Part 1

E350 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: INSTALLATION

1. INSTALL SYNCHRONIZER PULL RING

(a) Install the No. 5 synchronizer ring middle, No. 5 synchronizer ring outer and synchronizer pull ring to the No. 5 synchronizer ring inner. Using a screwdriver, secure them in place with the synchronizer pull ring snap ring.

2. INSPECT NO. 5 SYNCHRONIZER RING MIDDLE

(a) Check that the No. 5 synchronizer ring middle rotates smoothly.

(b) Check that the No. 5 synchronizer ring middle does not rotate while being pushed against the No. 3 clutch hub.

3. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY SPRING

(a) Install the No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.

NOTICE:

Align the projection of the shifting key spring with the hole of the No. 3 clutch hub and install it.

(b) Install the synchronizer ring set and No. 3 synchromesh shifting key spring to the No. 3 transmission clutch hub.

NOTICE:

* Engage the shifting key spring claw to the center of the teeth of the synchronizer ring.

* Align the projection of the shifting key spring with the hole of the No. 3 clutch hub.

4. INSTALL FRONT TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, install a new front transaxle case oil seal.

SST : 09608-10010

SST : 09950-70010

09951-07200

Standard depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

(b) Coat the lip of the oil seal with MP grease.

5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Install the front differential oil baffle.

NOTICE:

Insert the front differential oil baffle key into the transaxle case groove.

(b) Using SST and a hammer, tap in a front tapered roller bearing (outer race) to the front transaxle case.

SST : 09950-60020

09951-00910

SST : 09950-70010

09951-07100

09951-07150

(c) Using SST and a press, press in a front tapered roller bearing to the front differential case.

SST : 09950-70010

09951-07100

09951-07150

SST : 09608-10010

6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Install the rear shim.

(b) Using SST and a hammer, tap in a rear tapered roller bearing (outer race).

SST : 09950-60020

09951-00890

SST : 09950-70010

09951-07100

(c) Using SST and a press, press in a rear tapered roller bearing to the front differential case.

SST : 09631-12090

SST : 09950-60010

09951-00600

SST : 09950-70010

09951-07100

7. INSTALL TRANSMISSION CASE OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal to the transmission case.

SST : 09608-32010

SST : 09950-70010

09951-07150

Standard depth:

3.0 to 4.0 mm (0.118 to 0.158 in.)

(b) Coat the oil seal lip with MP grease.

8. INSTALL OUTPUT SHAFT REAR BEARING OUTER RACE

(a) Using SST and a hammer, tap in a output shaft rear bearing outer race to the transmission case.

SST : 09950-60020

09951-00680

SST : 09950-70010

09951-07100

Standard clearance:

3.8 to 4.4 mm (0.150 to 0.173 in.)

9. INSTALL OUTPUT SHAFT COVER

(a) Coat the shaft cover with MP grease, and install it to the transaxle case.

NOTICE:

Align the projection of the output shaft cover with the transaxle groove and install it.

10. INSTALL OUTPUT SHAFT FRONT BEARING OUTER RACE

(a) Using SST and a hammer, tap in a output shaft front bearing outer race.

SST : 09950-60020

09951-00730

SST : 09950-70010

09951-07100

11. ADJUST OUTPUT SHAFT BEARING PRELOAD

(a) Install the output shaft to the transaxle case.

(b) Install the transmission case to the transaxle case with the 14 bolts.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(c) Install the 3 bolts on the transaxle side.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(d) Install the output shaft rear bearing shim to the output shaft.

(e) Using a T45 "TORX" socket, install the rear bearing retainer with the 7 "TORX" screws to the transmission case.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

(f) Turn the output shaft in both directions to make sure that it starts to turn smoothly.

(g) Temporarily install the output shaft rear set nut.

(h) Using a socket wrench and torque wrench, inspect the preload.

Standard preload:

(i) If the preload is out of specification, select a proper output shaft rear bearing shim and adjust it.

HINT

The preload of all the output shaft rear bearing shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf)

Standard shim thickness:

(j) Remove the output shaft rear set nut from the output shaft.

(k) Using a T45 "TORX" socket, remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case.

(l) Remove the output shaft rear bearing shim from the output shaft.

(m) Remove the 3 bolts.

(n) Remove the 14 bolts and transmission case from the transaxle case.

(o) Remove the output shaft assembly from the front transaxle case.

12. ADJUST TAPERED ROLLER BEARING PRELOAD

(a) Install the differential case assembly to the transaxle case.

(b) Install the 14 bolts and transmission case to the transaxle case.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(c) Install the 3 bolts on the front transaxle case side.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(d) Turn the differential case in both directions to make sure that it starts to turn smoothly.

(e) Using SST and a torque wrench, measure the preload.

SST : 09564-32011

Standard preload:

(f) If the preload is out of specification, select a proper front differential case rear shim and adjust it.

HINT

The preload of all the front differential case rear shims varies in torque from about 0.04 to 0.06 N*m (0.408 to 0.612 kgf*cm, 0.354 to 0.531 in.*lbf).

Standard shim thickness:

(g) Remove the 3 bolts.

(h) Remove the 14 bolts and transmission case from the transaxle case.

(i) Remove the differential case assembly from the transaxle case.

13. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal to the transaxle case.

SST : 09950-60010

09951-00420

SST : 09950-70010

09951-07150

Standard distance:

1 to 2 mm (0.04 to 0.08 in.)

(b) Coat the lip of the oil seal with MP grease.

14. INSTALL INPUT SHAFT FRONT BEARING

(a) Coat the a new input shaft front bearing with gear oil, and using SST, install it to the transaxle case.

SST : 09950-60010

09951-00570

SST : 09950-70010

09951-07150

Standard distance:

4.28 to 4.60 mm (0.1685 to 0.1811 in.)

15. INSTALL MANUAL TRANSAXLE CASE RECEIVER

(a) Install the 3 bolts and the receiver to the transaxle case.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

16. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Coat the differential case tapered roller bearing with gear oil, and install the differential case to the transaxle case.

17. INSTALL OUTPUT SHAFT ASSEMBLY

(a) Apply gear oil to each sliding part of the output shaft.

(b) Lift the differential case assembly while tilting output shaft assembly, and install it to the manual transaxle case.

18. INSTALL INPUT SHAFT ASSEMBLY

(a) Apply gear oil to each sliding part of the input shaft.

(b) Install the input shaft assembly to the manual transaxle case while tilting the output shaft assembly.

19. 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.

20. INSTALL NO. 3 GEAR SHIFT FORK

(a) Install the reverse 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 No. 3 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 transaxle case.

21. 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.

22. 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 a new shift fork set bolt to the No. 2 gear shift fork.

Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

(d) Install a new shift head set bolt to the No. 1 gear shift head.

Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

23. INSTALL REVERSE SHIFT FORK ROLLER

(a) Using a magnet hand, install the reverse shift fork roller to the reverse shift fork.

24. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

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

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

Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

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 TRANSMISSION MAGNET

(a) Clean the transmission magnet, and install it to the transaxle case.

28. INSTALL NO. 1 OIL RECEIVER PIPE

(a) Install the oil receiver pipe to the transmission case with the bolt.

Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

NOTICE:

Do not damage the pipe.

29. INSTALL NO. 2 OIL RECEIVER PIPE

(a) Install the oil receiver pipe to the transmission case with the bolt.

Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

NOTICE:

Do not damage the pipe.

30. INSTALL REVERSE RESTRICT PIN ASSEMBLY

(a) Install the transmission oil baffle and reverse restrict pin with the bolt.

Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

(b) Install the reverse restrict pin to the transaxle case.

(c) Using a 5 mm pin punch, install 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 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