Part 2
C50 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT (for Hatchback): REASSEMBLY - (Continued)
30. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING
(a) Using a snap ring expander, install the output shaft rear bearing hole snap ring onto the output shaft assembly.
31. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using a brass bar and a hammer, install a new shift fork shaft shaft snap ring onto the No. 2 shift fork shaft.
32. INSTALL REAR BEARING RETAINER
(a) Coat the 5 bolts with adhesive, and install the rear bearing retainer onto the manual transmission case with the 5 bolts.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
Torque : 27 Nm (280 kgf-cm, 20 ft-lbf)
33. INSTALL 5TH DRIVEN GEAR
(a) Using SST, install the 5th driven gear onto the output shaft assembly.
SST : 09309-12020
34. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft assembly.
35. INSTALL 5TH GEAR
(a) Coat the 5th gear with gear oil and install it onto the input shaft assembly.
36. INSTALL NO. 3 SYNCHRONIZER RING
(a) Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.
37. INSTALL NO. 3 TRANSMISSION CLUTCH HUB
(a) Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the No. 3 transmission clutch hub as shown in the illustration.
Text in Illustration
NOTICE:
Do not set the 2 shifting key spring openings in the same position.
(b) Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft assembly.
SST : 09636-20010
Text in Illustration
NOTICE:
* Do not install the No. 3 transmission clutch hub in the wrong direction.
* Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key aligned.
* Check that the 5th gear is rotating.
* Place a suitable sized wooden block to support the input shaft.
(c) Select a No. 3 clutch hub shaft snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.00394 in.) or less
Snap Ring Thickness:
(d) Using a brass bar and a hammer, install the No. 3 clutch hub shaft snap ring onto the input shaft assembly.
38. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 5th gear thrust clearance.
Standard clearance:
0.1 to 0.55 mm (0.00394 to 0.0217 in.)
Maximum clearance:
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, the 5th gear or input shaft rear radial ball bearing.
39. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure 5th gear radial clearance.
Standard clearance:
JTEKT made
0.015 to 0.058 mm (0.000591 to 0.00228 in.)
NSK made
0.015 to 0.056 mm (0.000591 to 0.00220 in.)
Maximum clearance:
JTEKT made
0.058 mm (0.00228 in.)
NSK made
0.056 mm (0.00220 in.)
If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.
40. INSTALL NO. 3 GEAR SHIFT FORK
(a) Coat the No. 3 transmission hub sleeve with gear oil and install it together with the No. 3 gear shift fork onto the No. 3 transmission clutch hub.
HINT
Set the No. 3 transmission clutch hub in the correct orientation.
(b) Coat the shift fork set bolt with adhesive, and install it onto the No. 3 gear shift fork.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
(a) Engage the 2 gears simultaneously to lock the transmission.
(b) Coat a new manual transmission output shaft rear set nut with adhesive.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(c) Install the new manual transmission output shaft rear set nut.
Torque : 118 Nm (1200 kgf-cm, 87 ft-lbf)
(d) Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
(e) Disengage the 2 gears.
42. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
(a) Apply a continuous bead of seal packing (Diameter 1.2 mm (0.0472 in.)) to the manual transaxle case cover sub-assembly 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) Apply adhesive to 2 or 3 threads on the end of the 9 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
(c) Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
43. INSTALL SHIFT AND SELECT LEVER SHAFT ASSEMBLY
(a) Coat the shift and select lever shaft assembly with gear oil, and install it onto the manual transmission case.
44. INSTALL CONTROL SHAFT COVER OIL SEAL
(a) Using SST and a hammer, install a new control shaft cover oil seal onto the control shaft cover.
Drive in depth:
0.2 to 1.2 mm (0.00787 to 0.0472 in.)
SST : 09950-60010
09951-00280
SST : 09950-70010
09951-07150
(b) Coat the control shaft cover oil seal with MP grease.
45. INSTALL CONTROL SHAFT COVER
(a) Coat the 4 bolts with adhesive. Install a new gasket and control shaft cover onto the manual transmission case with the 4 bolts.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
NOTICE:
Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
46. INSTALL SHIFT GATE PIN
(a) Coat the shift gate pin with adhesive.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(b) Install the washer and shift gate pin.
Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)
47. INSTALL NO. 1 LOCK BALL ASSEMBLY
(a) Coat No. 1 lock ball assembly with adhesive, install it onto the manual transmission case.
Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
48. INSTALL SHIFT LEVER DAMPER
(a) Install the dust boot onto the control shaft cover.
(b) Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.
(c) Install the spring washer with the nut.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER
(a) Install the dust boot onto the shift and select lever shaft oil seal.
(b) Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.
(c) Install the spring washer with the nut.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
50. INSTALL SELECTING BELL CRANK ASSEMBLY
(a) Install the selecting bell crank assembly together with the control bell crank dust cover onto the manual transmission case with the 2 bolts and nut.
for Bolt - Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
for Nut - Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
NOTICE:
Apply MP grease to the inside circumferential surface of the control bell crank dust cover.
51. INSTALL BACK UP LIGHT SWITCH ASSEMBLY
(a) Using SST, install the back up light switch assembly onto the manual transmission case with a new gasket.
SST : 09817-16011
Torque : 40 Nm (410 kgf-cm, 30 ft-lbf)
(b) Install the back up light switch wire harness into the 2 clamps.
52. INSTALL MANUAL TRANSMISSION FILLER PLUG
(a) Install the manual transmission filler plug onto the manual transmission case with a new gasket.
Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)
53. INSTALL DRAIN PLUG SUB-ASSEMBLY
(a) Install the drain plug sub-assembly onto the manual transmission case with a new gasket.
Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)