0.0915)
    		R
    		2.725 (0.1073)
    A
    		2.350 (0.0925)
    		S
    		2.750 (0.1083)
    B
    		2.375 (0.0935)
    		T
    		2.775 (0.1093)
    C
    		2.400 (0.0945)
    		U
    		2.800 (0.1102)
    D
    		2.425 (0.0955)
    		V
    		2.825 (0.1112)
    E
    		2.450 (0.0965)
    		W
    		2.850 (0.1122)
    F
    		2.475 (0.0974)
    		-
    		-
    New Version:
    Mark
    		Thickness
    mm (in.)
    		Mark
    		Thickness
    mm (in.)
    10
    		2.100 (0.0827)
    		26
    		2.500 (0.0984)
    11
    		2.125 (0.0837)
    		27
    		2.525 (0.0994)
    12
    		2.150 (0.0846)
    		28
    		2.550 (0.1004)
    13
    		2.175 (0.0856)
    		29
    		2.575 (0.1014)
    14
    		2.200 (0.0866)
    		30
    		2.600 (0.1024)
    15
    		2.225 (0.0876)
    		31
    		2.625 (0.1033)
    16
    		2.250 (0.0886)
    		32
    		2.650 (0.1043)
    17
    		2.275 (0.0896)
    		33
    		2.675 (0.1053)
    18
    		2.300 (0.0906)
    		34
    		2.700 (0.1063)
    19
    		2.325 (0.0915)
    		35
    		2.725 (0.1073)
    20
    		2.350 (0.0925)
    		36
    		2.750 (0.1083)
    21
    		2.375 (0.0935)
    		37
    		2.775 (0.1093)
    22
    		2.400 (0.0945)
    		38
    		2.800 (0.1102)
    23
    		2.425 (0.0955)
    		39
    		2.825 (0.1112)
    24
    		2.450 (0.0965)
    		40
    		2.850 (0.1122)
    25
    		2.475 (0.0974)
    		-
    		-

    HINT:
    1. Select a thicker plate washer to increase the preload; a thinner plate washer to decrease the preload
    2. Underlines are stamped to distinguish between marks "6" and "9".
    3. Make a memo as the torque values will be needed for Output Shaft Bearing Preload.

  1. Remove the 16 bolts and the manual transmission case.

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



4. INSTALL OUTPUT SHAFT COVER


    C198662

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

    NOTICE:
    Insert the output shaft cover key into the case groove.



5. INSTALL FRONT OUTPUT SHAFT BEARING


    C198661E01

  1. Using SST and a press, install the front output shaft bearing (outer race) onto the front transaxle case.
    Text in Illustration 
    *1
    		Front output shaft bearing (outer race)
    *2
    		Output shaft cover

    SST
    09950-60010   (09951-00630)
    09950-70010   (09951-07100)



6. INSTALL REAR OUTPUT SHAFT BEARING


    C198679E01

  1. Using SST and a press, install the rear output shaft bearing (outer race) with the rear output shaft bearing shim onto the manual transmission case.
    Text in Illustration 
    *1
    		Rear output shaft bearing (outer race)
    *2
    		Rear output shaft bearing shim

    SST
    09950-60010   (09951-00590)
    09950-70010   (09951-07200)



7. ADJUST OUTPUT SHAFT BEARING PRELOAD


    C198656

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



    C198690

  1. Coat the output shaft assembly with gear oil and install it onto the front transaxle case.



    C198635

  1. Install the manual transmission case with the 16 bolts.

    Torque:
    29 N*m{ 300 kgf*cm , 22 ft.*lbf }



    C198689E01

  1. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
    Text in Illustration 
    *1
    		Rear output shaft bearing shim

    SST
    09564-32011  

  1. Using SST and a torque wrench, measure the preload. Calculate the rear output shaft bearing shim value using the following formula.

    SST
    09564-32011  

    Formula:
    (Differential side bearing preload + Output shaft bearing preload) - Differential side bearing preload = Output shaft bearing preload


    Preload (at starting):
    Standard New bearing 
    Final Gear Combination
    		Differential Ratio
    		Specified Condition
    68/21
    		3.238
    		3.3 to 5.6 N*m (34 to 57 kgf*cm, 29 to 50 in.*lbf)
    Standard Used bearing 
    Final Gear Combination
    		Differential Ratio
    		Specified Condition
    68/21
    		3.238
    		2.1 to 3.6 N*m (21 to 37 kgf*cm, 19 to 32 in.*lbf)

    If the preload is out of specification, select a rear output shaft bearing shim.

    Plate Washer Thickness:
    Previous Version:
    Mark
    		Thickness
    mm (in.)
    		Mark
    		Thickness
    mm (in.)
    33
    		1.750 (0.0689)
    		J
    		2.300 (0.0906)
    22
    		1.775 (0.0699)
    		K
    		2.325 (0.0915)
    11
    		1.800 (0.0709)
    		L
    		2.350 (0.0925)
    00
    		1.825 (0.0719)
    		M
    		2.375 (0.0935)
    0
    		1.850 (0.0728)
    		N
    		2.400 (0.0945)
    1
    		1.875 (0.0738)
    		P
    		2.425 (0.0955)
    2
    		1.900 (0.0748)
    		Q
    		2.450 (0.0965)
    3
    		1.925 (0.0758)
    		R
    		2.475 (0.0974)
    4
    		1.950 (0.0768)
    		S
    		2.500 (0.0984)
    5
    		1.975 (0.0778)
    		T
    		2.525 (0.0994)
    6
    		2.000 (0.0787)
    		U
    		2.550 (0.1004)
    7
    		2.025 (0.0797)
    		V
    		2.575 (0.1014)
    8
    		2.050 (0.0807)
    		W
    		2.600 (0.1024)
    9
    		2.075 (0.0817)
    		X
    		2.625 (0.1033)
    A
    		2.100 (0.0827)
    		Y
    		2.650 (0.1043)
    B
    		2.125 (0.0837)
    		Z
    		2.675 (0.1053)
    C
    		2.150 (0.0846)
    		ZZ
    		2.700 (0.1063)
    D
    		2.175 (0.0856)
    		YY
    		2.725 (0.1073)
    E
    		2.200 (0.0866)
    		XX
    		2.750 (0.1083)
    F
    		2.225 (0.0876)
    		WW
    		2.775 (0.1093)
    G
    		2.250 (0.0886)
    		VV
    		2.800 (0.1102)
    H
    		2.275 (0.0896)
    		-
    		-
    New Version:
    Mark
    		Thickness
    mm (in.)
    		Mark
    		Thickness
    mm (in.)
    50
    		1.750 (0.0689)
    		72
    		2.300 (0.0906)
    51
    		1.775 (0.0699)
    		73
    		2.325 (0.0915)
    52
    		1.800 (0.0709)
    		74
    		2.350 (0.0925)
    53
    		1.825 (0.0719)
    		75
    		2.375 (0.0935)
    54
    		1.850 (0.0728)
    		76
    		2.400 (0.0945)
    55
    		1.875 (0.0738)
    		77
    		2.425 (0.0955)
    56
    		1.900 (0.0748)
    		78
    		2.450 (0.0965)
    57
    		1.925 (0.0758)
    		79
    		2.475 (0.0974)
    58
    		1.950 (0.0768)
    		80
    		2.500 (0.0984)
    59
    		1.975 (0.0778)
    		81
    		2.525 (0.0994)
    60
    		2.000 (0.0787)
    		82
    		2.550 (0.1004)
    61
    		2.025 (0.0797)
    		83
    		2.575 (0.1014)
    62
    		2.050 (0.0807)
    		84
    		2.600 (0.1024)
    63
    		2.075 (0.0817)
    		85
    		2.625 (0.1033)
    64
    		2.100 (0.0827)
    		86
    		2.650 (0.1043)
    65
    		2.125 (0.0837)
    		87
    		2.675 (0.1053)
    66
    		2.150 (0.0846)
    		88
    		2.700 (0.1063)
    67
    		2.175 (0.0856)
    		89
    		2.725 (0.1073)
    68
    		2.200 (0.0866)
    		90
    		2.750 (0.1083)
    69
    		2.225 (0.0876)
    		91
    		2.775 (0.1093)
    70
    		2.250 (0.0886)
    		92
    		2.800 (0.1102)
    71
    		2.275 (0.0896)
    		-
    		-

    HINT:
    1. Select a thicker plate washer to increase the preload; a thinner plate washer to decrease the preload
    2. Underlines are stamped to distinguish between marks "6" and "9".

  1. Remove the 16 bolts and the manual transmission case.

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

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



8. INSTALL BREATHER PLUG


    C198685E01

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

    SST
    09350-30020   (09350-07110)



9. INSTALL OUTER SHIFT LEVER OIL SEAL


    C198683E01

  1. Using SST and a hammer, install a new outer shaft lever oil seal onto the manual transmission case.
    Text in Illustration 
    *1
    		Drive in depth

    SST
    09950-60010   (09951-00260)
    09950-70010   (09951-07100)

    Driven in depth:
    0.5 to 1.0 mm (0.0197 to 0.0394 in.)

  1. Coat the lip of the outer shaft lever oil seal with MP grease.



10. INSTALL OUTER NO. 1 SHIFT LEVER


    C198680E01

  1. Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever onto the manual transmission case.
    Text in Illustration 
    *1
    		Driven in depth
    *2
    		Inner slotted spring pin

    Driven in depth:
    -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

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

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



11. INSTALL NO. 2 TRANSMISSION OIL SEPARATOR


    C198677

  1. Install the No. 2 transmission oil separator with the 2 bolts.

    Torque:
    17 N*m{ 173 kgf*cm , 13 ft.*lbf }



12. INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY


    C198675

  1. Install the manual transmission oil separator sub-assembly onto the manual transmission case with the bolt.

    Torque:
    17 N*m{ 173 kgf*cm , 13 ft.*lbf }

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



13. INSTALL NO. 1 TRANSMISSION OIL SEPARATOR


    C198674

  1. Install the No. 1 transmission oil separator onto the manual transmission case with the 2 bolts.

    Torque:
    17 N*m{ 173 kgf*cm , 13 ft.*lbf }

    HINT:
    Make sure that the tip of the transmission oil separator is inserted in the groove of the transmission case.



14. INSTALL NO. 1 OIL RECEIVER PIPE


    C198673

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

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



15. INSTALL STRAIGHT PIN


    C198668E01

  1. Using a plastic-faced hammer, tap in 4 new straight pins to the specified protrusion height.
    Text in Illustration 
    *1
    		Protrusion height

    Protrusion height:
    8.5 to 9.5 mm (0.335 to 0.374 in.)



16. INSTALL REVERSE RESTRICT PIN ASSEMBLY


    C198666

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



17. INSTALL TRANSMISSION OIL SEPARATOR


    C198657

  1. Install the transmission oil separator onto the front transaxle case with the 3 bolts.

    Torque:
    17 N*m{ 173 kgf*cm , 13 ft.*lbf }



18. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    C198663E01

  1. Using SST and a hammer, install a new front transaxle case oil seal onto the front transaxle case.
    Text in Illustration 
    *1
    		Drive in depth

    SST
    09950-60010   (09951-00350)
    09950-70010   (09951-07100)

    Driven in depth:
    0.9 to 1.9 mm (0.0354 to 0.0748 in.)

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



19. INSTALL TRANSMISSION MAGNET


    C198655

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



20. INSTALL INPUT SHAFT COVER


    C198672

  1. Install the output shaft cover onto the manual transmission case.

    NOTICE:
    Insert the output shaft cover key into the manual transmission case groove.



21. INSTALL REAR INPUT SHAFT BEARING SHIM


    C194661E02

  1. Rear input shaft bearing shim should be washed before assembly.

    NOTICE:
    Apply grease allowed on shim, (to avoid) falling shim off, from case during assembly.

    Text in Illustration 
    *1
    		Manual transmission case
    *2
    		Input shaft assembly
    *3
    		Front transaxle case
    *4
    		Dimension A
    *5
    		Dimension B
    *6
    		Dimension C

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

  1. Measure the area between the end of the front transaxle case and the installation surface of the front input shaft bearing (Dimension B).

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

    NOTICE:
    Measure Dimension C with each bearing having no axial clearance.

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

    Formula:
    (Dimension A + Dimension C) - Dimension B - rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

    If the thickness is out of specification, select a rear output shaft bearing shim.

    Rear Input Shaft Bearing Shim Thickness:
    Previous Version:
    Mark
    		Thickness
    mm (in.)
    		Mark
    		Thickness
    mm (in.)
    G
    		1.40 (0.0551)
    		P
    		1.75 (0.0689)
    H
    		1.45 (0.0571)
    		Q
    		1.80 (0.0709)
    J
    		1.50 (0.0591)
    		R
    		1.85 (0.0728)
    K
    		1.55 (0.0610)
    		S
    		1.90 (0.0748)
    L
    		1.60 (0.0630)
    		T
    		1.95 (0.0768)
    M
    		1.65 (0.0650)
    		U
    		2.00 (0.0787)
    N
    		1.70 (0.0669)
    		V
    		2.05 (0.0807)
    New Version:
    Mark
    		Thickness
    mm (in.)
    		Mark
    		Thickness
    mm (in.)
    08
    		1.30 (0.0512)
    		16
    		1.70 (0.0669)
    09
    		1.35 (0.0531)
    		17
    		1.75 (0.0689)
    10
    		1.40 (0.0551)
    		18
    		1.80 (0.0709)
    11
    		1.45 (0.0571)
    		19
    		1.85 (0.0728)
    12
    		1.50 (0.0591)
    		20
    		1.90 (0.0748)
    13
    		1.55 (0.0610)
    		21
    		1.95 (0.0768)
    14
    		1.60 (0.0630)
    		22
    		2.00 (0.0787)
    15
    		1.65 (0.0650)
    		23
    		2.05 (0.0807)



    C198671

  1. Coat the rear input shaft bearing shim with MP grease and install it onto the manual transmission case.

    NOTICE:
    Do not apply MP grease to the oil grooves.



22. INSTALL DIFFERENTIAL CASE ASSEMBLY


    C198656

  1. Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.



23. INSTALL INPUT SHAFT ASSEMBLY

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



    C200825E01

  1. Coat the No. 1 gear shift fork shaft with gear oil and install it.
    Text in Illustration 
    *1
    		No. 1 gear shift fork shaft
    *2
    		Output shaft assembly



    C200824E01

  1. Coat the No. 2 gear shift fork shaft and No. 3 gear shift fork shaft with gear oil and install them.
    Text in Illustration 
    *1
    		No. 2 gear shift fork shaft
    *2
    		No. 3 gear shift fork shaft
    *3
    		Input shaft assembly

  1. Provisionally install the output shaft, input shaft and 3 gear shift fork shafts, and tie them with a rope or string.



    C200823

  1. Install the input shaft assembly, output shaft assembly and 3 gear shift fork shaft assemblies from the front transaxle case.



24. INSTALL OUTER SELECT LEVER OIL SEAL


    C198651E01

  1. Using SST and a hammer, install a new outer select lever oil seal onto the front transaxle case.
    Text in Illustration 
    *1
    		Drive in depth

    SST
    09950-60010   (09951-00240)
    09950-70010   (09951-07100)

    Driven in depth:
    0.5 to 1.0 mm (0.0197 to 0.0394 in.)

  1. Coat the lip of the outer select lever oil seal with MP grease.



25. INSTALL OUTER SELECT LEVER


    C198649E01

  1. Install the outer select lever and inner select lever onto the front transaxle case.
    Text in Illustration 
    *1
    		Inner select lever
    *2
    		Outer select lever

    HINT:
    Install the lever with its mark positioned outside of the front transaxle case.



    C198648

  1. Coat the threads of the inner select lever set bolt with sealant and install them using a socket hexagon 6 mm.

    Sealant:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }



26. INSTALL SHIFT INTER LOCK PLATE


    C198647

  1. Install the shift inter lock plate.



27. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY


    C200826

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

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



28. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY


    C200828

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

    Torque:
    17 N*m{ 173 kgf*cm , 13 ft.*lbf }



29. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY


    C198752

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



30. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY


    C200822E01

  1. Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.
    Text in Illustration 
    *1
    		Parallel

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

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



31. INSTALL MANUAL TRANSMISSION CASE


    C198644E01

  1. Apply FIPG to the manual transmission case as shown in the illustration.
    Text in Illustration 
    *1
    		Seal diameter 1.2 mm (0.0472 in.)

    FIPG:
    Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    NOTICE:
    1. Remove any oil from the contact surfaces.
    2. Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.



    C198638

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

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



    C198639

  1. Pull the outer No. 1 shift lever counterclockwise and turn the outer No. 1 shift lever.



    C198635

  1. Install the 16 bolts onto the manual transmission case.

    Torque:
    29 N*m{ 300 kgf*cm , 22 ft.*lbf }



32. INSTALL OUTER SHIFT LEVER E RING


    C198634

  1. Install the outer shift lever E ring onto the outer No. 1 shift lever.



33. INSTALL TRANSMISSION CASE OIL SEAL


C195374E01

  1. Coat the lip of a new oil seal with MP grease.

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

    SST
    09316-60011   (09316-00011)
    Text in Illustration 
    *1
    		Installation depth

    Installation depth:
    10.6 to 11.6 mm (0.417 to 0.457 in.)

    NOTICE:
    Do not damage the oil seal lip.



34. INSTALL TRANSAXLE CASE OIL SEAL


C195375E01

  1. Coat the lip of a new oil seal with MP grease.

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

    SST
    09630-24014   (09620-24051)
    09950-60010   (09951-00410, 09951-00520, 09952-06010)
    09950-70010   (09951-07100)
    Text in Illustration 
    *1
    		Installation depth

    Installation depth:
    1.4 to 2.4 mm (0.055 to 0.094 in.)

    NOTICE:
    Do not damage the oil seal lip.



35. INSTALL SHIFT DETENT BALL


    C198632E02

  1. Install the 2 shift detent balls and 2 shift detent ball compression springs onto the manual transmission case.
    Text in Illustration 
    *1
    		Sealant

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

    Sealant:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    Torque:
    22 N*m{ 224 kgf*cm , 16 ft.*lbf }



    C198630E01

  1. Install the shift detent ball and shift detent ball compression spring onto the manual transmission case.
    Text in Illustration 
    *1
    		Sealant

  1. Coat the threads of the shift detent ball plug with sealant and install it using a socket hexagon 6 mm.

    Sealant:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    Torque:
    22 N*m{ 224 kgf*cm , 16 ft.*lbf }



36. INSTALL LOCK BALL PIN


    C198628E01

  1. Install the lock ball pin and compression spring onto the manual transmission case.
    Text in Illustration 
    *1
    		Sealant

  1. Coat the threads of the shift detent ball plug with sealant and install it using a socket hexagon 10 mm.

    Sealant:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    Torque:
    25 N*m{ 250 kgf*cm , 18 ft.*lbf }

    NOTICE:
    Be careful not to drop the ball pin into the manual transmission case.



37. INSTALL REVERSE IDLER GEAR SHAFT BOLT


    C198627E01

  1. Coat the reverse idler gear shaft bolt and install it with a new gasket.
    Text in Illustration 
    *1
    		Sealant

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }



38. INSTALL NO. 1 LOCK BALL ASSEMBLY


    C198625

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

    Sealant:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    Torque:
    29 N*m{ 300 kgf*cm , 22 ft.*lbf }



39. INSTALL TRANSMISSION CASE PLUG


    C198623

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

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }



    C198624

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

    Torque:
    40 N*m{ 410 kgf*cm , 30 ft.*lbf }



40. INSTALL NO. 1 TRANSMISSION CASE PLUG

  1. Using a 30 mm socket wrench, install the No. 1 transmission case plug.

    Torque:
    65 N*m{ 663 kgf*cm , 48 ft.*lbf }



41. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

  1. Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.



    C195359

  1. Temporarily tighten the bleeder clutch release tube onto the clutch release with bearing cylinder assembly.



    C195361

  1. Install the new clutch release with the bearing cylinder assembly with 3 new bolts.

    NOTICE:
    1. The clutch release with bearing cylinder assembly and installation bolts cannot be reused and must be replaced with new ones.
    2. Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder assembly fits securely with the transaxle during installation. The first bolt should be tightened by hand the clutch release with bearing cylinder assembly.
    3. Ensure that none of the clutch disc spline grease adheres to the clutch release with bearing cylinder assembly.
    4. The clutch release with bearing cylinder assembly cannot be disassembled.

    Torque:
    23 N*m{ 229 kgf*cm , 17 ft.*lbf }

  1. Install the clutch tube boot onto the transaxle.

  1. Install the release cylinder bleeder plug onto the clutch release bleeder.

    Torque:
    8.4 N*m{ 86 kgf*cm , 74 in.*lbf }

  1. Install the release cylinder bleeder plug cap.



    C195353E01

  1. Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.
    Text in Illustration 
    *1
    		Bleeder clutch release tube
    *2
    		Clutch release bleeder

  1. Temporarily tighten the 2 bolts and install the clutch release bleeder.



    C203690

  1. Using a union nut wrench 10 mm, install the bleeder clutch release tube onto the clutch release with bearing cylinder assembly.

    Torque:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).



42. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


C195353

  1. Separate the bleeder clutch release tube from the clutch release bleeder.

  1. Remove the 2 bolts and the clutch release bleeder.



43. INSPECT CLUTCH PIPE LINE


C195354E01

  1. Using SST, apply pressure of 0.1 MPa to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

    SST
    09992-00242  
    If the pressure drops, replace the bleeder clutch release tube.



44. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


C195353E01
Text in Illustration 
*1
Bleeder clutch release tube
*2
Clutch release bleeder

  1. Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.

  1. Install the 2 bolts and clutch release bleeder.

    Torque:
    17 N*m{ 170 kgf*cm , 12 ft.*lbf }

  1. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

    Torque:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).



45. INSTALL NO. 1 CLUTCH HOUSING COVER


C195363

  1. Install the No. 1 clutch housing cover onto the transaxle.



46. INSTALL WIRE HARNESS CLAMP BRACKET


    C195401

  1. Install the wire harness clamp bracket with a bolt as shown in the illustration.

    Torque:
    13 N*m{ 130 kgf*cm , 9 ft.*lbf }



    C195444

  1. Install the wire harness clamp bracket for back up light switch with a bolt as shown in the illustration.

    Torque:
    13 N*m{ 130 kgf*cm , 9 ft.*lbf }



47. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    C195443E01

  1. Using SST, install the back-up light switch and a new gasket onto the manual transmission case.

    SST
    09817-16011  

    Torque:
    40 N*m{ 410 kgf*cm , 30 ft.*lbf }



    C198727

  1. Connect the back up light switch wire harness with the 3 clamps.



48. INSTALL MANUAL TRANSMISSION FILLER PLUG


    C195440

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

    Torque:
    39 N*m{ 400 kgf*cm , 29 ft.*lbf }



49. INSTALL MANUAL TRANSMISSION DRAIN PLUG


    C195441

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

    Torque:
    45 N*m{ 459 kgf*cm , 33 ft.*lbf }