Part 1
C50 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT (for Hatchback): REASSEMBLY
1. INSTALL OUTPUT SHAFT COVER
Text in Illustration
(a) Coat the output shaft cover with MP grease and install it onto the front transaxle case.
NOTICE:
Insert the output shaft cover projection into the case side hollow.
2. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Coat a new output shaft front bearing with gear oil. Using SST and a press, install it onto the front transaxle case.
SST : 09950-60010
09951-00550
SST : 09950-70010
09951-07150
NOTICE:
* Install the 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 at the same time.
3. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new front transaxle case oil seal onto the front transaxle case.
SST : 09950-60010
09951-00370
SST : 09950-70010
09951-07150
Drive in depth:
15.6 to 16.0 mm (0.614 to 0.630 in.)
(b) Coat the lip of the front transaxle case oil seal with MP grease.
4. INSTALL INPUT SHAFT FRONT BEARING
(a) Coat a new input shaft front bearing with gear oil, and using SST and a press, install it onto the front transaxle case.
SST : 09950-60010
09951-00420
SST : 09950-70010
09951-07150
Drive in depth:
0 to 0.3 mm (0 to 0.0118 in.)
5. INSTALL SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
(a) Using SST and a hammer, install the shift and select lever shaft slide ball bearing onto the manual transmission case.
SST : 09950-60010
09951-00220
SST : 09950-70010
09951-07100
Drive in depth:
0 to 0.5 mm (0 to 0.00197 in.)
6. INSTALL SHIFT AND SELECT LEVER SHAFT OIL SEAL
(a) Using SST, install the shift and select lever shaft oil seal onto the manual transmission case.
SST : 09950-70010
09951-07150
SST : 09950-60010
09951-00240
Drive in depth:
9.7 to 10.3 mm (0.382 to 0.406 in.)
7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case front tapered roller bearing (inner race) onto the front differential case.
SST : 09350-32014
09351-32120
SST : 09950-60010
09951-00530
(b) Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the front differential case front plate washer onto the front transaxle case.
SST : 09950-60020
09951-00680
SST : 09950-70010
09951-07150
8. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential case rear tapered roller bearing (inner race) onto the differential case.
SST : 09350-32014
09351-32120
SST : 09950-60010
09951-00530
(b) Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with front differential case rear plate washer onto the manual transmission case.
SST : 09309-36010
SST : 09950-60020
09951-00710
SST : 09950-70010
09951-07150
HINT
Use a plate washer of the same thickness as the removed one.
9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Coat the differential case assembly with gear oil, and install it onto the front 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
Preload (at starting):
New bearing
0.78 to 1.57 N*m (8.0 to 16.0 kgf*cm, 7.0 to 13.8 in.*lbf)
Used bearing
0.49 to 0.98 N*m (5.0 to 9.0 kgf*cm, 4.4 to 8.6 in.*lbf)
If the preload is outside the specifications, select another plate washer.
Plate Washer Thickness:
HINT
The preload changes by approximately 0.3 to 0.4 N*m (3.1 to 4.0 kgf*cm, 2.7 to 3.5 in.*lbf) per each 0.05 mm (0.00197 in.) change in plate washer thickness.
(e) Remove the 16 bolts and the manual transmission case.
(f) Remove the differential case assembly from the front transaxle case.
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Using SST and a hammer, install a new transmission case oil seal onto 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 front transmission case oil seal with MP grease.
11. INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new transaxle case oil seal onto the front transaxle case.
Drive in depth:
1.4 to 2.0 mm (0.0551 to 0.0787 in.)
SST : 09710-20011
09710-06071
SST : 09950-70010
09951-07150
(b) Coat the lip of the transaxle case oil seal with MP grease.
12. INSTALL TRANSMISSION MAGNET
(a) Clean the transmission magnet and install it onto the front transaxle case.
13. INSTALL BEARING LOCK PLATE
(a) Install the bearing lock plate onto the front transaxle case with the bolt.
Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)
14. INSTALL NO. 1 OIL RECEIVER PIPE
(a) Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt.
Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)
NOTICE:
* Do not deform the No. 1 oil receiver pipe.
* Install the No. 1 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.
15. INSTALL NO. 2 OIL RECEIVER PIPE
(a) Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt.
Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)
NOTICE:
* Do not deform the No. 2 oil receiver pipe.
* Install the No. 2 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.
16. INSTALL REVERSE RESTRICT PIN ASSEMBLY
(a) Install the reverse restrict pin assembly onto the manual transmission case.
NOTICE:
Set the reverse restrict pin assembly in the correct orientation.
(b) Using a pin punch (dia5 mm) and a hammer, install the slotted pin onto the reverse restrict pin assembly.
Drive in depth:
15.5 to 16.5 mm (0.611 to 0.650 in.)
(c) Apply adhesive to the reverse restrict pin plug.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(d) Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
17. INSTALL MANUAL TRANSAXLE CASE RECEIVER
(a) Install the manual transaxle case receiver onto the front transaxle case with the bolt.
Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)
18. INSTALL DIFFERENTIAL CASE ASSEMBLY
(a) Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.
NOTICE:
Do not damage the tapered roller bearing.
19. INSTALL INPUT SHAFT ASSEMBLY
(a) Coat the sliding and rotating surfaces of the input shaft assembly and output shaft assembly with gear oil and install them onto the front transaxle case.
NOTICE:
Do not damage the oil seal.
20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
(a) Coat the reverse idler gear sub-assembly, reverse idler thrust washer and reverse idler gear shaft with gear oil and install them as shown in the illustration.
Text in Illustration
HINT
Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.
21. INSTALL NO. 1 GEAR SHIFT FORK SHAFT
(a) Coat the No. 1 gear shift fork and the No. 2 gear shift fork with gear oil and install them.
Text in Illustration
(b) Coat the No. 1 gear shift fork shaft with gear oil and install it.
Text in Illustration
(c) Apply adhesive to the shift fork set bolt.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(d) Install the shift fork set bolt.
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
(e) Using a brass bar and a hammer, install a new snap ring onto the No. 1 gear shift fork shaft.
22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT
(a) Coat the 2 shift fork balls with MP grease and install them onto the reverse shift fork.
(b) Install the reverse shift fork onto the No. 3 shift fork shaft gear.
(c) Using a brass bar and a hammer, install 2 new snap rings onto the No. 3 shift fork shaft.
(d) Coat the No. 3 shift fork shaft gear with gear oil and install it.
23. INSTALL NO. 2 GEAR SHIFT FORK SHAFT
(a) Coat the No. 1 gear shift head and the No. 2 gear shift fork shaft with gear oil and install them.
NOTICE:
To avoid interference by the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.
(b) Coat the 2 shift fork set bolts with adhesive and install them onto the No. 2 gear shift fork and the No. 1 shift head.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY
(a) Install the reverse shift arm bracket assembly onto the front transaxle case with 2 bolts.
Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)
25. INSTALL MANUAL TRANSMISSION CASE
(a) Apply a continuous bead of seal packing (Diameter 1.2 mm (0.0472 in.)) to the manual transmission case as shown in the illustration.
Text in Illustration
Seal Packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
NOTICE:
* Remove any oil from the contact surfaces.
* Assemble the parts within 10 minutes of application. Otherwise, the seal packing material must be removed and reapplied.
(b) Install the 13 bolts onto the manual transmission side.
Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
(c) Install the 3 bolts onto the manual transaxle side.
Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
26. INSTALL REVERSE IDLER GEAR SHAFT BOLT
(a) Coat the reverse idler gear shaft bolt with adhesive and install it with a new gasket.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
27. INSTALL NO. 2 LOCK BALL ASSEMBLY
(a) Coat the No. 2 lock ball assembly with adhesive and install it with a hexagon wrench.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
28. INSTALL SHIFT DETENT BALL
(a) Install the 2 shift detent balls, 2 compression springs and 2 spring seats onto the manual transmission case.
(b) Coat the 2 shift detent ball plugs with adhesive and install them using a hexagon wrench.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)
(c) Install the shift detent ball, compression spring and the spring seat onto the front transaxle case.
(d) Coat the shift detent ball plug with adhesive and install it using a hexagon wrench.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)
29. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING
(a) Using a snap ring expander, install the input shaft rear bearing hole snap ring onto the input shaft assembly.