Reassembly Part 1

C59 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY PART 1

REASSEMBLY

1. INSTALL OUTPUT SHAFT COVER

(a) Coat the output shaft cover with MP grease and install it onto the transaxle case.
NOTE: Insert the output shaft cover key into the case groove.

2. INSTALL OUTPUT SHAFT FRONT BEARING

(a) Coat a new output shaft front bearing with gear oil.
(b) Using SST and a press, install it onto the transaxle case.
SST: 09950-60010
09951-00550
SST: 09950-70010
09951-07150
NOTICE:
- Install the new bearing in the correct direction as shown in the illustration.
- When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.

3. INSTALL FRONT TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, install a new front transaxle case oil seal onto the transaxle case.
SST: 09950-60010
09951-00370
SST: 09950-70010
09951-07150
Driven in depth:
15.6 to 16.0 mm (0.6141 to 0.6299 in.)
(b) Coat the lip of the front transaxle case oil seal with MP grease.
4. INSTALL INPUT SHAFT FRONT BEARING

(a) Coat a new input shaft front bearing with gear oil, and using SST and a press, install it onto the transaxle case.
SST: 09950-60010
09951-00420
SST: 09950-70010
09951-07150
Driven in depth:
0 to 0.3 mm (0 to 0.0118 in.)
5. INSTALL SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING

(a) Using SST and a hammer, install a new shift and select lever shaft slide ball bearing onto the manual transmission case.
SST: 09950-60010
09951-00220
SST: 09950-70010
09951-07100
Driven in depth:
0 to 0.5 mm (0 to 0.0197 in.)
6. INSTALL SHIFT AND SELECT LEVER SHAFT OIL SEAL

(a) Using SST, install a new shift and select lever shaft oil seal onto the manual transmission case.
SST: 09950-70010
09951-07150
SST: 09950-60010
09951-00240
Driven in depth:
9.7 to 10.3 mm (0.382 to 0.406 in.)
7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, install a new front differential case front tapered roller bearing (inner race) onto the front differential case.
SST: 09350-32014
09351-32120
SST: 09950-60010
09951-00530

(b) Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the transaxle case.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07150
8. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the differential case.
SST: 09350-32014
09351-32120
SST: 09950-60010
09951-00530

(b) Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with the plate washer onto the manual transmission case.
SST: 09309-36010
SST: 09950-60020
09951-00710
SST: 09950-70010
09951-07150
HINT: Use a plate washer of the same thickness as the removed one.

9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Coat the differential case assembly with gear oil and install it onto the transaxle case.
(b) Install the manual transmission case with the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)

(c) Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
SST: 09564-32011

(d) Using SST and a torque wrench, measure the preload.
SST: 09564-32011
Preload (at starting):
New bearing
0.8 to 1.5 N*m (8 to 16 kgf*cm, 7 to 13 in.*lbf)
Used bearing
0.5 to 0.9 N*m (5 to 10 kgf*cm, 5 to 8 in.*lbf)
If the preload is out of the specification, select a different plate washer.
Plate Washer Thickness:

HINT: The preload changes by approximately 0.3 to 0.4 N*m (3 to 4 kgf*cm, 3 to 4 in.*lbf) per each 0.05 mm (0.0020 in.) change in the plate washer thickness.

(e) Remove the 16 bolts and the manual transmission case.
(f) Remove the differential case assembly from the transaxle case.
10. INSTALL TRANSMISSION CASE OIL SEAL

(a) Using SST and a hammer, install a new transmission case oil seal onto the manual transmission case.
SST: 09316-60011
09316-00011
Driven in depth:
9.6 to 10.2 mm (0.378 to 0.402 in.)
(b) Coat the lip of the front transmission case oil seal with MP grease.
11. INSTALL TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, install a new transaxle case oil seal onto the transaxle case.
SST: 09710-20011
09710-06071
SST: 09950-70010
09951-07150
Driven in depth:
1.6 to 2.2 mm (0.0630 to 0.0866 in.)
(b) Coat the lip of the transaxle case oil seal with MP grease.
12. INSTALL TRANSMISSION MAGNET

(a) Clean the transmission magnet and install it onto the transaxle case.
13. INSTALL BEARING LOCK PLATE

(a) Install the bearing lock plate onto the transaxle case with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)
14. INSTALL NO. 1 OIL RECEIVER PIPE

(a) Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt.
Torque: 17 Nm (175 kgf-cm, 13 ft-lbf)

NOTICE:
- Do not deform the No. 1 oil receiver pipe.
- Install the No. 1 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.

15. INSTALL NO. 2 OIL RECEIVER PIPE

(a) Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt.
Torque: 17 Nm (175 kgf-cm, 13 ft-lbf)

NOTICE:
- Do not deform the No. 2 oil receiver pipe.
- Install the No. 2 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.

16. INSTALL REVERSE RESTRICT PIN ASSEMBLY

(a) Install the reverse restrict pin assembly onto the manual transmission case.
NOTE: Set the reverse restrict pin assembly in the correct direction.

(b) Using a pin punch (dia5 mm) and a hammer, install the slotted spring pin onto the reverse restrict pin assembly.
Drive in depth:
15.5 to 16.5 mm (0.6102 to 0.6496 in.)

(c) Apply sealant to the reverse restrict pin plug.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case.
Torque: 13 Nm (130 kgf-cm, 9 ft-lbf)
17. INSTALL MANUAL TRANSAXLE CASE RECEIVER

(a) Install the manual transaxle case receiver onto the transaxle case with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)
18. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the transaxle case.
19. INSTALL INPUT SHAFT ASSEMBLY

(a) Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.
20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

(a) 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.
HINT: Align the mark on the reverse idler gear shaft with the bolt hole as shown in the illustration.

21. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

(a) Coat the No. 1 gear shift fork and No. 2 gear shift fork with gear oil and install them.

(b) Coat the No. 1 gear shift fork shaft with gear oil and install it.
(c) Apply sealant to the shift fork set bolt.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Install the shift fork set bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)

(e) Using a brass bar and a hammer, install a new shaft snap ring onto the No. 1 gear shift fork shaft.
22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

(a) Coat the 2 shift fork balls with MP grease and install them onto the reverse shift fork.
(b) Install the reverse shift fork onto the No. 3 gear shift fork shaft.

(d) Coat the No. 3 gear shift fork shaft with gear oil and install it.
23. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

(a) Coat the No. 1 gear shift head and No. 2 gear shift fork shaft with gear oil and install them.
NOTE: To avoid interference from the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.

(b) Coat the 2 shift lock bolts with sealant and install them onto the No. 2 gear shift fork and No. 1 shift head.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)
24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Install the reverse shift arm bracket assembly onto the front transaxle case with the 2 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft-lbf)
25. INSTALL MANUAL TRANSMISSION CASE

(a) Apply FIPG to the manual transmission case as shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTE: Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

(b) Install the 13 bolts onto the manual transmission side.
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)

(c) Coat the 3 bolts with sealant and install them onto the manual transaxle side.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
26. INSTALL REVERSE IDLER GEAR SHAFT BOLT

(a) Coat the reverse idler gear shaft bolt with sealant and install it with a new gasket.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
27. INSTALL NO. 2 LOCK BALL ASSEMBLY

(a) Coat the No. 2 lock ball assembly with sealant and install it using a hexagon wrench.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
28. INSTALL SHIFT DETENT BALL

(a) Install the 2 shift detent balls, 2 shift detent ball springs, and 2 shift spring seats onto the manual transmission case.

(b) Coat the threads of the 2 shift detent ball plugs with sealant and install them using a hexagon wrench.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)

(d) Coat the threads of the shift detent ball plug with sealant and install it using a hexagon wrench.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
29. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING

(a) Using a snap ring expander, install a new input shaft rear bearing hole snap ring onto the input shaft.
30. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING

(a) Using a snap ring expander, install a new output shaft rear bearing hole snap ring onto the output shaft.
31. INSTALL SHIFT FORK SHAFT SNAP RING

(a) Using a brass bar and a hammer, install a new shift fork shaft snap ring onto the No. 2 shift fork shaft.
32. INSTALL REAR BEARING RETAINER

(a) Coat the 5 bolts with sealant and install the rear bearing retainer onto the manual transmission case with the 5 bolts.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 27 Nm (280 kgf-cm, 20 ft-lbf)
33. INSTALL 5TH DRIVEN GEAR

(a) Using SST, install the 5th driven gear onto the output shaft.
SST: 09309-12020
34. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

(a) Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.
35. INSTALL 5TH GEAR

(a) Coat the 5th gear with gear oil and install it onto the input shaft.
36. INSTALL NO. 3 SYNCHRONIZER RING

(a) Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.
37. INSTALL NO. 3 TRANSMISSION CLUTCH HUB

(a) Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the No. 3 transmission clutch hub as shown in the illustration.
NOTE: Do not set the 2 shifting key spring openings in the same position.

(b) Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft.
SST: 09636-20010

NOTICE:
- Do not install the No. 3 transmission clutch hub in the wrong direction.
- Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key aligned.
- Check that the 5th gear can rotate smoothly.
- Place a suitable sized wooden block to support the input shaft.

(c) Select a snap ring that will allow minimum axial play.
Clearance:
0.1 mm (0.00394 in.) or less
Snap Ring Thickness:

(d) Using a brass bar and a hammer, install a new snap ring onto the input shaft.
38. INSPECT 5TH GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance:
0.10 to 0.55 mm (0.00394 to 0.0217 in.)
Maximum clearance:
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.
39. INSPECT 5TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance:
NSK made bearing
0.015 to 0.056 mm (0.000591 to 0.00220 in.)
KOYO made bearing
0.015 to 0.058 mm (0.000591 to 0.00228 in.)
Maximum clearance:
NSK made bearing
0.056 mm (0.00220 in.)
KOYO made bearing
0.058 mm (0.00228 in.)
If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.
40. INSTALL NO. 3 GEAR SHIFT FORK

(a) Coat the No. 3 transmission clutch hub sleeve with gear oil and install it together with the No. 3 gear shift fork onto the No. 3 transmission clutch hub.
HINT: Set the No. 3 transmission clutch hub in the correct direction.

(b) Coat the gear shift fork lock bolt with sealant and install it onto the No. 3 gear shift fork.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)
41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT

(a) Engage 2 gears simultaneously to lock the transmission.
(b) Install a new manual transmission output shaft rear set nut.
Torque: 118 Nm (1200 kgf-cm, 87 ft-lbf)

(c) Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
(d) Disengage the 2 gears.
42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY

(a) Apply FIPG to the manual transmission case cover sub-assembly as shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTE: Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.