Part 1

C59 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. INSPECT SYNCHRONIZER RING NO. 3 (Transaxle Unit)

2. INSPECT TRANSMISSION HUB SLEEVE NO. 3 (Transaxle Unit)

3. INSPECT 5TH GEAR (Transaxle Unit)

4. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY (Transaxle Unit)

5. INSTALL OUTPUT SHAFT (MTM) COVER

(a) Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.

NOTE: Fit the output shaft (MTM) cover projection into the case side hollow.

6. INSTALL OUTPUT SHAFT FRONT BEARING

(a) Coat a new output shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.
SST: 09950-60010
09951-00550
SST: 09950-70010
09951-07150

- Be sure to install a new bearing in the correct direction, as shown in the illustration.
- When replacing the output shaft front bearing, replace the output shaft front bearing inner race along with it.

7. INSTALL FRONT TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.
SST: 09950-60010
09951-00370
SST: 09950-70010
09951-07150
Drive in depth:
15.6 to 16.0 mm (0.6142 to 0.6299 in.)
(b) Coat the lip of the front transaxle case oil seal with MP grease.
8. INSTALL INPUT SHAFT FRONT BEARING

(a) Coat a new input shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.
SST: 09950-60010
09951-00420
SST: 09950-70010
09951-07150
Drive in depth:
0 to 0.3 mm (0 to 0.012 in.)
9. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, install a new FR differential case front tapered roller bearing (inner race) to the front differential case.
SST: 09350-32014
09351-32120
SST: 09950-60010
09951-00530

(b) Using SST and a press, install a new FR differential case front tapered roller bearing (outer race) with the shim to the transaxle case.
SST: 09950-60020
09951-00680
SST: 09950-70010
09951-07150
10. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST and a press, install a new FR differential case rear tapered roller bearing (inner race) to the front differential case.
SST: 09350-32014
09351-32120
SST: 09950-60010
09951-00530

(b) Using SST and a press, install a new FR differential case rear tapered roller bearing (outer race) with the shim to the manual transmission case.
SST: 09309-36010
SST: 09950-60020
09951-00710
SST: 09950-70010
09951-07150
11. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

(a) Coat the differential case assembly with gear oil, and install it to the transaxle case.
(b) Install the manual transmission case with the 16 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)

(c) Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle.
SST: 09564-32011

(d) Using SST and a torque wrench, measure the preload.
SST: 09564-32011
New bearing preload (at starting) - Torque: 0.78 to 1.57 Nm (8 to 16 kgf-cm, 6.9 to 13.9 in-lbf)
If the preload is out of specification, select another shim.
Shim thickness:

HINT: The preload will change by about 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) corresponding to a change of 0.05mm(0.0020 in.) in shim thickness.

(e) Remove the 16 bolts and manual transmission case from the transaxle case.
(f) Remove the differential case assembly from the transaxle case.
12. INSTALL TRANSMISSION CASE OIL SEAL

(a) Using SST and a hammer, install a new transmission case oil seal to the manual transmission case.
SST: 09316-60011
09316-00011
Drive in depth:
9.6 to 10.2 mm (0.378 to 0.402 in.)
(b) Coat the lip of the transmission case oil seal with MP grease.
13. INSTALL TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, install a new transaxle case oil seal in the transaxle case.
SST: 09710-20011
09710-06071
SST: 09950-70010
09951-07150
Drive in depth:
1.6 to 2.2 mm (0.063 to 0.087 in.)
(b) Coat the lip of the transaxle case oil seal with MP grease.
14. INSTALL TRANSMISSION MAGNET

(a) Clean the transmission magnet, and install it to the transmission case.
15. INSTALL BEARING LOCK PLATE

(a) Install the bearing lock plate with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)
16. INSTALL OIL RECEIVER PIPE NO. 1 (MTM)

(a) Install the oil receiver pipe No. 1 (MTM) with the bolt to the manual transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft-lbf)

- Prevent the oil receiver pipe No. 1 (MTM) from being deformed.
- Install the oil receiver pipe No. 1 (MTM) while placing it against the manual transmission case, as shown in the illustration.

17. INSTALL OIL RECEIVER PIPE NO. 2 (MTM)

(a) Install the oil receiver pipe No. 2 (MTM) with the bolt to the manual transmission case.
Torque: 17 Nm (175 kgf-cm, 13 ft-lbf)

- Prevent the oil receiver pipe No. 2 (MTM) from being deformed.
- Install the oil receiver pipe No. 2 (MTM) while placing it against the manual transmission case, as shown in the illustration.

18. INSTALL REVERSE RESTRICT PIN ASSEMBLY

(a) Install the reverse restrict pin assembly to the manual transmission case.

NOTE: Do not set the reverse restrict pin assembly in an incorrect orientation.

(b) Using a pin punch (dia5 mm) and hammer, install the slotted pin to the reverse restrict pin assembly.
Standard clearance (A):
15.5 to 16.5 mm (0.6102 to 0.6496 in.)
(c) Apply sealant to the reverse restrict pin plug.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(d) Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug to the manual transmission case.
Torque: 13 Nm (130 kgf-cm, 9 ft-lbf)
19. INSTALL MANUAL TRANSAXLE CASE RECEIVER

(a) Install the manual transaxle case receiver with the bolt to the transaxle case.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)
20. INSTALL DIFFERENTIAL CASE ASSEMBLY

(a) Coat the differential case tapered roller bearing with gear oil, and install the differential case assembly to the transaxle case.
21. INSTALL INPUT SHAFT ASSEMBLY

(a) Coat the sliding and rotating surfaces of the input and output shafts with gear oil, and install them to the transaxle case.
22. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

HINT: Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.

23. INSTALL GEAR SHIFT FORK SHAFT SUB-ASSEMBLY NO. 1

(a) Coat the gear shift fork No. 1 and gear shift fork No. 2 with gear oil, and install them.

(b) Coat the gear shift fork shaft sub-assembly No. 1 with gear oil, and install it.
(c) Apply sealant to the shift fork lock bolt.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Install the gear shift fork lock bolt.
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)

(e) Using a brass bar and a hammer, install the snap ring to the gear shift fork shaft No. 1.
24. INSTALL GEAR SHIFT FORK SHAFT NO. 3

(a) Coat the 2 balls with MP grease, and install them to the reverse shift fork.
(b) Install the reverse shift fork to the gear shift fork shaft No. 3.

(d) Coat the gear shift fork shaft No. 3 with gear oil, and install it.
25. INSTALL GEAR SHIFT FORK SHAFT NO. 2

(a) Coat the gear shift head No. 1 and gear shift fork shaft No. 2 with gear oil, and install them.

NOTE: To avoid the interference of the 2 shift fork balls, lift up the gear shift fork shaft No. 3 to the position shown in the illustration.

(b) Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No. 2 and gear shift head No. 1.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft-lbf)
26. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Install the reverse shift arm bracket assembly with the 2 bolts to the transaxle case.
Torque: 17 Nm (175 kgf-cm, 13 ft-lbf)
27. INSTALL MANUAL TRANSMISSION CASE

(a) Apply FIPG to the manual transmission case, as shown in the illustration.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

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

(b) Install the 13 bolts with sealant, and install them to the manual transmission case.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)

(c) Install the 3 bolts with sealant, and install them to the transaxle case.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
28. 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)