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HOMESERVICE MANUALSSCION2016IM AUTOMATIC CVT TRANSREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 2 (MANUAL TRANSMISSION - SERVICE INFORMATION)MANUAL TRANSAXLE UNITREASSEMBLY [06/2015 - ]PROCEDURE
2016 Scion iM Automatic CVT Trans

Reassembly [06/2015 - ]: Procedure

2016 Scion iM Automatic CVT TransSECTION Procedure
WARNING: This page is about a different variant/trim than selected.
  1. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the differential case assembly.
      GTY490493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09309-37010 
      • SST: 09506-35010 
    2. Using SST and a press, install a new front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer to the front transaxle case.
      GTY492539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        1. 09951-00680
      • SST: 09950-70010 
        1. 09951-07200
  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the differential case assembly.
      GTY425031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09636-20010 
      • SST: 09726-40010 
    2. Using SST and a press, install a new front differential case rear tapered roller bearing (outer race) together with the front differential case rear plate washer to the manual transmission case.
      GTY486865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09309-36010 
      • SST: 09950-60020 
        1. 09951-00730
      • SST: 09950-70010 
        1. 09951-07100

      HINT: 

      Use a front differential case rear plate washer of the same thickness as the removed one.

  3. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Remove any remaining seal packing from the contact surfaces of the front transaxle case and manual transmission case.
    2. Coat the differential case assembly with gear oil and install it to the front transaxle case.
      GTY449676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the manual transmission case to the front transaxle case with the 16 bolts.

      Torque: 29.4 N*m (300 kgf*cm, 22 ft.*lbf) 

      GTY491226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
      GTY483951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Case Rear Plate Washer
      • SST: 09564-32011 
    5. Using SST and a torque wrench, measure the preload.
      • SST: 09564-32011 

      Preload (at Starting)

      New Bearing 

      1.0 to 1.6 N*m (10 to 16 kgf*cm, 9 to 14 in.*lbf)

      Used Bearing 

      0.8 to 1.3 N*m (8 to 13 kgf*cm, 7 to 12 in.*lbf)

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

      Front Differential Case Rear Plate Washer Thickness

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      10 2.100 (0.0827) 26 2.500 (0.0984)
      11 2.125 (0.0837) 27 2.525 (0.0994)
      12 2.150 (0.0846) 28 2.550 (0.100)
      13 2.175 (0.0856) 29 2.575 (0.101)
      14 2.200 (0.0866) 30 2.600 (0.102)
      15 2.225 (0.0876) 31 2.625 (0.103)
      16 2.250 (0.0886) 32 2.650 (0.104)
      17 2.275 (0.0896) 33 2.675 (0.105)
      18 2.300 (0.0906) 34 2.700 (0.106)
      19 2.325 (0.0915) 35 2.725 (0.107)
      20 2.350 (0.0925) 36 2.750 (0.108)
      21 2.375 (0.0935) 37 2.775 (0.109)
      22 2.400 (0.0945) 38 2.800 (0.110)
      23 2.425 (0.0955) 39 2.825 (0.111)
      24 2.450 (0.0965) 40 2.850 (0.112)
      25 2.475 (0.0974) - -

      HINT: 

      • Select a thicker front differential case rear plate washer to increase the preload or a thinner front differential case rear plate washer to decrease the preload.
      • Make a memo as the torque values will be needed to adjust output shaft bearing preload.
    6. Remove the 16 bolts and manual transmission case from the front transaxle case.
    7. Remove the differential case assembly from the front transaxle case.
  4. INSTALL FRONT OUTPUT SHAFT BEARING (OUTER RACE) 
    1. Install the output shaft cover to the front transaxle case.
      GTY485341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Key
      NOTE:

      Insert the key of the output shaft cover into the front transaxle case groove.

    2. Using SST and a press, install a new front output shaft bearing (outer race) to the front transaxle case.
      GTY490991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00630
      • SST: 09950-70010 
  5. INSTALL REAR OUTPUT SHAFT BEARING (OUTER RACE) 
    1. Using SST and a press, install a new rear output shaft bearing (outer race) together with the rear output shaft bearing shim to the manual transmission case.
      GTY483198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00590
      • SST: 09950-70010 
        1. 09951-07200

      HINT: 

      Use a rear output shaft bearing shim of the same thickness as the removed one.

  6. ADJUST OUTPUT SHAFT BEARING PRELOAD 
    1. Remove any remaining seal packing from the contact surfaces of the front transaxle case and manual transmission case.
    2. Coat the differential case assembly with gear oil and install it to the front transaxle case.
      GTY449676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the output shaft assembly with gear oil and install it to the front transaxle case.
      GTY436835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the manual transmission case to the front transaxle case with the 16 bolts.

      Torque: 29.4 N*m (300 kgf*cm, 22 ft.*lbf) 

      GTY491226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.
      GTY492846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Output Shaft Bearing Shim
      • SST: 09564-32011 
    6. Using SST and a torque wrench, measure the preload. Calculate the rear output shaft bearing preload using the following formula.
      • SST: 09564-32011 

      Formula

      Measured preload - Differential side bearing preload = Output shaft bearing preload

      Bearing Preload (at Starting)
      New bearing 4.3 to 7.4 N*m (44 to 75 kgf*cm, 38 to 65 in.*lbf)
      Used bearing 2.8 to 4.7 N*m (29 to 48 kgf*cm, 25 to 42 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.

      Rear Output Shaft Bearing Shim Thickness

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      50 1.750 (0.0689) 72 2.300 (0.0906)
      51 1.775 (0.0699) 73 2.325 (0.0915)
      52 1.800 (0.0709) 74 2.350 (0.0925)
      53 1.825 (0.0719) 75 2.375 (0.0935)
      54 1.850 (0.0728) 76 2.400 (0.0945)
      55 1.875 (0.0738) 77 2.425 (0.0955)
      56 1.900 (0.0748) 78 2.450 (0.0965)
      57 1.925 (0.0758) 79 2.475 (0.0974)
      58 1.950 (0.0768) 80 2.500 (0.0984)
      59 1.975 (0.0778) 81 2.525 (0.0994)
      60 2.000 (0.0787) 82 2.550 (0.100)
      61 2.025 (0.0797) 83 2.575 (0.101)
      62 2.050 (0.0807) 84 2.600 (0.102)
      63 2.075 (0.0817) 85 2.625 (0.103)
      64 2.100 (0.0827) 86 2.650 (0.104)
      65 2.125 (0.0837) 87 2.675 (0.105)
      66 2.150 (0.0846) 88 2.700 (0.106)
      67 2.175 (0.0856) 89 2.725 (0.107)
      68 2.200 (0.0866) 90 2.750 (0.108)
      69 2.225 (0.0876) 91 2.775 (0.109)
      70 2.250 (0.0886) 92 2.800 (0.110)
      71 2.275 (0.0896) - -

      HINT: 

      Select a thicker rear output shaft bearing shim to increase the preload or a thinner rear output shaft bearing shim to decrease the preload.

    7. Remove the 16 bolts and manual transmission case from the front transaxle case.
    8. Remove the output shaft assembly from the front transaxle case.
    9. Remove the differential case assembly from the front transaxle case.
  7. INSTALL OUTER SHIFT LEVER OIL SEAL 
    1. Using SST and a hammer, install a new outer shift lever oil seal to the manual transmission case.
      GTY484182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
      • SST: 09950-60010 
        1. 09951-00260
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

      0.5 to 1.0 mm (0.0197 to 0.0394 in.)

    2. Coat the lip of the outer shift lever oil seal with MP grease.
  8. INSTALL OUTER NO. 1 SHIFT LEVER 
    1. Install the inner No. 1 shift lever, outer shift lever spacer and outer No. 1 shift lever to the manual transmission case.
      GTY494887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark
      *b Depth

      HINT: 

      Install the inner No. 1 shift lever with its mark facing the outside of the manual transmission case.

    2. Using a 5 mm pin punch and a hammer, install the inner shift lever slotted spring pin to the inner No. 1 shift lever.

      Standard Depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  9. INSTALL MANUAL TRANSMISSION OIL SEPARATOR SUB-ASSEMBLY 
    1. Install the manual transmission oil separator sub-assembly to the manual transmission case with the 4 bolts.
      GTY449681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

      HINT: 

      Make sure that the end tabs of the manual transmission oil separator sub-assembly are inserted into the grooves of the manual transmission case.

  10. INSTALL TRANSMISSION OIL SEPARATOR 
    1. Install the transmission oil separator to the manual transmission case with the 2 bolts.
      GTY449680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

      HINT: 

      Make sure that the tip of the transmission oil separator is inserted into the groove of the manual transmission case.

  11. INSTALL NO. 1 OIL RECEIVER PIPE 
    1. Install the No. 1 oil receiver pipe to the manual transmission case.
      GTY449691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure that the No. 1 oil receiver pipe fully contacts the manual transmission case.

  12. INSTALL STRAIGHT PIN 
    1. Using a plastic hammer, install 5 new straight pins to the front transaxle case to the specified protrusion height.
      GTY425189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion Height

      Protrusion Height

      8.5 to 9.5 mm (0.335 to 0.374 in.)

  13. INSTALL REVERSE RESTRICT PIN ASSEMBLY 
    1. Install the reverse restrict pin assembly to the front transaxle case.
      GTY440084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL BREATHER PLUG 
    1. Using SST and a hammer, install the breather plug to the front transaxle case.
      GTY484730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-30020 
        1. 09350-07110
  15. INSTALL TRANSMISSION OIL SEPARATOR 
    1. Install the transmission oil separator to the front transaxle case with the 4 bolts.
      GTY449678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

  16. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new front transaxle case oil seal to the front transaxle case.
      GTY482905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
      • SST: 09950-60010 
        1. 09951-00350
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

      0.9 to 1.9 mm (0.0354 to 0.0748 in.)

    2. Coat the lip of the front transaxle case oil seal with MP grease.
  17. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet and install it to the front transaxle case.
      GTY456006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL INPUT SHAFT COVER 
    1. Install the input shaft cover to the manual transmission case.
      GTY493120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Key
      NOTE:

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

  19. INSTALL REAR INPUT SHAFT BEARING SHIM 
    1. Install the rear input shaft bearing shim to the manual transmission case.
      NOTE:

      The rear input shaft bearing shim should be cleaned before assembly.

      GTY449692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the distance between the end of the manual transmission case and rear input shaft bearing shim (Dimension (A)).
      GTY494842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Manual Transmission Case *2 Input Shaft Assembly
      *3 Front Transaxle Case - -
      *a Dimension (A) *b Dimension (B)
      *c Dimension (C) - -
    3. Measure the distance between the end of the front transaxle case and installation surface of the front input shaft bearing (Dimension (B)).
    4. Measure the distance between both input shaft bearing outer races (Dimension (C)).
      NOTE:

      Measure Dimension (C) with each bearing having no axial clearance.

    5. Calculate the rear input shaft bearing shim value using the following formula.

      Formula

      (Dimension (A) + Dimension (B)) - Dimension (C) - Rear input shaft bearing shim thickness = 0.02 mm (0.000787 in.) to 0.14 mm (0.00551 in.)

      If the preload 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 preload is within the specification.

      Rear Input Shaft Bearing Shim Thickness

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      08 1.30 (0.0512) 14 1.60 (0.0630)
      09 1.35 (0.0531) 15 1.65 (0.0650)
      10 1.40 (0.0551) 16 1.70 (0.0669)
      11 1.45 (0.0571) 17 1.75 (0.0689)
      12 1.50 (0.0591) 18 1.80 (0.0709)
      13 1.55 (0.0610) 19 1.85 (0.0728)
    6. Coat the rear input shaft bearing shim with MP grease and install it to the manual transmission case.
      NOTE:

      Do not apply MP grease to the oil grooves.

  20. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. Coat the differential case assembly with gear oil and install it to the front transaxle case.
      GTY449676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL INPUT SHAFT ASSEMBLY 
    1. Apply gear oil to all sliding and rotating parts.
    2. Coat the No. 1 gear shift fork shaft assembly with gear oil and install it to the output shaft assembly.
      GTY443631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Gear Shift Fork Shaft Assembly
      *2 Output Shaft Assembly
    3. Coat the No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly with gear oil and install them to the input shaft assembly.
      GTY446600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Gear Shift Fork Shaft Assembly
      *2 No. 3 Gear Shift Fork Shaft Assembly
      *3 Input Shaft Assembly
    4. Temporarily install the output shaft assembly, input shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly, and tie them with a rope or string.
    5. Install the input shaft assembly, output shaft assembly, No. 1 gear shift fork shaft assembly, No. 2 gear shift fork shaft assembly and No. 3 gear shift fork shaft assembly to the front transaxle case.
      GTY449677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL OUTER SELECT LEVER OIL SEAL 
    1. Using SST and a hammer, install a new outer select lever oil seal to the front transaxle case.
      GTY483108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
      • SST: 09950-60010 
        1. 09951-00240
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

      0.5 to 1.0 mm (0.0197 to 0.0394 in.)

    2. Coat the lip of the outer select lever oil seal with MP grease.
  23. INSTALL OUTER SELECT LEVER 
    1. Clean the bolt hole of the outer select lever.
    2. Install the outer select lever and inner select lever to the front transaxle case.
      GTY486026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark

      HINT: 

      Install the inner select lever with its mark facing the outside of the front transaxle case.

  24. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Turn the shift and select lever shaft assembly and shift inter lock plate counterclockwise, and install them to the front transaxle case.
      GTY485191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shift and Select Lever Shaft Assembly
      *2 Inner Select Lever
      *3 Shift Inter Lock Plate

      HINT: 

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

    2. Clean the inner select lever set bolt.
    3. Apply adhesive to 2 or 3 threads on the end of the inner select lever set bolt.
      GTY447355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper installation of the inner select lever set bolt, apply adhesive to the inner select lever set bolt and install it within 10 minutes of adhesive application.

    4. Using a 6 mm hexagon socket wrench, install the inner select lever set bolt.
      GTY455988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  25. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Install the reverse shift arm bracket assembly to the front transaxle case with the 2 bolts.
      GTY449601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

  26. INSTALL REVERSE SHIFT FORK SHAFT ASSEMBLY 
    1. Coat the reverse shift fork shaft assembly with gear oil and install it to the front transaxle case.
      GTY440236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Clean the reverse idler gear shaft bolt hole.
    2. Coat the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft with gear oil, and install them to the front transaxle case as shown in the illustration.
      GTY489566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Parallel
      *b Reverse Idler Gear Shaft Bolt Hole
      *c Screw Hole
      NOTE:

      Make sure that the reverse idler gear shaft bolt hole is parallel to the screw hole on the front transaxle case.

      HINT: 

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

  28. INSTALL MANUAL TRANSMISSION CASE 
    1. Remove any remaining seal packing from the contact surfaces of the front transaxle case and manual transmission case.
    2. Apply FIPG to the manual transmission case as shown in the illustration.

      FIPG

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      NOTE:
      • Remove any oil from the contact surfaces.
      • Install the parts within 10 minutes of application. Otherwise, the seal packing (FIPG) must be removed and reapplied.
      GTY486502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a FIPG
      (Seal Diameter 1.2 mm (0.0472 in.))
    3. Push the outer No. 1 shift lever and temporarily install the manual transmission case.
      GTY449427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    4. Pull the outer No. 1 shift lever out and turn it counterclockwise.
      GTY449415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the manual transmission case to the front transaxle case with the 16 bolts.
      GTY491226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N*m (300 kgf*cm, 22 ft.*lbf) 

  29. INSTALL OUTER SHIFT LEVER E-RING 
    1. Install the outer shift lever E-ring to the outer No. 1 shift lever.
      GTY455990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FRONT DRIVE SHAFT OIL SEAL LH 
    1. Using SST and a hammer, install a new front drive shaft oil seal LH to the manual transmission case.
      GTY486931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
      • SST: 09316-60011 
        1. 09316-00011

      Standard Depth

      10.6 to 11.6 mm (0.417 to 0.457 in.)

      NOTE:
      • Be sure to install the front drive shaft oil seal LH in the correct direction.
      • Make sure to install the front drive shaft oil seal LH as specified, otherwise malfunctions such as a fluid leak will occur.
      • Do not damage the lip of the front drive shaft oil seal LH.
    2. Coat the lip of the front drive shaft oil seal LH with MP grease.
  31. INSTALL FRONT DRIVE SHAFT OIL SEAL RH 
    1. Using SST and a hammer, install a new front drive shaft oil seal RH to the front transaxle case.
      GTY429870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Depth
      • SST: 09630-24014 
        1. 09620-24051
      • SST: 09950-60010 
        1. 09951-00410
        2. 09951-00530
        3. 09952-06010
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

      1.2 to 2.2 mm (0.0472 to 0.0866 in.)

      NOTE:
      • Be sure to install the front drive shaft oil seal RH in the correct direction.
      • Make sure to install the front drive shaft oil seal RH as specified, otherwise malfunctions such as a fluid leak will occur.
      • Do not damage the lip of the front drive shaft oil seal RH.
    2. Coat the lip of the front drive shaft oil seal RH with MP grease.
  32. INSTALL SHIFT DETENT BALL 
    1. Clean the shift detent ball plugs and installation holes in the manual transmission case.
    2. Apply adhesive to 2 or 3 threads on the ends of the 2 shift detent ball plugs.
      GTY490981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      NOTE:

      In order to ensure proper installation of the 2 shift detent ball plugs, apply adhesive to the 2 shift detent ball plugs and install them within 10 minutes of adhesive application.

    3. Install the 2 shift detent balls and 2 shift detent ball compression springs to the manual transmission case.
      GTY449451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a 6 mm hexagon socket wrench, install the 2 shift detent ball plugs to the manual transmission case.

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

      NOTE:

      Be careful not to drop the shift detent balls into the manual transmission case.

    5. Clean the shift detent ball plug and installation hole in the manual transmission case.
    6. Apply adhesive to 2 or 3 threads on the end of the shift detent ball plug.
      GTY490981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      NOTE:

      In order to ensure proper installation of the shift detent ball plug, apply adhesive to the shift detent ball plug and install it within 10 minutes of adhesive application.

    7. Install the shift detent ball and shift detent ball compression spring to the manual transmission case.
      GTY455984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a 6 mm hexagon socket wrench, install the shift detent ball plug to the manual transmission case.

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

      NOTE:

      Be careful not to drop the shift detent ball into the manual transmission case.

  33. INSTALL LOCK BALL PIN 
    1. Clean the shift and select lever shaft straight screw with head plug and installation hole in the manual transmission case.
    2. Apply adhesive to 2 or 3 threads on the end of the shift and select lever shaft straight screw with head plug.
      GTY490981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      NOTE:

      In order to ensure proper installation of the shift and select lever shaft straight screw with head plug, apply adhesive to the shift and select lever shaft straight screw with head plug and install it within 10 minutes of adhesive application.

    3. Install the lock ball pin and shift and select lever shaft compression spring to the manual transmission case.
      GTY449585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a 10 mm hexagon socket wrench, install the shift and select lever shaft straight screw with head plug to the manual transmission case.

      Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf) 

  34. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Clean the reverse idler gear shaft bolt.
    2. Apply adhesive to 2 or 3 threads on the end of the reverse idler gear shaft bolt.
      GTY447355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper installation of the reverse idler gear shaft bolt, apply adhesive to the reverse idler gear shaft bolt and install it within 10 minutes of adhesive application.

    3. Install the reverse idler gear shaft bolt and a new gasket to the manual transmission case.
      GTY449586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

  35. INSTALL NO. 1 LOCK BALL ASSEMBLY 
    1. Clean the No. 1 lock ball assembly and installation hole in the manual transmission case.
    2. Apply adhesive to 2 or 3 threads on the end of the No. 1 lock ball assembly.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      NOTE:

      In order to ensure proper installation of the No. 1 lock ball assembly, apply adhesive to the No. 1 lock ball assembly and install it within 10 minutes of adhesive application.

      GTY484512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive
    3. Install the No. 1 lock ball assembly to the manual transmission case.
      GTY449583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 29.4 N*m (300 kgf*cm, 22 ft.*lbf) 

  36. INSTALL TRANSMISSION CASE PLUG 
    1. Install the transmission case plug and a new gasket to the manual transmission case.
      GTY492854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  37. INSTALL NO. 1 CLUTCH HOUSING COVER 
    1. Install the No. 1 clutch housing cover to the front transaxle case.
      GTY449588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL RELEASE CYLINDER BLEEDER PLUG 
    1. Install the release cylinder bleeder plug to the clutch release bleeder sub-assembly.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

  39. INSTALL RELEASE CYLINDER BLEEDER PLUG CAP 
    1. Install the release cylinder bleeder plug cap to the release cylinder bleeder plug.
  40. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  41. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  42. INSPECT CLUTCH PIPE LINE 

    Refer to PROCEDURE - Step 6

  43. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  44. INSTALL CONTROL CABLE BRACKET ASSEMBLY 
    1. Hook the outer select lever to the reverse restrict pin assembly to secure it.
      GTY446906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the control cable bracket assembly to the manual transmission case with the 3 bolts.
      GTY432890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

  45. INSTALL TRANSMISSION CASE PLUG 
    1. Install the transmission case plug and a new gasket to the manual transmission case.
      GTY435749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 40.2 N*m (410 kgf*cm, 30 ft.*lbf) 

      HINT: 

      Face the tapered side of the gasket toward the manual transmission case.

  46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Using a 27 mm deep socket wrench, install the back-up light switch assembly and a new gasket to the manual transmission case.
      GTY449636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 40.2 N*m (410 kgf*cm, 30 ft.*lbf) 

  47. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install the manual transmission filler plug and a new gasket to the manual transmission case.
      GTY436439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf) 

      HINT: 

      Face the tapered side of the gasket toward the manual transmission case.

  48. INSTALL MANUAL TRANSMISSION DRAIN PLUG 
    1. Using a 10 mm hexagon socket wrench, install the manual transmission drain plug and a new gasket to the front transaxle case.
      GTY435751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

      HINT: 

      Face the tapered side of the gasket toward the front transaxle case.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.