БЛОК МЕХАНИЧЕСКОЙ ТРАНСМИССИИ > ПОВТОРНАЯ СБОРКА

для подготовки Нажмите здесь



1. INSTALL OUTPUT SHAFT ASSEMBLY


    A00JW22E01

  1. Install the output shaft to the intermediate plate by pushing on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.

  1. Using a snap ring expander, install the snap ring to the center bearing.

    УКАЗАНИЕ:
    Make sure the shaft snap ring is flush with the intermediate plate surface.



2. INSTALL INPUT SHAFT ASSEMBLY


    A00JZHT

  1. Coat the input shaft and No. 2 synchronizer ring with gear oil, and install them to the output shaft.



3. INSTALL COUNTER GEAR ASSEMBLY


    A00JXSNE01

  1. Coat the input shaft and No. 2 synchronizer ring with gear oil.

  1. Temporarily install the counter gear, input shaft and a new center bearing to the intermediate plate.

    ПРИМЕЧАНИЕ:
    Install the bearing (with snap ring) to the rear side of the counter gear.



    A00JW8JE01

  1. Using a plastic-faced hammer, install the center bearing to the intermediate plate by tapping the outer race to the counter gear center bearing.

    УКАЗАНИЕ:
    Hold the front side of the counter gear by hand.

  1. Using a snap ring expander, install the counter shaft center bearing snap ring to the counter shaft center bearing.



4. INSTALL OUTPUT SHAFT REAR BEARING RETAINER

  1. Using a T40 "TORX" socket, install the output shaft rear bearing retainer to the intermediate plate with the 4 screws.

    Момент затяжки:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }



5. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

  1. Install the reverse idler gear shaft and reverse idler gear to the intermediate plate.

  1. Install the reverse idler gear shaft stopper to the intermediate plate with the bolt.

    Момент затяжки:
    17 N*m{ 173 kgf*cm , 13 ft.*lbf }



6. INSTALL REVERSE SHIFT ARM BRACKET

  1. Install the reverse shift arm bracket to the intermediate plate with the 2 bolts.

    Момент затяжки:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }



7. INSTALL 5TH GEAR BEARING INNER RACE LOCK BALL

  1. Install the lock ball.



8. INSTALL 5TH GEAR THRUST WASHER

  1. Install the 5th gear thrust washer.



9. INSTALL NO. 3 TRANSMISSION HUB SLEEVE

  1. Coat the counter shaft 5th gear with gear oil.



    A00JZ1PE01
    A00JZMB

  1. Install the counter 5th gear, counter shaft 5th gear bearing, 3 synchromesh shifting keys, 2 synchromesh shifting key springs and No. 3 transmission hub sleeve.
    Text in Illustration 
    *1
    		No. 3 Transmission Hub Sleeve
    *2
    		No. 3 Synchromesh Shifting Key Spring
    *3
    		Counter Shaft 5th Gear Bearing
    *4
    		No. 3 Synchromesh Shifting Key
    *5
    		Counter Shaft 5th Gear

    УКАЗАНИЕ:
    Be sure to set the No. 3 transmission hub sleeve and 3 synchromesh shifting keys to the counter shaft 5th gear incorrect direction.
    Text in Illustration 
    A00JWY4
    		Front



10. INSTALL COUNTER SHAFT 5TH GEAR


    A00JVO1E01

  1. Install the counter 5th gear bearing to the 5th gear.

  1. Install the counter shaft 5th gear to the counter gear.



    A00K268E01

  1. Temporarily install the No. 1 synchronizer ring on the No. 5 gear spline piece.



    A00JZ3NE01

  1. Remove the intermediate plate from the vise.

  1. Stand the transmission as shown in the illustration.



    A00JZV3E01

  1. Using a press and 22 mm socket wrench, install the No. 5 gear spline piece with the No. 1 synchronizer ring slots aligned with the shifting keys.

  1. Fix the intermediate plate in a vise between aluminum plates.



    A00JU1JE01

  1. Select a snap ring that will allow minimal axial play.

    Standard clearance:
    0.10 mm (0.00394 in.) or less

    Standard Counter Gear Rear Shaft Snap Ring:
    Mark
    		Thickness
    A
    		2.80 to 2.85 mm (0.110 to 0.112 in.)
    B
    		2.85 to 2.90 mm (0.112 to 0.114 in.)
    C
    		2.90 to 2.95 mm (0.114 to 0.116 in.)
    D
    		2.95 to 3.00 mm (0.116 to 0.118 in.)
    E
    		3.00 to 3.05 mm (0.118 to 0.120 in.)
    F
    		3.05 to 3.10 mm (0.120 to 0.122 in.)
    G
    		3.10 to 3.15 mm (0.122 to 0.124 in.)



    A00K245E01

  1. Using a brass bar and hammer, tap the snap ring to the counter gear.



11. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    A00JVGHE01

  1. Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

    Standard clearance:
    0.10 to 0.30 mm (0.00394 to 0.0118 in.)

    1. If the result is not as specified, replace the counter shaft 5th gear.



12. INSTALL NO. 2 GEAR SHIFT FORK SHAFT


    A00K0HKE02

  1. Install the No. 2 gear shift fork and No. 1 gear shift fork.

  1. Pass the No. 2 gear shift fork shaft through the intermediate plate, No. 2 gear shift fork and No. 1 gear shift fork to install it.



    A00JX1QE01

  1. Using a brass bar and hammer, tap the shaft snap ring onto the No. 2 gear shift fork shaft.

  1. Install the bolt to the No. 2 gear shift fork.

    Момент затяжки:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



13. INSTALL NO. 2 SHIFT INTERLOCK PIN


    A00K1MBE01

  1. Coat the No. 2 shift interlock pin with MP grease and install it to the No. 1 gear shift fork shaft.



14. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

  1. Coat the No. 1 shift interlock pin with MP grease.



    A00JVQGE01

  1. Using a magnet hand, install the No. 1 shift interlock pin to the intermediate plate.

  1. Pass the No. 1 gear shift fork shaft through the intermediate plate and No. 2 gear shift fork to install it.

  1. Install the bolt to the No. 1 shift fork.

    Момент затяжки:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



    A00JUPFE01

  1. Using pliers, install the shaft snap ring to the No. 1 gear shift fork shaft.



15. INSTALL REVERSE SHIFT ARM


    A00K1A8

  1. Install the shift arm shoe E-ring and the shift arm shoe to the reverse shift arm.



    A00JWIO

  1. Install the reverse shift arm E-ring and reverse shift fork to the reverse shift arm.

  1. Install the reverse shift arm to the reverse shift arm bracket.



16. INSTALL NO. 2 SHIFT INTERLOCK PIN


    A00JTXVE01

  1. Coat the No. 2 shift interlock pin with MP grease, and install it to the No. 3 gear shift fork shaft.



17. INSTALL NO. 3 SHIFT INTERLOCK PIN


    A00JYUN

  1. Coat the No. 3 shift interlock pin with MP grease.

  1. Using a magnet hand, install the No. 3 shift interlock pin to the intermediate plate.



18. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

  1. Install the No. 3 gear shift fork shaft through the reverse shift fork and intermediate plate.



    A00JV0P

  1. Install the reverse shift head ring to the reverse shift fork shaft.

  1. Using a 5 mm pin punch and a hammer, tap in the slotted spring pin to the No. 3 shift fork shaft.



19. INSTALL NO. 5 GEAR SHIFT FORK SHAFT


    A00K00PE03

  1. Install the No. 5 gear shift fork shaft and reverse shift head.

  1. Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the No. 3 shift fork shaft.



20. INSTALL NO. 4 GEAR SHIFT FORK SHAFT


    A00K17A

  1. Coat the 2 shift detent balls with MP grease.

  1. Using a magnet hand, install the 2 shift detent balls to the intermediate plate.



    A00K1R6

  1. Pass the No. 4 gear shift fork shaft through the reverse shift fork, intermediate plate and reverse shift head to install it.

  1. Install a new No. 3 gear shift fork with the bolt.

    Момент затяжки:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



21. INSTALL NO. 2 SHIFT DETENT BALL


    A00K02ZE01

  1. Coat the No. 2 detent ball with MP grease.

  1. Install the No. 2 detent ball and compression spring to the intermediate plate.

  1. Coat the spring seat with adhesive.

    Adhesive:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  1. Using a T40 "TORX" socket, install the spring seat to the intermediate plate.

    Момент затяжки:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



22. INSTALL SHIFT DETENT BALL

  1. Coat the 3 shift detent balls with MP grease, and then install them and the 3 compression springs to the intermediate plate.

  1. Coat the spring seat and 2 ball plugs with adhesive.

    Adhesive:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  1. Using a T40 "TORX" socket, install the spring seat and 2 ball plugs to the intermediate plate.

    Момент затяжки:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



23. INSTALL MANUAL TRANSMISSION CASE


    A00JTWSE02

  1. Apply seal packing to the transmission case as shown in the illustration.

    Seal packing:
    Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    Text in Illustration 
    *1
    		Seal Packing



    A00JZJR

  1. Stand the intermediate plate as shown in the illustration.

  1. Using a plastic-faced hammer, install the transmission case to the intermediate plate as shown in the illustration.



24. INSTALL NO. 1 COUNTER GEAR FRONT BEARING SNAP RING

  1. Using a snap ring expander, install the snap ring to the counter gear front bearing.



25. INSTALL FRONT BEARING SHAFT SNAP RING

  1. Using a snap ring expander, install the snap ring to the input shaft front bearing.



26. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL


    A00JZ50E03

  1. Using SST, press in a new oil seal to the front bearing retainer.

    SST
    09950-60010   (09951-00440, 09952-06010)

    Standard depth:
    12.2 to 13.2 m (0.480 to 0.519 in.)

    Text in Illustration 
    *a
    		Oil Seal Depth

    ПРИМЕЧАНИЕ:
    Do not damage the oil seal lip.

  1. Apply a light coat of MP grease to the lip of the oil seal.



27. INSTALL FRONT BEARING RETAINER

  1. Install a new gasket and the front bearing retainer to the transmission case.

  1. Install the 8 bolts.

    Момент затяжки:
    17 N*m{ 173 kgf*cm , 13 ft.*lbf }



28. INSTALL TRANSFER ADAPTER OIL SEAL


    A00K0JIE01

  1. Using SST, tap in a new oil seal to the transfer adaptor.

    SST
    09223-00010  

    Standard depth:
    45 to 46 mm (1.78 to 1.81 in.)

    ПРИМЕЧАНИЕ:
    Be careful not to damage the lip of the oil seal.

  1. Apply a light coat of MP grease to the lip of the oil seal.



29. INSTALL NO. 1 REVERSE RESTRICT PIN ASSEMBLY

  1. Install the restrict pin to the transfer adaptor.

  1. Using a 5 mm pin punch and hammer, tap in the slotted spring pin to the transfer adaptor.

  1. Using a T40 "TORX" socket, install the plug to the transfer adaptor.

    Момент затяжки:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



30. INSTALL SHIFT AND SELECT LEVER


    A00JZSXE03

  1. Install the shift and select lever and shift lever housing to the transfer adaptor.
    Text in Illustration 
    *1
    		Shift Lever Housing
    *2
    		Shift and Select Lever



31. INSTALL TRANSFER OIL RECEIVER PIPE

  1. Install the oil receiver pipe to the transfer adaptor.



32. INSTALL TRANSMISSION MAGNET

  1. Install the magnet to the transfer adaptor.



33. INSTALL TRANSFER ADAPTER


    A00JU88E02

  1. Apply seal packing to the transfer adaptor as shown in the illustration.

    Seal packing:
    Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    Text in Illustration 
    *1
    		Seal Packing



    A00K0L6E01

  1. Install the transfer adaptor to the manual transmission case with the 8 bolts.

    Момент затяжки:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

    УКАЗАНИЕ:
    Each bolt length is indicated below.
    80 mm (3.15 in.) for bolt A
    130 mm (5.12 in.) for bolt B

  1. Install the bolt to the shift lever housing.

    Момент затяжки:
    33 N*m{ 340 kgf*cm , 25 ft.*lbf }



34. INSTALL SHIFT DETENT BALL


    A00K284E02

  1. Coat the shift detent ball with MP grease, and then install it and the compression spring to the transfer adapter.

  1. Using a T40 "TORX" socket, install the spring seat to the transfer adapter.

    Момент затяжки:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



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

  1. Install a new gasket to the transfer adapter.

  1. Install the shift lever retainer with the 4 bolts.

    Момент затяжки:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }



36. INSTALL RESTRICT PIN

  1. Install the 2 restrict pins to the transfer adaptor.

    Момент затяжки:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }



37. INSTALL FRONT TRANSMISSION CASE


    A00JZ8DE01

  1. Install the front transmission case.

  1. Apply adhesive to the bolt threads.

    Adhesive:
    Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

  1. Install the 9 bolts.

    Момент затяжки:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



38. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY


    A00JYGGE01

  1. Using SST, install a new gasket and the back-up light switch to the manual transmission case.

    SST
    09817-16011  

    Момент затяжки:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



39. INSTALL CLUTCH RELEASE FORK BOOT

  1. Install the release fork boot to the front transmission case.



40. INSTALL RELEASE FORK SUPPORT

  1. Install the release fork support to the front transmission case.

    Момент затяжки:
    39 N*m{ 400 kgf*cm , 29 ft.*lbf }



41. INSTALL CLUTCH RELEASE BEARING ASSEMBLY


A00JZJTE01

  1. Apply release hub grease to the clutch release bearing, and then install it to the clutch release fork with the clip.

    Grease:
    Toyota Genuine Release Hub Grease or equivalent

    Text in Illustration 
    *a
    		Release hub grease



42. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

  1. Install the clutch release fork.

    ПРИМЕЧАНИЕ:
    After the installation, move the fork forward and backward to check that the release bearing slides smoothly.



    A00K167E01

  1. Apply clutch spline grease to the spline of the input shaft.

    Grease:
    Toyota Genuine Clutch Spline Grease or equivalent

    Text in Illustration 
    *a
    		Clutch spline grease



43. INSTALL DRAIN PLUG SUB-ASSEMBLY

  1. Install a new gasket and the drain plug to the transmission case.

    Момент затяжки:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



44. INSTALL MANUAL TRANSMISSION FILLER PLUG

  1. Install a new gasket and the filler plug to the transmission case.

    Момент затяжки:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }