Part 2

RA62 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSMISSION UNIT: REASSEMBLY

25. INSTALL COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING

(a) Coat a new counter gear rear cylindrical roller bearing with gear oil, and using SST and a press, install it into the rear transmission case.

SST : 09950-60010

09951-00650

SST : 09950-70010

09951-07360

(b) Install the bearing lock plate with the bolt.

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

26. INSTALL OUTPUT SHAFT REAR BEARING OUTER RACE

(a) Using SST and a press, press in 2 new bearing outer races.

SST : 09223-15020

SST : 09950-60020

09951-00790

SST : 09950-70010

09951-07100

09951-07360

27. INSTALL OIL SEPARATOR PACKING SEAL

(a) Install the oil separator packing seal onto the rear transmission case.

HINT
Insert the protruding part of the oil separator packing seal into the groove on the rear transmission case.

28. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

(a) Install the extension housing oil receiver pipe onto the rear transmission case.

29. INSTALL MANUAL TRANSMISSION FILLER PLUG

(a) Install the 2 transmission filler plugs with 2 new gaskets onto the rear transmission case.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

30. INSTALL REAR TRANSMISSION CASE

(a) Clean the seal packing attached on the rear transmission case and center transmission case using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

NOTICE:
Do not scratch the fitting surface.

(b) Apply FIPG to the rear transmission case as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

Text in Illustration

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

Text in Illustration

31. INSTALL SHIFT DETENT BALL PLUG

(a) Install the ball and compression spring onto the rear transmission case.

(b) Install a new shift detent ball plug onto the rear transmission case.

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

32. INSTALL OUTPUT SHAFT ADJUST NUT

(a) Using a belt and wooden block, securely fasten the transmission to the workbench.

(b) Install a new spacer and a new No. 2 taper roller bearing.

HINT
Fit the spacer and No. 2 taper roller bearing securely.

Text in Illustration

(d) Move the shift and select lever shaft to N.

(e) Fit the bearing into the output shaft by turning the output shaft 15 times.

(f) Using SST and a torque wrench, inspect preload (at starting)*1.

SST : 09326-35010

09326-03020

SST : 09326-35020

(g) Engage the 5th gear, and then secure the input shaft using SST.

SST : 09322-35010

09322-03010

09322-03020

09322-03030

90170-12030

90901-05003

94622-51200

HINT
* Install SST securely so that (A) is in-line with the input shaft.
* Make sure that (A) moves back and forth by hand after installing SST.

Text in Illustration

(h) Using SST, tighten the nut.

SST : 09326-35020

Reference without SST - Torque : 410 to 750 Nm (4180 to 7648 kgf-cm, 302 to 551 ft-lbf)

Reference with SST - Torque : 374 to 684 Nm (3814 to 6974 kgf-cm, 275 to 502 ft-lbf)

NOTICE:
* The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 1040 mm (3.41 ft.).
* The "with SST" torque value is effective when SST is parallel to the torque wrench.
(i) Move the shift and select lever shaft to N.

(j) Fit the bearing into the output shaft by turning the output shaft 15 times.

(k) Using SST and a torque wrench, inspect preload (at starting)*2.

SST : 09326-35010

09326-03020

SST : 09326-35020

(l) Adjust the preload so that the difference between *1 and *2 is within the specified range.

Preload (at starting) without SST:

*2 - *1 = 0.5 to 1.4 N*m (5 to 13 kgf*cm, 4 to 11 in.*lbf)

Preload (at starting) with SST:

*2 - *1 = 0.3 to 0.8 N*m (3 to 7 kgf*cm, 3 to 6 in.*lbf)

NOTICE:
* If the result is not as specified, tighten and adjust the output shaft adjust nut.
* If the output shaft adjust nut is loose or removed due to excess preload, always replace the spacer and nut with new ones.
(m) Using a chisel and hammer, stake the output shaft adjust nut.

33. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

(a) Install the oil receiver pipe.

(b) Using a snap ring expander, install the snap ring.

34. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

(a) Using SST and a hammer, install a new oil seal into the extension housing in accordance with the dimension specified in the illustration.

SST : 09950-60020

09951-00640

SST : 09950-70010

09951-07100

Dimension A:

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

(b) Apply gear oil to the lip of the oil seal.

35. INSTALL REAR EXTENSION HOUSING OIL SEAL

(a) Using SST and a hammer, install a new rear extension housing oil seal.

SST : 09612-70100

09612-07210

Installation depth:

4.6 to 5.4 mm (0.181 to 0.213 in.)

36. INSTALL EXTENSION HOUSING DUST DEFLECTOR

(a) Using a plastic hammer, install a new extension housing dust deflector.

37. INSTALL EXTENSION HOUSING SUB-ASSEMBLY

(a) Clean the seal packing attached on the center transmission case and extension housing sub-assembly using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

NOTICE:
Do not scratch the fitting surface.

(b) Apply FIPG to the extension housing sub-assembly, as shown in the illustration.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

38. INSTALL SHIFT AND SELECT LEVER SHAFT SUPPORT

(a) Using a pin punch (5 mm (0.197 in.)) and a hammer, install the shift and select lever shaft support and a new slotted spring pin onto the shift and select lever shaft.

Driven in depth:

1.0 to 2.0 mm (0.0394 to 0.0787 in.)

Text in Illustration

39. INSTALL FLOOR SHIFT CONTROL SHAFT

(a) Install a new control shaft collar onto the shift and select lever shaft.

(b) Install the shift lever damper and floor shift control shaft to the shift and select lever shaft.

(c) Using a pin punch (5 mm (0.197 in.)) and a hammer, align the floor shift control shaft hole and the shift and select lever shaft hole with the cutout of the control shaft collar, and insert the shaft pin from above.

(d) Slide the control shaft collar until it comes into contact with the stopper of the floor shift control shaft, then turn the control shaft collar 90° and stake it to the cutout.

NOTICE:
Be careful to install the floor shift control shaft in the proper direction.

Text in Illustration

40. INSTALL TRANSMISSION CONTROL CABLE WEIGHT

(a) Install the shift lever boot dust seal to the dust boot plate.

(b) Using a hexagon socket wrench (8 mm), install the dust boot plate, 2 shift arm pivot collars and transmission control cable weight to the extension housing sub-assembly with a new shift arm pivot.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
When tightening the shift arm pivot, position the arrow-shaped portion of the transmission control cable weight up, and insert it to the groove of the shift and select lever shaft support.

(c) Install the control shaft cover.

Text in Illustration

41. INSTALL CONTROL SHAFT

(a) Install the 2 collars to the floor shift control shaft.

(b) Install the control shaft with a new E-ring.

42. INSTALL SHIFT LEVER RETAINER BUSHING

(a) Install the 4 shift lever retainer bushings.

43. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER

(a) Install the floor shift control shift lever retainer with the 2 shift lever pins.

(b) Secure the shift lever pins to the extension housing.

44. INSTALL SHIFT AND SELECT LEVER BOOT

(a) Install the shift and select lever boot.

45. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY

(a) Install the floor shift control shift lever retainer sub-assembly to the control shift lever retainer in accordance with the dimension specified in the illustration.

Dimension A:

18 mm (0.709 in.)

46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

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

SST : 09817-16011

Torque : 44 Nm (450 kgf-cm, 33 ft-lbf)

(b) Install the bracket with the bolt.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(c) Install the wire harness with the 3 clamps.