Part 2

E351 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY CONTINUED
15. INSTALL DIFFERENTIAL CASE ASSEMBLY





(a) Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the manual transaxle case.
16. INSTALL OUTPUT SHAFT ASSEMBLY





(a) Apply gear oil to each sliding part of the output shaft assembly.
(b) Lift the differential case assembly while tilting output shaft assembly, and install it to the manual transaxle case.
17. INSTALL INPUT SHAFT ASSEMBLY





(a) Apply gear oil to each sliding part of the input shaft assembly.
(b) Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.
18. INSTALL NO. 2 GEAR SHIFT FORK





(a) Coat the No. 2 gear shift fork with gear oil, and install it to the input shaft assembly.
19. INSTALL NO. 3 GEAR SHIFT FORK





(a) Install the No. 3 gear shift fork to the No. 3 gear shift fork shaft.
(b) Using a brass bar and a hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft.






(c) Apply gear oil to each sliding part of the No. 3 gear shift fork shaft, and install it to the manual transaxle case.
20. INSTALL NO. 1 GEAR SHIFT FORK





(a) Apply gear oil to each sliding part of the No. 1 gear shift fork, and install it to the output shaft assembly.
21. INSTALL NO. 2 GEAR SHIFT FORK SHAFT





(a) Install the No. 1 gear shift head to the No. 2 gear shift fork shaft.
(b) Apply gear oil to each sliding part of the No. 2 gear shift fork shaft, and install it to the manual transaxle case.





(c) Install the shift fork set bolt and shift head set bolt to the No. 1 gear shift head.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
22. INSTALL REVERSE SHIFT FORK ROLLER





(a) Using a magnetic pick-up tool, install the reverse shift fork roller to the reverse shift fork.
23. INSTALL NO. 1 GEAR SHIFT FORK SHAFT





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





(b) Install the No. 1 gear shift fork shaft to the manual transaxle case.





(c) Install the shift fork set bolt to the No. 1 gear shift fork.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY





(a) Install the reverse shift arm bracket assembly to the manual transaxle case with the 2 bolts.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)
25. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY





(a) Coat the reverse idler gear and reverse idler thrust washer with MP grease, and install them to the reverse idler gear shaft.





(b) Install the reverse idler gear to the manual transaxle case.
HINT: Align the mark of the reverse idler gear shaft with the bolt hole.



26. INSTALL TRANSMISSION MAGNET





(a) Clean the transmission magnet and install it to the manual transaxle case.
27. INSTALL NO. 1 OIL RECEIVER PIPE





(a) Install the No. 1 oil receiver pipe to the manual transmission case with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)
NOTE: Do not damage the pipe.

28. INSTALL NO. 2 OIL RECEIVER PIPE





(a) Install the No. 2 oil receiver pipe to the manual transmission case with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)
NOTE: Do not damage the pipe.

29. INSTALL REVERSE RESTRICT PIN ASSEMBLY





(a) Install the transmission oil baffle and reverse restrict pin with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)





(b) Using a pin punch (dia 5 mm), install the slotted pin to the reverse restrict pin assembly.
Clearance A:
12.5 to 13.5 mm (0.492 to 0.531 in.)





(c) Coat the reverse restrict pin plug with adhesive. Using a hexagon wrench (6 mm), install the manual transmission case.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
30. INSTALL MANUAL TRANSMISSION CASE





(a) Apply a bead of FIPG to the manual transmission case as shown in the illustration.
HINT: Install the manual transmission case within 10 minutes after applying FIPG.





(b) Install the manual transmission case to the manual transaxle case with the 14 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)





(c) Coat the 3 bolts with adhesive.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(d) Install the 3 bolts to the manual transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
31. INSTALL REVERSE IDLER GEAR SHAFT BOLT





(a) Coat the bolt with adhesive. Install a new gasket to the manual transmission case with the bolt.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
32. INSTALL SHIFT FORK SHAFT SNAP RING





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





(b) Using a brass bar and a hammer, install the shift fork shaft snap ring to the No. 2 gear shift fork shaft.
33. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING





(a) Using a snap ring expander, install the input shaft rear bearing shaft snap ring.
34. INSTALL OUTPUT SHAFT REAR BEARING SHIM





(a) Install the output shaft rear bearing shim to the output shaft.
35. INSTALL REAR BEARING RETAINER





(a) Coat the 7 screws with adhesive.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Using a "TORX" socket wrench (T45), install the rear bearing retainer to the manual transmission case with the 7 screws.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)


36. INSTALL 5TH DRIVEN GEAR





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





(a) Coat the 5th gear needle roller bearing with gear oil and install it to the input shaft.
38. INSTALL 5TH GEAR





(a) Coat the 5th gear with gear oil and install it to the input shaft.
39. INSTALL NO. 3 TRANSMISSION CLUTCH HUB





(a) Using SST, install the No. 3 transmission clutch hub to the input shaft.
SST: 09950-30012
09951-03010
09953-03010
09954-03010
NOTE: Align the projection of the synchronizer ring with the hole in the 5th gear.





(b) Install the No. 3 transmission hub sleeve and No. 3 gear shift fork to the No. 3 transmission clutch hub.





(c) Coat the shift fork set bolt with adhesive and install it to the No. 3 gear shift fork.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent





(d) Select a snap ring that will allow minimal axial play. Using a brass bar and a hammer, install the shaft snap ring.
Clearance:
0.1 mm (0.00394 in.) or less
Snap Ring:






40. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT





(a) Engage the 1st and 2nd gears simultaneously.





(b) Install a new manual transmission output shaft rear set nut.
Torque: 123 Nm (1254 kgf-cm, 90 ft-lbf)






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





(a) Apply FIPG to the manual transmission case cover sub-assembly as shown in the installation.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTE: Install the part within 10 minutes after applying packing material (FIPG).





(b) Install the manual transmission case cover sub-assembly to the manual transaxle case with the 10 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
42. INSTALL DRAIN PLUG SUB-ASSEMBLY





(a) Install the drain plug sub-assembly to the manual transmission case with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
43. INSTALL MANUAL TRANSMISSION FILLER PLUG





(a) Install the manual transmission filler plug to the transaxle case with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
44. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY





(a) Coat the shift and select lever shaft assembly with gear oil, and install it to the manual transmission case.
45. INSTALL CONTROL SHAFT COVER





(a) Coat the 4 bolts with adhesive. Install a new gasket and the control shaft cover with the bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY





(a) Install the back-up light switch assembly to the manual transmission case with a new gasket.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
47. INSTALL MANUAL TRANSMISSION BREATHER PLUG





(a) Install the manual transmission breather plug to the manual transmission case.


48. INSTALL SHIFT GATE PIN





(a) Install the shift gate pin to the manual transmission case.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
49. INSTALL NO. 1 LOCK BALL ASSEMBLY





(a) Install the No. 1 lock ball assembly to the manual transmission case.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
50. INSTALL NO. 2 CLUTCH TUBE BRACKET





(a) Install the No. 2 clutch tube bracket with the bolt.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
51. INSTALL CONTROL SHIFT LEVER





(a) Install the control shift lever with the shift outer lever lock pin to the shift and select lever shaft.
(b) Install the spring washer with the nut.
Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
52. INSTALL SELECTING BELLCRANK ASSEMBLY





(a) Coat the 2 bolts with adhesive. Install the selecting bellcrank assembly to the manual transmission case with the bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
53. INSTALL CONTROL CABLE BRACKET





(a) Install the control cable bracket to the manual transaxle case with the 3 bolts.
Torque: 17 Nm (173 kgf-cm, 12 ft-lbf)
54. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Install a new O-ring and the speedometer driven hole cover sub-assembly to the transmission case with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 48 in-lbf)
55. INSTALL CLUTCH RELEASE FORK BOOT
(a) Install the clutch release fork boot to the manual transaxle case.
56. INSTALL RELEASE FORK SUPPORT





(a) Using a deep socket wrench, install the release fork support to the manual transaxle case.
Torque: 47 Nm (480 kgf-cm, 36 ft-lbf)
57. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
(a) Coat the clutch release bearing assembly with release hub grease, and install it to the clutch release fork sub-assembly.
Sealant:
Toyota Genuine Release Hub Grease or equivalent
(b) Apply clutch spline grease to the input shaft spline.
58. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY





(a) Install the clutch release fork sub-assembly to the input shaft.