Installation
RA62 MANUAL TRANSMISSION: MANUAL TRANSMISSION ASSEMBLY: INSTALLATION
1. INSTALL TRANSMISSION UPPER COVER SUB-ASSEMBLY
(a) Install the transmission upper cover sub-assembly with the 2 bolts.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
2. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
(a) Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
3. INSTALL CLUTCH COVER ASSEMBLY Installation
4. INSTALL CLUTCH DISC ASSEMBLY Installation
5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
(a) Apply release hub grease to the contact surface between the release fork and release bearing hub, the contact surface between the release fork and push rod, and the release fork pivot points as shown in the illustration.
Grease:
Toyota Genuine Release Hub Grease or equivalent
(b) Install the clutch release fork sub-assembly to the release fork support.
NOTICE:
* Do not use excess force to install the clutch release fork sub-assembly.
* After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.
6. INSTALL MANUAL TRANSMISSION ASSEMBLY
(a) Make sure that the knock pins are not loose, bent, damaged or scratched and then install the manual transmission onto the engine with the contact surfaces of the engine and manual transmission flat against each other.
(b) Install the manual transmission to the engine with the 9 bolts.
Bolt A - Torque : 72 Nm (730 kgf-cm, 53 ft-lbf)
Bolt B - Torque : 37 Nm (380 kgf-cm, 28 ft-lbf)
NOTICE:
* Temporarily tighten bolt A*1, fully tighten bolt A*2, lift the rear end of the transmission, and fully tighten bolt A*1 and the other bolts. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.
* Do not apply excessive force to the transmission assembly as this will break the input shaft
* Insert dowel pins into the dowel holes securely so that the end face of the transmission assembly fits close against the engine assembly before tightening the bolts.
7. INSTALL ENGINE REAR MOUNTING MEMBER
(a) Install the engine rear mounting member with the 4 bolts and 4 nuts.
Nut - Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)
Bolt - Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)
8. INSTALL FLOOR SHIFT LEVER ASSEMBLY
(a) Install the 2 bushings to the shift lever assembly.
(b) Install the washer to the floor shift lever assembly.
(c) Install the shift lever assembly with a new E-ring.
(d) Install the shift and select lever boot.
9. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY
(a) Install the floor shift control shift lever retainer sub-assembly with the 2 nuts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
10. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmarks on the clutch cover assembly and the flywheel sub-assembly.
(b) Install the clutch cover to the flywheel sub-assembly with the 6 new bolts.
Torque : 19 Nm (195 kgf-cm, 14 ft-lbf)
NOTICE:
Tighten the bolts a little at a time in a diagonal pattern until they are all tightened.
11. INSTALL NO. 1 CLUTCH HOUSING COVER
(a) Install the No. 1 clutch housing cover with the 4 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Bolt length:
20 mm (0.787 in.)
12. INSTALL NO. 2 CLUTCH HOUSING COVER
(a) Install the No. 2 clutch housing cover with the 4 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Bolt length:
16 mm (0.630 in.)
13. CONNECT WIRE HARNESS
(a) Connect the back-up light switch connector and install the wire harness.
14. CONNECT GROUND CABLE
(a) Connect the ground cable with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(a) Install the clutch release cylinder assembly with the 2 bolts.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
16. INSTALL CLUTCH ACCUMULATOR ASSEMBLY
(a) Install the clutch accumulator assembly with the 3 bolts and nut.
Bolt - Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
Nut - Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
17. INSTALL STARTER ASSEMBLY
Installation
18. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET
(a) Install the engine under cover air guide bracket with the 2 bolts.
Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)
19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY Installation
20. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE Installation
21. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR Installation
22. INSTALL OUTSIDE AIR GUIDE PLATE RH Installation
23. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
24. INSTALL HEATED OXYGEN SENSOR Installation
25. INSTALL FRONT CENTER FLOOR BRACE Installation
26. INSTALL NO. 1 REAR FLOOR PANEL BRACE Installation
27. INSTALL NO. 2 ENGINE UNDER COVER
28. INSTALL ENGINE UNDER COVER
29. INSTALL SHIFT LEVER CAP
(a) Temporarily install the shift lever cap with the 4 bolts.
(b) Move the shift lever to the 2nd gear position. Adjust the shift lever cap by pushing it towards neutral until dimension A is as shown in the illustration.
Dimension A:
0.3 to 0.6 mm (0.0118 to 0.0236 in.)
(c) Fully tighten the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
30. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT
(a) Install the No. 1 shift and select lever boot with the 4 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
31. INSTALL NO. 2 CONSOLE BOX DUCT Installation
32. INSTALL CONSOLE BOX Installation
33. INSTALL CONSOLE BOX REGISTER ASSEMBLY Installation
34. INSTALL FRONT ASH RECEPTACLE SUB-ASSEMBLY Installation
35. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY Installation
36. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY Installation
37. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
39. ADD MANUAL TRANSMISSION OIL Replacement
40. INSPECT AND ADJUST MANUAL TRANSMISSION OIL LEVEL Testing and Inspection
41. INSPECT FOR EXHAUST GAS LEAK Installation