Reassembly

EB60 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

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

SST : 09316-20011

SST : 09950-60010

09951-00580

09952-06010

SST : 09950-60020

09951-00910

SST : 09950-40011

09957-04010

SST : 09950-70010

09951-07100

(b) Using SST and a press, press in the front differential case front tapered roller bearing (outer race) together with the front differential oil baffle to the front transaxle case.

Text in Illustration

SST : 09950-60010

09952-06010

SST : 09950-60020

09951-00780

09951-00890

SST : 09950-70010

09951-07100

2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

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

SST : 09316-20011

SST : 09950-60010

09951-00580

09952-06010

SST : 09950-60020

09951-00910

SST : 09950-40011

09957-04010

SST : 09950-70010

09951-07100

(b) Using SST, install the front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate shim as shown in the illustration.

Text in Illustration

SST : 09950-60020

09951-00770

09951-00890

3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Coat the differential case assembly with gear oil and install it to the front transaxle case.

(b) Install the manual transmission case sub-assembly with the 17 bolts.

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

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

SST : 09564-50010

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

SST : 09564-50010

Standard preload (at starting):

New bearing
1.50 to 2.30 N*m (15 to 23 kgf*cm, 13 to 20 in.*lbf)

Used bearing
0.24 to 0.37 N*m (2.4 to 3.8 kgf*cm, 2.1 to 3.3 in.*lbf)

If the preload is not as specified, replace the front differential case rear shim with one of a different thickness. Use the table below to select a front differential case rear plate shim which will ensure that the preload is within the specification.

Shim Thickness:

HINT
* Select a thicker plate shim to increase the preload, or a thinner plate shim to decrease the preload.
* Make a memo as the torque values will be needed for the Adjust Output Shaft Bearing Preload procedure.

(e) Remove the 17 bolts and manual transmission case sub-assembly.

(f) Remove the differential case assembly from the front transaxle case.

(g) Replace the installed front differential case rear plate shim with the one selected above.

4. INSTALL FRONT OUTPUT SHAFT BEARING

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

NOTICE:
Insert the output shaft cover key into the case groove.

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

SST : 09950-60010

09951-00620

09952-06010

SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07100

5. INSTALL REAR OUTPUT SHAFT BEARING

(a) Using SST and a press, press in the rear output shaft bearing (outer race) together with the rear output shaft bearing shim to the manual transmission case sub-assembly.

SST : 09950-60010

09951-00490

09951-00620

09952-06010

SST : 09950-70010

09951-07150

6. ADJUST OUTPUT SHAFT BEARING PRELOAD

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

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

(c) Install the manual transmission case sub-assembly with the 17 bolts.

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

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

SST : 09564-50010

Text in Illustration

(e) Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing preload using the following formula.

SST : 09564-50010

Formula:

Value A - Differential side bearing preload = Output shaft bearing preload

Preload (at starting):

New bearing
2.80 to 5.60 N*m (29 to 57 kgf*cm, 25 to 50 in.*lbf)

Used bearing
2.31 to 4.62 N*m (24 to 47 kgf*cm, 20 to 41 in.*lbf)

If the preload is not as specified, replace the rear output shaft bearing shim with one of a different thickness. Use the table below to select a rear output shaft bearing shim which will ensure that the preload is within the specification.

Bearing Shim Thickness:

HINT
Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

(f) Remove the 17 bolts and manual transmission case sub-assembly.

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

(h) Remove the differential case assembly from the front transaxle case.

(i) Replace the installed rear output shaft bearing shim with the one selected above.

7. INSTALL OUTER SHIFT LEVER OIL SEAL

(a) Using SST and a hammer, tap in a new outer shift lever oil seal to the manual transmission case sub-assembly.

Text in Illustration

SST : 09950-60010

09951-00280

SST : 09950-70010

09951-07100

Standard depth:

0.5 to 1.0 mm (0.0197 to 0.0393 in.)

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

8. INSTALL OUTER NO. 1 SHIFT LEVER

(a) Install the inner No. 1 shift lever, No. 1 shift lever shaft housing washer and outer No. 1 shift lever to the manual transmission case sub-assembly.

Text in Illustration

(b) Using a 5 mm pin punch and hammer, tap in the inner shift lever slotted spring pin to the inner No. 1 shift lever.

Standard depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

9. INSTALL MANUAL TRANSMISSION CASE RECEIVER

(a) Install the manual transmission case receiver to the manual transmission case sub-assembly.

HINT
Make sure that the manual transmission case receiver fully contacts the manual transmission case sub-assembly.

10. INSTALL STRAIGHT PIN

(a) Using a plastic-faced hammer, tap in 5 new straight pins to the specified protrusion height.

Text in Illustration

Protrusion height:

10.5 to 11.5 mm (0.414 to 0.452 in.)

11. INSTALL BREATHER PLUG

(a) Using SST and a hammer, tap in the breather plug to the front transaxle case.

SST : 09350-30020

09350-07110

12. INSTALL FRONT TRANSAXLE CASE OIL SEAL

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

Text in Illustration

SST : 09612-22011

Standard depth:

1.0 to 2.0 mm (0.0394 to 0.0787 in.)

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

13. INSTALL TRANSMISSION MAGNET

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

14. INSTALL INPUT SHAFT COVER

(a) Install the input shaft cover to the manual transmission case sub-assembly.

NOTICE:
Insert the input shaft cover key into the manual transmission case groove.

15. INSTALL REAR INPUT SHAFT BEARING SHIM

(a) Install the rear input shaft bearing shim to the manual transmission case sub-assembly.

NOTICE:
Apply MP grease to the shim to prevent it from falling off the case during assembly.

(b) Measure the distance between the end of the manual transmission case sub-assembly and the rear input shaft bearing shim (dimension A).

Text in Illustration

(c) Measure the distance between the end of the front transaxle case and the installation surface of the front input shaft bearing (dimension B).

(d) Measure the distance between both input shaft bearing outer races (dimension C).

NOTICE:
Measure dimension C when both bearings have no clearance.

(e) Calculate the rear input shaft bearing shim clearance using the following formula.

Formula:

(Dimension A + Dimension B) - Dimension C - Rear input shaft bearing shim thickness = Between 0 mm and 0.1 mm (0.00394 in.)

If the clearance is not as specified, replace the rear input shaft bearing shim with one of a different thickness. Use the table below to select a rear input shaft bearing shim which will ensure that the clearance is within the specification.

Rear Input Shaft Bearing Shim Thickness:

(f) Coat the selected rear input shaft bearing shim with MP grease, and then replace the installed rear input shaft bearing shim with the one selected above.

NOTICE:
Do not apply MP grease to the oil grooves.

16. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Coat the differential case assembly with gear oil and install it to the front transaxle case.

17. INSTALL INPUT SHAFT ASSEMBLY AND OUTPUT SHAFT ASSEMBLY

(a) Apply gear oil to all sliding and rotating parts.

(b) Coat the No. 1 gear shift fork shaft with gear oil and install it to the output shaft assembly.

(d) Temporarily install the output shaft with No. 1 gear shift fork shaft to the input shaft assembly and tie them together with a rope or string.

(e) Install the input shaft assembly together with the output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.

18. INSTALL OUTER SELECT LEVER OIL SEAL

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

Text in Illustration

SST : 09950-60010

09951-00250

SST : 09950-70010

09951-07100

Standard depth:

0.5 to 1.0 mm (0.0197 to 0.0393 in.)

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

19. INSTALL OUTER SELECT LEVER

(a) Install the outer select lever and inner select lever to the front transaxle case.

Text in Illustration

HINT
Install the lever with its mark positioned outside of the front transaxle case.

(b) Coat the threads of the inner select lever set bolt with adhesive and install the bolt.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

20. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Install the shift interlock plate and the shift and select lever shaft assembly to the front transaxle case, and then turn them counterclockwise.

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

21. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Coat the threads of the 2 bolts with adhesive, and then, using a 6 mm hexagon wrench, install the reverse shift arm bracket with the 2 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)

22. INSTALL REVERSE SHIFT FORK

(a) Install the No. 1 gear shift fork shaft assembly to the reverse shift fork, and then align their holes.

NOTICE:
Make sure the No. 1 gear shift fork shaft assembly is installed in the correct direction.

(b) Using a 5 mm pin punch and hammer, tap in the reverse shift fork slotted spring pin to the No. 4 gear shift fork shaft assembly.

Text in Illustration

Standard depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

(c) Coat the No. 4 gear shift fork shaft assembly with gear oil and install it to the front transaxle case.

23. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Coat the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft with gear oil, and then install them as shown in the illustration.

Text in Illustration

NOTICE:
Using the bolt hole of the case for reference, align the I-groove mark of the reverse idler gear shaft within the range shown (approximately 20°).

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

24. INSTALL MANUAL TRANSMISSION CASE SUB-ASSEMBLY

(a) Apply seal packing to the manual transmission case as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Seal packing diameter:

1.2 mm (0.0472 in.)

NOTICE:
* Remove any oil from the contact surfaces.
* Assemble the parts within 10 minutes of application. Otherwise, the seal packing (FIPG material) must be removed and reapplied.

(b) Push the outer No. 1 shift lever and install the manual transmission case sub-assembly.

HINT
Pushing the outer No. 1 shift lever allows the manual transmission case to be installed.

(c) Turn the outer No. 1 shift lever counterclockwise and then pull it.

(d) Install the 17 bolts.

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

25. INSTALL OUTER SHIFT LEVER E-RING

(a) Install the outer shift lever E-ring to the outer No. 1 shift lever.

26. INSTALL TRANSAXLE CASE OIL SEAL

(a) for LH Side:

(1) Using SST and a hammer, tap in a new transaxle case oil seal LH to the manual transmission case sub-assembly.

Text in Illustration

SST : 09608-32010

SST : 09950-70010

09951-07100

Standard depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

NOTICE:
Do not damage the lip of the oil seal.

(2) Coat the lip of the transaxle case oil seal LH with MP grease.

(b) for RH Side:

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

Text in Illustration

SST : 09710-30050

SST : 09950-70010

09951-07100

Standard depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

NOTICE:
Do not damage the lip of the oil seal.

(2) Coat the lip of the transaxle case oil seal RH with MP grease.

27. INSTALL SHIFT DETENT BALL

(a) Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case sub-assembly.

NOTICE:
Be careful not to drop the balls into the manual transmission case.

(b) Coat the threads of the 2 shift detent ball plugs with adhesive and install the plugs using a 6 mm hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(c) Install the shift detent ball and shift detent ball compression spring to the manual transmission case sub-assembly.

NOTICE:
Be careful not to drop the ball into the manual transmission case.

(d) Coat the threads of the shift detent ball plug with adhesive and install the plug using a 6 mm hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

28. INSTALL LOCK BALL PIN

(a) Install the 2 lock ball pins and 2 shift and select lever shaft compression springs to the manual transmission case sub-assembly.

NOTICE:
Be careful not to drop the lock ball pins into the manual transmission case.

(b) Coat the threads of the 2 shift and select lever shaft straight screw with head plugs with adhesive and install the plugs using a 10 mm hexagon socket wrench.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

29. INSTALL REVERSE IDLER GEAR SHAFT BOLT

(a) Coat the threads of the reverse idler gear shaft bolt with adhesive and install a new gasket and the bolt to the manual transmission case sub-assembly.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

30. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP

31. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY Installation

32. INSPECT CLUTCH PIPE LINE Installation

33. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY Installation

34. INSTALL CONTROL CABLE BRACKET ASSEMBLY

(a) Install the control cable bracket assembly to the manual transmission case sub-assembly with the 3 bolts.

Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)

35. INSTALL TRANSMISSION CASE PLUG

(a) Install a new gasket and the transmission case plug to the manual transmission case sub-assembly.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

36. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using SST, install a new gasket and the back-up light switch to the manual transmission case sub-assembly.

SST : 09817-16011

Torque : 40 Nm (410 kgf-cm, 30 ft-lbf)

37. INSTALL MANUAL TRANSMISSION FILLER PLUG

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

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

38. INSTALL MANUAL TRANSMISSION DRAIN PLUG

(a) Install a new gasket and the manual transmission drain plug to the front transaxle case.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)