Part 2

E351 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

Part 2

24. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

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

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

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

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

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

27. INSTALL TRANSAXLE MAGNET
(a) Clean the transaxle magnet, and install it to the transaxle case.
28. 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) Install the reverse restrict pin to the transaxle case.
(c) Using a 5 mm pin punch and hammer, tap in the slotted spring pin.
Standard clearance:
12.5 to 13.5 mm (0.492 to 0.531 in.)

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

29. INSTALL NO. 1 OIL RECEIVER PIPE
(a) Install the oil receiver pipe to the transaxle case with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)
NOTICE: Do not damage the pipe.

30. INSTALL NO. 2 OIL RECEIVER PIPE
(a) Install the oil receiver pipe to the transaxle case with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)
NOTICE: Do not damage the pipe.

31. INSTALL MANUAL TRANSMISSION CASE

(a) Apply seal packing to the transaxle case in a continuous line, as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE: Install the part within 10 minutes after applying packing material.

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

(c) Coat the 3 bolts with adhesive, and install them on the transaxle case side.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
32. INSTALL CLUTCH TUBE BRACKET
(a) Install the clutch tube bracket with the bolt.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)

33. INSTALL REVERSE IDLER GEAR SHAFT BOLT
(a) Coat the reverse idler gear shaft bolt with adhesive, and install a new reverse idler gear shaft gasket and the reverse idler gear shaft bolt to the transaxle case.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
34. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING

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

(b) Using a brass bar and hammer, tap in the shaft snap ring to the No. 2 gear shift fork shaft.

35. INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING
(a) Using a snap ring expander, install the shaft snap ring.

36. INSTALL OUTPUT SHAFT REAR BEARING SHIM
(a) Install the output shaft rear bearing shim to the output shaft.

37. INSTALL REAR BEARING RETAINER
(a) Coat the 7 bolts with adhesive. Using a T45 "TORX" socket, install the bearing retainer with the bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

38. INSTALL 5TH DRIVEN GEAR
(a) Using SST, install the 5th driven gear to the output shaft.
SST: 09309-12020

39. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
(a) Coat the needle roller bearing with gear oil, and install it to the input shaft.

40. INSTALL 5TH GEAR
(a) Coat the 5th gear with gear oil, and install it to the input shaft.
41. INSTALL NO. 3 TRANSAXLE CLUTCH HUB

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

(b) Install the No. 3 transaxle hub sleeve and No. 3 gear shift fork to the No. 3 transaxle 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 an appropriate No. 3 transaxle clutch hub shaft snap ring that allows the minimum amount of axial play. Using a brass bar and hammer, tap in the No. 3 transaxle clutch hub shaft snap ring.
Standard clearance:
0.1 mm (0.004 in.) or less
Standard snap ring:

42. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance:
0.009 to 0.050 mm (0.0004 to 0.0020 in.)
If the clearance is out of the specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.

43. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance:
0.10 to 0.65 mm (0.0039 to 0.0260 in.)
If the clearance is out of the specification, replace the No. 3 transaxle clutch hub, 5th gear or input shaft rear radial ball bearing.
44. INSTALL TRANSAXLE OUTPUT SHAFT REAR SET NUT

(a) Engage the 2 gears simultaneously to lock the transaxle.

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

(c) Using a chisel and hammer, stake the rear set nut.
(d) Disengage the 2 gears.
45. INSTALL MANUAL TRANSAXLE CASE COVER SUB-ASSEMBLY

(a) Apply seal packing to the transaxle case cover, as shown in the illustration.
Seal packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE: Install the part within 10 minutes after applying packing material.

(b) Install the transaxle case cover to the transaxle case with the 10 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)

46. INSTALL DRAIN PLUG SUB-ASSEMBLY
(a) Install a new gasket and the drain plug to the transaxle case.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

47. INSTALL MANUAL TRANSMISSION FILLER PLUG
(a) Install a new gasket and the filler plug to the transaxle case.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

48. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
(a) Coat the shift and select lever shaft with gear oil, and install it to the transaxle case.

49. INSTALL CONTROL SHAFT COVER
(a) Coat the 4 bolts with adhesive, and install a new gasket and the control shaft cover with the 4 bolts.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)

50. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY
(a) Install a new gasket and the back-up light switch to the manual transaxle case.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)

51. INSTALL SHIFT GATE PIN
(a) Install a new gasket and shift gate pin to the case.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)

52. INSTALL NO. 1 LOCK BALL ASSEMBLY
(a) Install the No. 1 lock ball to the transaxle case.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)

53. 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)

54. INSTALL SELECTING BELLCRANK ASSEMBLY
(a) Install the shift and select lever bush to the selecting bellcrank.
(b) Coat the 2 bolts with adhesive, and install the selecting bellcrank to the transaxle case with the bolts.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
55. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Install a new O-ring to the hole cover.
(b) Install the hole cover to the transaxle case with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)