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Home >> Toyota >> 2005 >> Matrix 2WD L4-1.8L (2ZZ-GE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Overhaul (Transmission) >> Manual Transmission Unit >> Part 3

Part 3

OVERHAUL Continued





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





b. Coat the gear shift fork shaft No.3 with gear oil, and install it to the transaxle case.





84. INSTALL GEAR SHIFT FORK SHAFT SUB-ASSEMBLY NO.1
a. Coat the gear shift fork shaft sub-assembly No.1 with gear oil, and install it to the transaxle case.
b. Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No.1.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





c. Using a brass bar and a hammer, install the shaft snap ring.





85. INSTALL SHIFT DETENT BALL
a. Install the shift detent ball, shift detent ball compression spring and shift detent ball compression spring seat to the transaxle case.





b. Coat the shift detent ball plug with sealant, and using SST, install it to the transaxle case.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





86. 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. lbs.)





87. 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. lbs.)





88. INSTALL MANUAL TRANSMISSION CASE
a. Apply FIPG to the manual transmission case, as shown in the illustration.
FIPG: Part No.08826-00090, 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.





b. Install the 13 bolts to the manual transmission side.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





c. Install the 3 bolts to the transaxle case side.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





89. INSTALL REVERSE IDLER GEAR SHAFT BOLT
a. Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket to the manual transmission case.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





90. INSTALL MANUAL TRANSMISSION CASE PLUG
a. Coat the transmission case plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





91. INSTALL REVERSE RESTRICT PIN PLUG
a. Coat the transmission case plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





92. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.





93. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
a. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.





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





95. INSTALL SHIFT DETENT BALL
a. Install the 2 shift detent balls, 2 shift detent ball springs and 2 shift detent ball spring seats to the manual transmission case.





b. Coat the 2 shift detent ball plugs with sealant, and install them to the manual transmission case.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





96. INSTALL BACK UP LAMP SWITCH ASSEMBLY
a. Using SST, install the back up lamp switch assembly with a new gasket to the manual transmission case.
SST 09817-16011
Torque: 40 Nm (411 kgf-cm, 30 ft. lbs.)





97. INSTALL SHIFT & SELECT LEVER SHAFT ASSEMBLY
a. Coat the shift & select lever shaft assembly with gear oil.
b. Coat the 2 bolts with sealant, and install them, 2 bolts, a new gasket and the shift & select lever shaft assembly to the manual transmission case.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





98. INSTALL LOCK BALL ASSEMBLY NO.1
a. Coat the lock ball assembly No.1 with sealant, and install it to the manual transmission case.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





99. INSTALL BEARING RETAINER REAR (MTM)
a. Coat the 5 bolts with sealant, and install the bearing retainer rear to the manual transmission case with the bolts.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 27 Nm (279 kgf-cm, 20 ft. lbs.)





100. INSTALL SHIFT FORK SHAFT SNAP RING
a. Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No.2.





101. INSTALL 5TH DRIVEN GEAR
a. Using SST, install the 5th driven gear to the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)





102. INSTALL OUTPUT GEAR SPACER
a. Install the output gear spacer to the output shaft.





103. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
a. Coat the two 5th gear bearing spacers and 5th gear needle roller bearing with gear oil, and install them to the input shaft.





b. Using a brass bar and a hammer, install the transmission clutch hub No.3 shaft snap ring to the input shaft.





104. INSTALL 5TH GEAR
a. Coat the 5th gear with gear oil, and install it to the input shaft.





105. INSTALL SYNCHRONIZER RING NO.3 (FOR 5TH GEAR MT)
a. Coat the synchronizer ring No.3 with gear oil, and install it to the 5th gear.





106. INSTALL TRANSMISSION CLUTCH HUB NO.3
a. Using SST and a hammer, install the transmission clutch hub No.3 with the gear shift fork No.3 to the input shaft. SST 09608-0403 1

NOTICE:
^ Before driving in the transmission clutch hub No.3, place a suitable sized wooden block under the rear side of the input shaft, as shown in the illustration.
^ When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded and might be damaged.





b. Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No.3.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)





c. Select the snap ring that allows the minimum amount of axial play.
Clearance: 0.1 mm (0.004 inch) or less





Snap ring thickness

d. Using a brass bar and a hammer, install the transmission clutch hub No.3 snap ring to the input shaft.





107. INSTALL COUNTER GEAR 6TH
a. Using SST, install the counter gear 6th to the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)





108. INSTALL SYNCHRONIZER RING NO.3 (FOR 6TH GEAR MT)
a. Coat the synchronizer ring No.3 with gear oil, and install it to the transmission clutch hub No.3.





109. INSTALL 6TH GEAR NEEDLE ROLLER BEARING
a. Coat the 6th gear needle roller bearing and 6th gear spacer with gear oil, and install them to the input shaft.





110. INSTALL 6TH GEAR SUB-ASSEMBLY
a. Coat the 6th gear sub-assembly with gear oil, and install it to the input shaft.





111. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING
a. Using SST, a steel block and a hammer, install the input shaft rear radial ball bearing to the input shaft.
SST 09608-04031





b. Select the input shaft snap ring that allows the minimum amount of axial play.
Clearance: 0.1 mm (0.004 inch) or less





Snap ring thickness

c. Using a brass bar and hammer, install the input shaft snap ring to the input shaft.





112. INSTALL OUTPUT SHAFT REAR BEARING
a. Using SST, install the output shaft rear bearing to the output shaft.
SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)





b. Select the output shaft RR snap ring that allows the minimum amount of axial play.
Clearance: 0.1 mm (0.004 inch) or less





Snap ring thickness

c. Using a brass bar and hammer, install the output shaft RR snap ring to the output shaft.





113. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance: 0.015 to 0.056 mm (0.0006 to 0.0022 inch)
If the clearance is out of specification, replace the 5th gear needle roller bearing.





114. INSPECT 6TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 6th gear radial clearance.
Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 inch)
If the clearance is out of specification, replace the 6th gear needle roller bearing.





115. INSPECT 5TH GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance: 0.10 to 0.62 mm (0.0039 to 0.0244 inch)





116. INSPECT 6TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the 6th gear thrust clearance.
Standard clearance: 0.10 to 0.60 mm (0.0039 to 0.0236 inch)





117. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
a. Apply FIPG to the manual transmission case cover sub-assembly.
FIPG: Parts No.08826-00090, 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.





b. Install the manual transmission case cover sub-assembly with the 9 bolts to the manual transmission case.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





118. INSTALL DRAIN (MTM) PLUG SUB-ASSEMBLY
a. Install the drain (MTM) plug sub-assembly with a new gasket to the manual transmission case.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





119. INSTALL MANUAL TRANSMISSION FILLER PLUG
a. Install the manual transmission filler plug with a new gasket to the manual transmission case cover.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





120. INSTALL SELECTING BELL CRANK ASSEMBLY
a. Install the selecting bell crank assembly and control shift lever bush with the 2 bolts to the manual transmission case.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

NOTICE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).





121. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
a. Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





122. INSTALL CLUTCH RELEASE FORK BOOT
a. Install the clutch release fork boot to the transaxle case.





123. INSTALL RELEASE FORK SUPPORT
a. Install the release fork support to the transaxle case.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
b. Coat the release fork support with release hub grease.
Release hub grease: Part No.08887-01806, RELEASE HUB GREASE or equivalent





124. INSTALL CLUTCH RELEASE BEARING ASSEMBLY
a. Coat the clutch release bearing assembly with release hub grease, and install it to the clutch release fork sub-assembly with the bearing clip.
Release hub grease: Part No.08887-01806, RELEASE HUB GREASE or equivalent





125. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a. Apply clutch spline grease to the input shaft spline.
Clutch spline grease: Part No.08887-01806, CLUTCH SPLINE GREASE or equivalent
b. Install the clutch release fork sub-assembly to the input shaft.
126. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
a. Install a new O-ring to the speedometer driven hole cover sub-assembly.
b. Install the speedometer driven hole cover sub-assembly with the bolt to the transaxle case.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
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