Part 2

C50 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY (Continued)

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)

29. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING





(a) Using a snap ring expander, install a new input shaft rear bearing hole snap ring onto the input shaft.

30. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING





(a) Using a snap ring expander, install a new output shaft rear bearing hole snap ring onto the output shaft.

31. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING





(a) Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring onto the No. 2 shift fork shaft.

32. INSTALL BEARING RETAINER REAR





(a) Coat the 5 bolts with sealant, and install the bearing retainer rear onto the manual transmission case with the 5 bolts.

Torque : 27 Nm (279 kgf-cm, 20 ft-lbf)

33. INSTALL 5TH DRIVEN GEAR





(a) Using SST, install the 5th driven gear onto the output shaft.

SST : 09309-12020

34. INSTALL 5TH GEAR NEEDLE ROLLER BEARING





(a) Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.

35. INSTALL 5TH GEAR





(a) Coat the 5th gear with gear oil and install it onto the input shaft.

36. INSTALL NO. 3 SYNCHRONIZER RING





(a) Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.

37. INSTALL NO. 3 TRANSMISSION CLUTCH HUB





(a) Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the No. 3 transmission clutch hub, as shown in the illustration.

NOTICE:
Do not set the 2 shifting key spring openings in the same position.

(b) Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft.

SST : 09636-20010





NOTICE:
* Do not install the No. 3 transmission clutch hub in the wrong direction.
* Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and No. 3 synchromesh shifting key aligned.
* Check that the 5th gear is rotating.
* Place a suitable sized wooden block to support the input shaft.

(c) Select a clutch hub No. 3 shaft snap ring that will allow minimum axial play.





Clearance:

0.1 mm or less

Snap ring thickness:





(d) Using a brass bar and a hammer, install the new snap ring onto the input shaft.

38. INSPECT 5TH GEAR THRUST CLEARANCE





(a) Using a dial indicator, measure the 5th gear thrust clearance.

Standard clearance:

0.1 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

39. INSPECT 5TH GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 5th gear radial clearance.

Standard clearance:

JTEKT made
0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made
0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

JTEKT made
0.058 mm (0.0023 in.)

NSK made
0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.

40. INSTALL NO. 3 GEAR SHIFT FORK





(a) Coat the No. 3 transmission clutch hub sleeve with gear oil and install it together with the No. 3 gear shift fork onto the No. 3 transmission clutch hub.

HINT
Set the No. 3 transmission clutch hub in the correct orientation.

(b) Coat the gear shift fork lock bolt with sealant, and install it onto the No. 3 gear shift fork.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)

41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT





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

(b) Coat a new manual transmission output shaft rear set nut with sealant.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Install a new manual transmission output shaft rear set nut.

Torque : 118 Nm (1199 kgf-cm, 87 ft-lbf)

(d) Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.





(e) Disengage the 2 gears.

42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY





(a) Apply FIPG to the manual transaxle case cover sub-assembly 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 manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.





Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

43. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY





(a) Coat the shift and select lever shaft assembly with gear oil, and install it onto the transmission case.

44. INSTALL CONTROL SHAFT COVER OIL SEAL





(a) Using SST and a hammer, install a new control shaft cover oil seal onto the control shaft cover.

Drive in depth:

0.2 to 1.2 mm (0.0079 to 0.0472 in.)

SST : 09950-60010

09951-00280

SST : 09950-70010

09951-07150

(b) Coat the control shaft cover oil seal with MP grease.

45. INSTALL CONTROL SHAFT COVER





(a) Coat the 4 bolts with sealant. Install a new gasket and control shaft cover onto the manual transmission case with the 4 bolts.

Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:
Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.

46. INSTALL SHIFT GUIDE PIN





(a) Coat the shift guide pin with sealant.

(b) Install the washer and shift guide pin.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

47. INSTALL NO. 1 LOCK BALL ASSEMBLY





(a) Coat the No. 1 lock ball assembly with sealant and install it onto the manual transmission case.

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

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

48. INSTALL SHIFT LEVER DAMPER





(a) Install the dust boot onto the control shaft cover.

(b) Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.

(c) Install the spring washer with the nut.

Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)

49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER





(a) Install the dust boot onto the shift and select lever shaft oil seal.

(b) Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.

(c) Install the spring washer with the nut.

Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)

50. INSTALL SELECTING BELL CRANK ASSEMBLY





(a) Install the selecting bell crank assembly together with the control shift lever bush onto the manual transmission case with the 2 bolts and nut.

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

Torque : 12 Nm (120 kgf-cm, 9 ft-lbf) for nut

NOTICE:
Apply MP grease to the inside circumferential surface of the control shift lever bush.

51. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY





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

SST : 09817-16011

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

(b) Install the back-up light switch wire harness into the 2 clamps.

52. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

(a) Install a new O-ring onto the speedometer driven hole cover sub-assembly.

(b) Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt.

Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)

53. INSTALL MANUAL TRANSMISSION FILLER PLUG





(a) Install the manual transmission filler plug onto the manual transmission case with a new gasket.

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

54. INSTALL DRAIN PLUG SUB-ASSEMBLY





(a) Install the drain plug onto the manual transmission case with a new gasket.

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