Assembly

1. Install bearing outer race and adjusting shim, determined previously, onto differential right hand side bearing.
2. Position differential assembly into transaxle case.
3. Install left hand side bearing retainer as follows:
a. Install O-ring.
b. Using a soft faced mallet, tap side bearing retainer onto transaxle case.
c. Clean bolt threads with a suitable solvent.
d. Coat bolt threads with a suitable sealer, then install and finger tighten bolts while turning the ring gear.
4. Install right hand side bearing cap. Torque cap bolts to 53 ft. lbs.
5. Torque left hand bearing retainer bolts to 14 ft. lbs.
6. Using a torque wrench, measure total preload of drive pinion shaft. Total preload, with drive pinion preload determined previously, should be 2.2-4.1 inch lbs. for new bearing and 1.2-2.0 inch lbs. for used bearings.
7. Using a suitable chisel and hammer, stake counter driven gear nut.
8. Install transmission case cap.
9. Install carrier cover onto transaxle case. Torque carrier cover bolts to 18 ft. lbs.

Fig. 10 Adjusting shim selective chart. Exc. MR2, Pickup, 4Runner, Tercel & 1986-88 Corolla w/A131 automatic transaxle:

10. Install differential into transaxle case, then install case with used gasket. Install attaching bolts and torque to 22 ft. lbs. Install thinnest shim into transaxle case, then the bearing retainer without O-ring. Measure bearing preload. Bearing preload should be 8.7-13.9 inch lbs. If preload is not within specifications, remove bearing retainer, then select adjusting shim using chart, Fig. 10.
11. Remove bearing retainer, shim and gasket.
12. Install input and output shafts.
13. Insert No. 2 fork shaft into transaxle case, then align slotted spring pin and install straight screw plug. Torque screw plug to 9 ft. lbs.
14. Insert reverse shift fork interlock pin into shift fork hole, then install reverse shift fork onto then install reverse shift arm into transaxle case. Shift reverse shift arm into reverse, then install reverse shift fork onto No. 2 fork shaft.
15. Place reverse shift arm pivot into reverse shift fork, then install reverse shift arm into transaxle case. Shift reverse shift arm into reverse, then insert attaching bolts and torque to 13 ft. lbs. Shift reverse shift arm into neutral.
16. Align transaxle case slot and slotted spring pin, then install reverse idler gear and shaft.
17. Place No. 1 and No. 2 shift fork into groove of hub sleeves Nos. 1 and 2. Hold No. 1 shift head, then insert No. 1 fork shaft into transaxle case, through No. 1 and 2 shift fork, No. 1 shift head and reverse shift fork. Using a suitable pin punch and hammer, drive slotted spring pin into No. 1 shift head and fork shaft. Shift fork shaft into reverse, then drive slotted spring pin into No. 1 fork shaft.
18. Install transaxle case with new gasket, then insert 17 attaching bolts and torque to 22 ft. lbs.
19. Install O-ring onto side bearing retainer, then insert bearing and retainer. Install six attaching bolts, then torque to 18 ft. lbs.
20. Install reverse idler gear shaft lock bolt, then torque to 18 ft. lbs.
21. Install two bearing snap rings, then install rear bearing retainer and torque five attaching bolts to 13 ft. lbs.
22. Assemble shift and selector assembly as follows:
a. Apply a suitable lubricant to shaft, then install No. 1 select spring seat, spring and E-ring.
b. Install No. 1 shift inner lever with fork lock plate, then align No. 2 inner lever with No. 1 and install.
c. Install No. 2 select spring seat, spring and E-ring, then drive in slotted spring pin.
d. Install control shaft cover and dust boot, then the control shift lever.
e. Insert lever lock pin, then install washer and locknut.
23. Apply a suitable sealant to control shaft cover, then torque control shaft cover attaching bolt to 27 ft. lbs.
24. Loosen locknut, then screw in lock ball. Rotate lock ball until shift lever outer tip has play of .004-.020 inch, then retain lock ball and torque lock nut to 27 ft. lbs. Ensure proper play at lever tip.
25. Install 5th driven gear, then the spacer. Apply a suitable lubricant to needle roller bearings, then install 5th drive gear with bearings and synchronizer ring.
26. Install No. 3 clutch hub, then insert shifting key into hub sleeve. Install shifting key springs under shifting keys.
27. Install No. 3 hub sleeve with No. 3 shift fork, ensuring to align synchronizer ring slots with shifting keys.
28. Measure 5th gear thrust clearance. Clearance should be .0079-.0157 inch.

Fig. 11 Snap ring selective chart. Exc. MR2, Pickup, 4Runner, 1984-86 Tercel & 1987-88 Tercel Wagon:

29. Install shifting key retainer, then select a suitable snap ring from chart, Fig. 11, that will allow minimum axial end play and install onto shaft.
30. Engage double meshing gear, then install locknut and torque to 90 ft. lbs. Disengage gear, then stake locknut.
31. Install No. 3 shift fork attaching bolt, then torque to 13 ft. lbs.
32. Install transaxle case cover, then insert eight attaching bolts and torque to 22 ft. lbs.
33. Install release bearing retainer, then torque to 65 inch lbs.
34. Apply a suitable lubricant to release bearing hub inside groove, input shaft spline, then the release fork contact surface.
35. Install back-up lamp switch, then torque attaching bolt to 33 ft. lbs.
36. Install speedometer driven gear.
37. Install transaxle assembly.