Part 1
C50 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY
1. INSTALL OUTPUT SHAFT COVER
(a) Coat the output shaft cover with MP grease and install it onto the front transaxle case.
NOTICE:
Insert the output shaft cover projection into the case side hollow.
2. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Coat a new output shaft front bearing with gear oil. Using SST and a press, install it onto the front transaxle case.
SST : 09950-60010
09951-00550
SST : 09950-70010
09951-07150
NOTICE:
Install the new bearing in the correct direction, as shown in the illustration.
3. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new front transaxle case oil seal onto the front transaxle case.
SST : 09950-60010
09951-00370
SST : 09950-70010
09951-07150
Drive in depth:
15.6 to 16.0 mm (0.6141 to 0.6299 in.)
(b) Coat the lip of the front transaxle case oil seal with MP grease.
4. INSTALL INPUT SHAFT FRONT BEARING
(a) Coat a new input shaft front bearing with gear oil, and using SST and a press, install it onto the front transaxle case.
SST : 09950-60010
09951-00420
SST : 09950-70010
09951-07150
Drive in depth:
0 to 0.3 mm (0 to 0.0118 in.)
5. INSTALL SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
(a) Using SST and a hammer, install the shift and select lever shaft slide ball bearing onto the transmission case.
SST : 09950-60010
09951-00220
SST : 09950-70010
09951-07100
Drive in depth:
0 to 0.5 mm (0 to 0.0020 in.)
6. INSTALL SHIFT AND SELECT LEVER SHAFT OIL SEAL
(a) Using SST, install the shift and select lever shaft oil seal onto the transmission case.
SST : 09950-70010
09951-07150
SST : 09950-60010
09951-00240
Drive in depth:
9.7 to 10.3 mm (0.382 to 0.406 in.)
7. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case front tapered roller bearing (inner race) onto the front differential case.
SST : 09350-32014
09351-32120
SST : 09950-60010
09951-00530
(b) Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the front transaxle case.
SST : 09950-60020
09951-00680
SST : 09950-70010
09951-07150
8. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case rear tapered roller bearing (inner race) onto the differential case.
SST : 09350-32014
09351-32120
SST : 09950-60010
09951-00530
(b) Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with plate washer onto the transmission case.
SST : 09309-36010
SST : 09950-60020
09951-00710
SST : 09950-70010
09951-07150
HINT
Use a plate washer of the same thickness as the removed one.
9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Coat the differential case assembly with gear oil, and install it onto the front transaxle case.
(b) Install the manual transmission case with the 16 bolts.
Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
(c) Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle.
SST : 09564-32011
(d) Using SST and a torque wrench, measure the preload.
SST : 09564-32011
Preload (at starting):
New bearing
0.78 to 1.57 N*m (7.95 to 16.0 kgf*cm, 6.9 to 13.89 in.*lbf)
Used bearing
0.49 to 0.98 N*m (5.0 to 10.0 kgf*cm, 4.34 to 8.67 in.*lbf)
(d) If the preload is outside the specifications, select another plate washer.
Plate washer thickness:
HINT
The preload changes by approximately 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) per each 0.05 mm (0.0020 in.) change in plate washer thickness.
(e) Remove the 16 bolts and the manual transmission case.
(f) Remove the differential case assembly from the front transaxle case.
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Using SST and a hammer, install a new transmission case oil seal onto the manual transmission case.
SST : 09309-37010
Drive in depth:
9.6 to 10.2 mm (0.378 to 0.402 in.)
(b) Coat the lip of the front transmission case oil seal with MP grease.
11. INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new transaxle case oil seal onto the front transaxle case.
SST : 09710-26011
09710-05061
Drive in depth:
1.6 to 2.2 mm (0.063 to 0.087 in.)
(b) Coat the lip of the transaxle case oil seal with MP grease.
12. INSTALL TRANSMISSION MAGNET
(a) Clean the transmission magnet and install it onto the front transaxle case.
13. INSTALL BEARING LOCK PLATE
(a) Install the bearing lock plate onto the front transaxle case with the bolt.
Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)
14. INSTALL NO. 1 OIL RECEIVER PIPE
(a) Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt.
Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)
NOTICE:
* Do not deform the No. 1 oil receiver pipe.
* Install the No. 1 oil receiver pipe while holding it against the manual transmission case, as shown in the illustration.
15. INSTALL NO. 2 OIL RECEIVER PIPE
(a) Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt.
Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)
NOTICE:
* Do not deform the No. 2 oil receiver pipe.
* Install the No. 2 oil receiver pipe while holding it against the manual transmission case, as shown in the illustration.
16. INSTALL REVERSE RESTRICT PIN ASSEMBLY
(a) Install the reverse restrict pin assembly onto the manual transmission case.
NOTICE:
Set the reverse restrict pin assembly in the correct orientation.
(b) Using a pin punch (dia5 mm) and a hammer, install the slotted pin onto the reverse restrict pin assembly.
Drive in depth:
15.5 to 16.5 mm (0.6102 to 0.6496 in.)
(c) Apply sealant to the reverse restrict pin plug.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
17. INSTALL MANUAL TRANSAXLE CASE RECEIVER
(a) Install the manual transaxle case receiver onto the front transaxle case with the bolt.
Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)
18. INSTALL DIFFERENTIAL CASE ASSEMBLY
(a) Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.
19. INSTALL INPUT SHAFT ASSEMBLY
(a) Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.
20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
(a) Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil and install them as shown in the illustration.
HINT
Align the mark on the reverse idler gear shaft with the bolt hole as shown in the illustration.
21. INSTALL NO. 1 GEAR SHIFT FORK SHAFT
(a) Coat the No. 1 gear shift fork and No. 2 gear shift fork with gear oil and install them.
(b) Coat the No. 1 gear shift fork shaft with gear oil and install it.
(c) Apply sealant to the shift fork set bolt.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Install the shift fork set bolt.
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
(e) Using a brass bar and a hammer, install a new shaft snap ring onto the No. 1 gear shift fork shaft.
22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT
(a) Coat the 2 shift fork balls with MP grease and install them onto the reverse shift fork.
(b) Install the reverse shift fork onto the No. 3 gear shift fork shaft.
(c) Using a brass bar and a hammer, install 2 new shift fork shaft snap rings onto the No. 3 shift fork shaft.
(d) Coat the No. 3 gear shift fork shaft with gear oil and install it.
23. INSTALL NO. 2 GEAR SHIFT FORK SHAFT
(a) Coat the No. 1 gear shift head and No. 2 gear shift fork shaft with gear oil and install them.
NOTICE:
To avoid interference by the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.
(b) Coat the 2 shift lock bolts with sealant and install them onto the No. 2 gear shift fork and No. 1 shift head.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
(a) Install the reverse shift arm bracket assembly onto the front transaxle case with the 2 bolts.
Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)
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
NOTICE:
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) Install the 3 bolts onto the manual transaxle side.
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 with a hexagon wrench.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
28. INSTALL SHIFT DETENT BALL
(a) Install the 2 shift detent balls, 2 shift detent ball springs and 2 No. 1 shift detent ball spring seats onto the manual transmission case.
(b) Coat 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)
(c) Install the shift detent ball, shift detent ball compression spring and No. 1 shift detent ball spring seat onto the front transaxle case.
(d) Coat 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)