Part 2

C59 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)

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 the 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.

(b) Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
43. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Coat the shift and select lever shaft assembly with gear oil and install it onto the transmission case.
44. INSTALL CONTROL SHAFT COVER OIL SEAL

(a) Using SST and a hammer, install a new control shaft cover oil seal onto the control shaft cover.
SST: 09950-60010
09951-00280
SST: 09950-70010
09951-07150
Driven in depth:
0.2 to 1.2 mm (0.00787 to 0.0472 in.)
(b) Coat the control shaft cover oil seal with MP grease.
45. INSTALL CONTROL SHAFT COVER

(a) Coat the threads of the 4 bolts with sealant. Install a new gasket and the control shaft cover onto the manual transmission case with the 4 bolts.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)
NOTE: Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.

46. INSTALL SHIFT GUIDE PIN

(a) Coat the threads of the shift guide pin with sealant.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the washer and shift guide pin.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
47. INSTALL NO. 1 LOCK BALL ASSEMBLY

(a) 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 Nm (300 kgf-cm, 22 ft-lbf)
48. INSTALL SHIFT LEVER DAMPER

(a) Install the dust boot onto the control shaft cover.
(b) Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.
(c) Install the washer with the nut.
Torque: 12 Nm (120 kgf-cm, 8 ft-lbf)
49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER

(a) Install the dust boot onto the shift and select lever shaft oil seal.
(b) Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.
(c) Install the washer with the nut.
Torque: 12 Nm (120 kgf-cm, 8 ft-lbf)
50. INSTALL SELECTING BELLCRANK ASSEMBLY

(a) Install the selecting bellcrank assembly together with the control bellcrank dust cover onto the manual transmission case with the 2 bolts and nut.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
Torque: 12 Nm (120 kgf-cm, 8 ft-lbf)
NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush.

51. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using SST, install the back-up light switch assembly onto the manual transmission case with a new gasket.
SST: 09817-16011
Torque: 40 Nm (410 kgf-cm, 30 ft-lbf)
(b) Install the back-up light switch wire harness into the 2 clamps.
52. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Install a new O-ring onto the speedometer driven hole cover sub-assembly.

(b) Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)
53. INSTALL MANUAL TRANSMISSION FILLER PLUG

(a) Install the manual transmission filler plug onto the manual transmission case with a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
54. INSTALL DRAIN PLUG SUB-ASSEMBLY

(a) Install the drain plug onto the manual transmission case with a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)