БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ "MULTIMODE" ПОВТОРНАЯ СБОРКА

PROCEDURE

  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

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

      A012IUPN06
      SST
      09309-37010
      09506-35010

    2. 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 to the front transaxle case.

      A012IOXN06
      SST
      09950-60020   ( 09951-00680 )
      09950-70010   ( 09951-07200 )

  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

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

      A012K83N06
      SST
      09636-20010
      09726-40010

    2. 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 to the manual transmission case.

      A012NCZN06
      SST
      09309-36010
      09950-60020   ( 09951-00730 )
      09950-70010   ( 09951-07100 )
      Tip:

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

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

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

      A012MD0

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

      A012KY2
      Момент затяжки
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }

    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.

      A012GAFC02
      *1 Front Differential Case Rear Plate Washer
      SST
      09564-32011

    4. 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 16 kgf*cm, 9 to 14 in.*lbf)
      Used bearing
      0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 12 in.*lbf)

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

      Front Differential Case Rear Plate Washer Thickness
      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) - -
      Tip:

      • Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

      • Make a memo as the torque values will be needed for adjusting output shaft bearing preload.

    5. Remove the 16 bolts and manual transmission case.

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

  4. INSTALL FRONT OUTPUT SHAFT BEARING

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

      A012HFD
      Note:

      Insert the output shaft cover key into the case groove.

    2. Using SST and a press, install the front output shaft bearing (outer race) to the front transaxle case.

      A012H1UN03
      SST
      09950-60010   ( 09951-00630 )
      09950-70010
      09950-70010

  5. INSTALL REAR OUTPUT SHAFT BEARING

    1. Using SST and a press, install the rear output shaft bearing (outer race) with the rear output shaft bearing shim to the manual transmission case.

      A012GF5N06
      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07200 )
      Tip:

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

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD

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

      A012MD0

    2. Coat the output shaft assembly with gear oil and install it to the front transaxle case.

      A012LRL

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

      A012KY2
      Момент затяжки
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }

    4. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

      A012L78C02
      *1 Rear Output Shaft Bearing Shim
      SST
      09564-32011

    5. 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)
      New Bearing
      4.0 to 6.9 N*m (41 to 70 kgf*cm, 35 to 61 in.*lbf)
      Used Bearing
      2.6 to 4.4 N*m (27 to 45 kgf*cm, 23 to 39 in.*lbf)

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

      Rear Output Shaft Bearing Shim
      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) - -
      Tip:

      Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

    6. Remove the 16 bolts and manual transmission case.

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

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

  7. INSTALL TRANSMISSION CASE GASKET

    1. Using SST and a hammer, install a new transmission case gasket to the manual transmission case.

      A012G86C01
      *a Depth
      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )
      Drive in Depth
      0 to 1.0 mm (0 to 0.0394 in.)

  8. INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY

    1. Install the manual transmission oil separator sub-assembly to the manual transmission case with the 4 bolts.

      A012KUA
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
      Tip:

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

  9. INSTALL TRANSMISSION OIL SEPARATOR

    1. Install the transmission oil separator to the manual transmission case with the 2 bolts.

      A012L7G
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
      Tip:

      Make sure that the tip of the transmission oil separator is inserted into the groove of the transmission case.

  10. INSTALL NO. 1 OIL RECEIVER PIPE

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

      A012G81
      Tip:

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

  11. INSTALL STRAIGHT PIN

    1. Using a plastic hammer, tap in 5 new straight pins to the specified protrusion height.

      A012KAIC02
      *a Depth
      Protrusion Height (A)
      8.5 to 9.5 mm (0.335 to 0.374 in.)
      Protrusion Height (B)
      8.5 to 9.5 mm (0.335 to 0.374 in.)

  12. INSTALL BREATHER PLUG

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

      A012LZGN01
      SST
      09350-30020   ( 09350-07110 )

  13. INSTALL TRANSMISSION OIL SEPARATOR

    1. Install the transmission oil separator to the front transaxle case with the 4 bolts.

      A012N01
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  14. 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.

      A012MONC02
      *a 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.)

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

  15. INSTALL TRANSMISSION MAGNET

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

      A012H1T

  16. INSTALL INPUT SHAFT COVER

    1. Install the input shaft cover to the manual transmission case.

      A012M5D
      Note:

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

  17. INSTALL REAR INPUT SHAFT BEARING SHIM

    1. The rear input shaft bearing shim should be washed before assembly.

      Note:

      Apply grease to the shim to prevent it from falling off from the case during reassembly.

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

      A012IN4C02
      *1 Manual Transmission Case *2 Input Shaft Assembly
      *3 Front Transaxle Case - -
      *a Dimension A *b Dimension B
      *c Dimension C - -

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

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

      Note:

      Measure Dimension C with each bearing having no axial clearance.

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

      Formula
      (Dimension A + Dimension B) - Dimension C - rear input shaft bearing shim thickness = Between 0 mm and 0.14 mm (0.00551 in.)

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

      Rear Input Shaft Bearing Shim Thickness
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      08 1.30 (0.0512) 14 1.60 (0.0630)
      09 1.35 (0.0531) 15 1.65 (0.0650)
      10 1.40 (0.0551) 16 1.70 (0.0669)
      11 1.45 (0.0571) 17 1.75 (0.0689)
      12 1.50 (0.0591) 18 1.80 (0.0709)
      13 1.55 (0.0610) 19 1.85 (0.0728)

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

      Note:

      Do not apply MP grease to the oil grooves.

  18. INSTALL DIFFERENTIAL CASE ASSEMBLY

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

      A012MD0

  19. INSTALL INPUT SHAFT ASSEMBLY

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

    2. Coat the No. 1 gear shift fork shaft assembly with gear oil and install it.

      A012NBOC01
      *1 No. 1 Gear Shift Fork Shaft Assembly

    3. Coat the No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly with gear oil and install them.

      A012KL1C01
      *1 No. 2 Gear Shift Fork Shaft Assembly
      *2 No. 3 Gear Shift Fork Shaft Assembly

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

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

      A012HRD

  20. INSTALL SHIFT INTER LOCK PLATE

    1. Install the shift inter lock plate to the front transaxle case.

      A012JBQ

  21. INSTALL SHIFT AND SELECT LEVER SHAFT

    1. Using a 5 mm pin punch and hammer, install the slotted spring pin and shift and select lever shaft head to the shift and select lever shaft.

      A012LQ3C02
      *a 5 mm Pin Punch
      *b Depth
      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  22. INSTALL INNER SELECT LEVER

    1. Using a 5 mm pin punch and hammer, install the slotted spring pin to the inner select lever.

      A012GXDC02
      *a 5 mm Pin Punch
      *b Depth
      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  23. INSTALL INNER NO. 1 SHIFT LEVER

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

      A012KJTC02
      *a 5 mm Pin Punch *b Depth
      *c Plane - -
      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
      Tip:

      The inner No. 1 shift lever can be installed in either direction.

  24. INSTALL FRONT INNER SHIFT LEVER

    1. Using a 5 mm pin punch and hammer, install the slotted spring pin to the front inner shift lever.

      A012FGRC02
      *a 5 mm Pin Punch
      *b Depth
      Driven in Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
      Note:

      Check the installation direction.

  25. INSTALL INNER NO. 2 SHIFT LEVER

    1. Using a 5 mm pin punch and hammer, install the slotted spring pin to the inner No. 2 shift lever.

      A012I8UC02
      *a 5 mm Pin Punch
      *b Depth
      Driven in Depth
      0 to 0.6 mm (0 to 0.0236 in.)
      Note:

      Check the installation direction.

  26. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY

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

      A012KJD
      Tip:

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

  27. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

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

      A012KLP
      Момент затяжки
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  28. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY

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

      A012N6A

  29. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

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

      A012JXUC03
      *a Parallel
      Note:

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

      Tip:

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

  30. INSTALL MANUAL TRANSMISSION CASE

    1. Apply FIPG to the manual transmission case as shown in the illustration.

      A012MB6C02
      *a FIPG
      *b Seal Diameter 1.2 mm (0.0472 in.)
      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Note:

      • Remove any oil from the contact surfaces.

      • Install the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

    2. Install the 16 bolts to the manual transmission case.

      A012KY2
      Момент затяжки
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }

  31. INSTALL TRANSMISSION CASE OIL SEAL

    Click hereНажмите здесь

  32. INSTALL TRANSAXLE CASE OIL SEAL

    Click hereНажмите здесь

  33. INSTALL SHIFT DETENT BALL

    1. Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.

      A012IU0

    2. Coat the threads of the 2 shift detent ball plugs with sealant.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a 6 mm hexagon socket wrench, install the 2 shift detent ball plugs.

      Момент затяжки
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    4. Install the shift detent ball and shift detent ball compression spring to the manual transmission case.

      A012FLC

    5. Coat the threads of the shift detent ball plug with sealant.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Using a 6 mm hexagon socket wrench, install the shift detent ball plugs.

      Момент затяжки
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT

    1. Coat the threads of the reverse idler gear shaft bolt with sealant.

      A012JVC
      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install a new gasket and the reverse idler gear shaft bolt to the manual transmission case.

      Момент затяжки
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  35. INSTALL TRANSMISSION CASE PLUG

    1. Install a new gasket and the transmission case plug to the manual transmission case.

      A012I7H
      Момент затяжки
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  36. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP

    1. Install the release cylinder bleeder plug cap to the release clutch bleeder plug.

  37. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click hereНажмите здесь

  38. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click hereНажмите здесь

  39. INSPECT CLUTCH PIPE LINE

    Click hereНажмите здесь

  40. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click hereНажмите здесь

  41. INSTALL NO. 1 CLUTCH HOUSING COVER

    1. Install the No. 1 clutch housing cover to the front transaxle case.

  42. INSTALL SHIFT AND SELECT ACTUATOR ASSEMBLY

    1. Install the breather plug cap to the shift and select actuator assembly.

      A012LXJ

    2. Install the breather protector to the shift and select actuator assembly with the bolt.

      A012N9X
      Момент затяжки
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    3. Using a plastic hammer, tap in 2 new ring pins to the specified protrusion height.

      A012HJ5
      Protrusion Height
      5.2 to 5.8 mm (0.205 to 0.228 in.)

    4. Apply FIPG to the shift and select actuator assembly as shown in the illustration.

      A012N8BC04
      *a FIPG
      *b Seal Diameter 1.2 mm (0.0472 in.)
      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Note:

      • Remove any oil from the contact surfaces.

      • Install the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

    5. When replacing the shift and select actuator with a new one:

      1. Move the select inner lever as shown in the illustration.

        A012MSP

      2. Install the shift and select actuator and wire harness clamp bracket to the transaxle case with the 6 bolts.

        A012MBBC03
        *a Shift and Select Lever Shaft Head
        *b Shift Actuator Plate
        *c Select Actuator Plate
        *d Inner Select Lever
        Момент затяжки
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }
        Note:

        • Securely engage the shift actuator plate to the shift and select lever shaft head.

        • Securely engage the select actuator plate to the inner select lever.

    6. When reusing the shift and select actuator:

      1. Install the shift and select actuator to the transaxle case with the 6 bolts.

        A012FP7C03
        *a Shift and Select Lever Shaft Head
        *b Shift Actuator Plate
        *c Select Actuator Plate
        *d Inner Select Lever
        Момент затяжки
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }
        Note:

        • Securely engage the shift actuator plate to the shift and select lever shaft head.

        • Securely engage the select actuator plate to the inner select lever.

  43. INSTALL NEUTRAL POSITION SWITCH

    1. Using a 27 mm deep socket wrench, install a new gasket and the neutral position switch to the manual transmission case.

      A012J9HC02
      *a 27 mm Deep Socket Wrench
      Момент затяжки
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }

  44. INSTALL TRANSMISSION REVOLUTION SENSOR

    1. Install a new O-ring to the transmission revolution sensor.

    2. Install the transmission revolution sensor with the bolt.

      A012F6D
      Момент затяжки
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  45. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

    1. Using a 27 mm deep socket wrench, install a new gasket and the back-up light switch to the manual transmission case.

      A012K6SC03
      *a 27 mm Deep Socket Wrench
      Момент затяжки
      40.2 N*m  { 410 kgf*cm, 30 ft.*lbf }

  46. INSTALL MANUAL TRANSMISSION FILLER PLUG

    1. Install a new gasket and the manual transmission filler plug to the manual transmission case.

      A012HGF
      Момент затяжки
      39.2 N*m  { 400 kgf*cm, 29 ft.*lbf }

  47. INSTALL MANUAL TRANSMISSION DRAIN PLUG

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

      A012KV6
      Момент затяжки
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }