Reassembly

RA62 MANUAL TRANSMISSION: MANUAL TRANSMISSION UNIT: REASSEMBLY

1. INSTALL SHIFT ARM

(a) Install the shift arm and shift arm pivot onto the shift interlock bracket.

(b) Install a new E-ring onto the shift arm pivot.

2. INSTALL NO. 4 GEAR SHIFT FORK SHAFT

(a) Install the compression spring and shift detent ball into the shift interlock bracket.

(b) Install the No. 4 gear shift fork shaft.

3. INSTALL NO. 4 GEAR SHIFT FORK

(a) Install the No. 4 gear shift fork onto the No. 4 gear shift fork shaft.

(b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 4 gear shift fork and No. 4 gear shift fork shaft.

Installation depth:

0 to 0.5 mm (0 to 0.020 in.)

4. INSTALL NO. 1 GEAR SHIFT FORK

(a) Install the No. 1 gear shift fork and No. 2 gear shift head onto the No. 4 gear shift fork shaft.

(b) Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 2 gear shift head and No. 4 gear shift fork shaft.

Installation depth:

0 to 0.5 mm (0 to 0.020 in.)

5. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

(a) Install the compression spring and shift detent ball onto the shift interlock bracket.

(b) Install the No. 3 gear shift head and No. 3 gear shift fork shaft into the shift interlock bracket.

HINT
Place the No. 4 gear shift fork shaft in the neutral position.

(c) Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 3 gear shift head and No. 3 gear shift fork shaft.

Installation depth:

0 to 0.5 mm (0 to 0.020 in.)

6. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

(a) Install the compression spring and shift detent ball into the shift interlock bracket.

(b) Install the No. 2 gear shift fork shaft onto the shift interlock bracket.

HINT
Place the No. 3 and No. 4 gear shift fork shafts in the neutral position.

7. INSTALL NO. 2 GEAR SHIFT FORK

(a) Install the No. 2 gear shift fork with a new bolt.

Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

8. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

(a) Install the compression spring and shift detent ball into the shift interlock bracket.

(b) Install the No. 1 gear shift head and No. 1 gear shift fork shaft onto the shift interlock bracket.

HINT
Place the No. 4, No. 3 and No. 2 gear shift fork shafts in the neutral position.

(c) Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 1 gear shift head and No. 1 gear shift fork shaft.

Installation depth:

0 to 0.5 mm (0 to 0.020 in.)

9. INSTALL NO. 3 GEAR SHIFT FORK

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

Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

(b) Install 4 new snap rings.

10. INSTALL FRONT TRANSMISSION CASE BEARING

(a) Using SST and a press, install the new front transmission case bearing to the front transmission case.

SST : 09950-60010

09951-00230

Installation depth:

0.5 to 1.5 mm (0.0197 to 0.0591 in.)

NOTICE:
Press on the marked side of the front transmission case bearing when installing it to the front transmission case.

11. INSTALL TRANSMISSION CASE OIL SEAL

(a) Using SST and a hammer, tap a new transmission case oil seal into the front case in accordance with the dimension specified in the illustration.

SST : 09950-70010

09951-07100

SST : 09950-60010

09951-00470

Dimension A:

60.0 to 60.8 mm (2.362 to 2.394 in.)

(b) Apply gear oil to the lip of the transmission case oil seal.

12. INSTALL FRONT BEARING SHAFT SNAP RING

(a) Using snap ring pliers, install the 2 front bearing shaft snap rings.

13. INSTALL NO. 1 OIL RECEIVER PIPE

(a) Install the No. 1 oil receiver pipe onto the front transmission case.

HINT
Align the convex portion of the oil receiver pipe with the cutout of the front case and install the oil receiver pipe onto the front transmission case.

14. INSTALL FRONT TRANSMISSION CASE

(a) Apply gear oil to all sliding and rotating parts.

NOTICE:
Make sure that gear oil is not applied to the splines of the input shaft assembly.

(b) Temporarily install the output shaft assembly, input shaft assembly, counter gear assembly and 4 gear shift fork shafts, and tie them with a rope or string.

(c) Using a snap ring expander, extend the 2 front bearing shaft snap rings and install the output shaft assembly, input shaft assembly, counter gear assembly and 4 gear shift fork shafts.

HINT
Make sure that the snap rings are fully engaged into the grooves of the input shaft assembly and front bearing of the counter gear assembly.

(d) Untie the output shaft assembly, input shaft assembly, counter gear assembly and 4 gear shift fork shafts.

(e) Using a hexagon wrench (27 mm), install the plug onto the front transmission case.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

(f) Install the 4 bolts onto the shift interlock bracket.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

15. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

(a) Install the reverse idler gear and reverse idler gear bearing to the reverse idler gear shaft.

(b) Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.050 mm (0.0006 to 0.0020 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

If the clearance exceeds the maximum, replace the reverse idler gear bearing, reverse idler gear shaft or reverse idler gear.

16. INSTALL REVERSE IDLER GEAR

(a) Install the reverse idler gear, reverse idler gear bearing and reverse idler gear shaft.

HINT
Make sure that the reverse idler gear is facing the correct direction as shown in the illustration.

NOTICE:
Make sure that the tapped hole portion of the reverse idler shaft is in the position shown in the illustration.

17. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.130 to 0.214 mm (0.00512 to 0.00842 in.)

Maximum clearance:

0.214 (0.00842 in.)

If the clearance exceeds the maximum, replace the reverse idler gear shaft, reverse idler gear or front transmission case.

18. INSTALL SHIFT AND SELECT LEVER SHAFT

(a) Install the lock ball pin and compression spring into the shift and select lever.

NOTICE:
Apply gear oil to each rotating part.

(b) Install the shift interlock plate, shift and select cam and shift and select lever to the shift and select lever shaft.

NOTICE:
Apply gear oil to each rotating part.

(c) Install the shift interlock plate, shift and select cam, shift and select lever and shift and select lever shaft to the front transmission case.

(d) Align the shift interlock plate and shift and select lever with the head of the control sub-assembly and insert the shift and select lever shaft to the front transmission case.

(e) Align the groove of the shift and select cam with the reverse idler gear shaft.

(f) Using a pin punch (dia5 mm) and a hammer, install a new slotted spring pin onto the shift and select lever.

Driven in depth:

1.0 to 2.0 mm (0.0394 to 0.0787 in.)

NOTICE:
Ensure that the shaft is facing the correct direction when tapping the slotted spring pin into the shift and select lever shaft.

(g) Install a new bolt onto the shift and select lever.

Torque : 33 Nm (340 kgf-cm, 25 ft-lbf)

NOTICE:
Apply gear oil to each rotating portion.

(h) Install a new E-ring to the shift and select lever shaft.

19. INSTALL NO. 2 OIL RECEIVER PIPE

(a) Install the No. 2 oil receiver pipe into the center transmission case.

20. INSTALL TRANSMISSION DRAIN PLUG

(a) Install the drain plug with a new gasket onto the center transmission case.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

21. INSTALL CENTER TRANSMISSION CASE SUB-ASSEMBLY

(a) Clean the seal packing attached on the center transmission case and front transmission case using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

NOTICE:
Do not scratch the fitting surface.

(b) Apply FIPG to the center transmission case, as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, 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.

(c) Install the center transmission case with the 11 bolts onto the front transmission case.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

Bolt length:

Bolt A
40 mm (1.57 in.)

Bolt B
80 mm (3.15 in.)

22. INSTALL REVERSE IDLER GEAR SHAFT BOLT

(a) Install a new gasket and the reverse idler gear shaft bolt onto the reverse idler gear shaft.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

23. INSTALL TRANSMISSION OIL SEPARATOR

(a) Install the transmission oil separator with the 2 bolts.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

24. INSTALL REAR TRANSMISSION CASE BEARING

(a) Using SST and a press, install the rear transmission case bearing to the rear transmission case.

SST : 09950-60010

09951-00230

Installation depth:

1.0 to 2.0 mm (0.0394 to 0.0787 in.)

NOTICE:
Press on the marked side of the rear transmission case bearing when installing it to the rear transmission case.

25. INSTALL COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING

(a) Coat a new counter gear rear cylindrical roller bearing with gear oil, and using SST and a press, install it into the rear transmission case.

SST : 09950-70010

09951-07360

SST : 09950-60010

09951-00650

(b) Install the bearing lock plate with the bolt.

Torque : 11 Nm (115 kgf-cm, 8.3 ft-lbf)

26. INSTALL OUTPUT SHAFT REAR BEARING OUTER RACE

(a) Using SST and a press, press in 2 new output shaft rear bearing outer races.

SST : 09223-15020

SST : 09950-70010

09951-07100

09951-07360

SST : 09950-60020

09951-00790

HINT
Fit the output shaft rear bearing outer race and rear transmission case securely.

27. INSTALL OIL SEPARATOR PACKING SEAL

(a) Install the oil separator packing seal onto the rear transmission case.

HINT
Insert the protruding part of the oil separator packing seal into the groove on the rear transmission case.

28. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

(a) Install the extension housing oil receiver pipe onto the rear transmission case.

29. INSTALL MANUAL TRANSMISSION FILLER PLUG

(a) Install the 2 manual transmission filler plugs with 2 new gaskets onto the rear transmission case.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

30. INSTALL REAR TRANSMISSION CASE

(a) Clean the seal packing attached on the rear transmission case and center transmission case using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

NOTICE:
Do not scratch the fitting surface.

(b) Apply FIPG to the rear transmission case as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, 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.

(c) Install the rear transmission case with the 10 bolts and bracket onto the center transmission case.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

31. INSTALL SHIFT DETENT BALL PLUG

(a) Install the ball and compression spring onto the rear transmission case.

(b) Install a new shift detent ball plug onto the rear transmission case.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

32. INSTALL OUTPUT SHAFT ADJUST NUT

(a) Using a belt and wooden block, securely fasten the transmission to the workbench.

(b) Install a new spacer and a new No. 2 taper roller bearing.

HINT
Fit the spacer and No. 2 taper roller bearing securely.

(d) Move the shift and select lever shaft to N.

(e) Fit the bearing into the output shaft by turning the output shaft 15 times.

(f) Using SST and a torque wrench, inspect preload (at starting)*1.

SST : 09326-35010

09326-03020

SST : 09326-35020

(g) Engage 5th gear, and then secure the input shaft using SST.

SST : 09322-35010

09322-03010

09322-03020

09322-03030

90901-05003

90170-12030

94622-51200

HINT
* Install SST securely so that (A) is in-line with the input shaft.
* Make sure that (A) moves back and forth by hand after installing SST.

(h) Using SST, tighten the output shaft adjust nut.

SST : 09326-35020

Reference without SST - Torque : 410 to 750 Nm (4180 to 7648 kgf-cm, 302 to 551 ft-lbf)

Reference with SST - Torque : 374 to 684 Nm (3814 to 6974 kgf-cm, 275 to 502 ft-lbf)

NOTICE:
* The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 1040 mm (40.9 in.).
* The "with SST" torque value is effective when SST is parallel to the torque wrench.

(i) Move the shift and select lever shaft to N.

(j) Fit the bearing into the output shaft by turning the output shaft 15 times.

(k) Using SST and a torque wrench, inspect preload (at starting)*2.

SST : 09326-35010

09326-03020

SST : 09326-35020

(l) Adjust the preload so that the difference between *1 and *2 is within the specified range.

Preload (at starting) without SST:

*2 - *1 = 0.45 to 1.35 N*m (4.59 to 13.77 kgf*cm, 3.98 to 11.95 in.*lbf)

Preload (at starting) with SST:

*2 - *1 = 0.25 to 0.76 N*m (2.55 to 7.74 kgf*cm, 2.21 to 6.73 in.*lbf)

NOTICE:
* If the result is not as specified, tighten and adjust the output shaft adjust nut.
* If the output shaft adjust nut is loose or removed due to excess preload, always replace the spacer and nut with new ones.

(m) Using a chisel and hammer, stake the output shaft adjust nut.

33. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

(a) Install the extension housing oil receiver pipe.

(b) Using a snap ring expander, install the snap ring.

34. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

(a) Using SST and a hammer, install a new manual transmission extension housing oil seal into the extension housing in accordance with the dimension specified in the illustration.

SST : 09950-60020

09951-00640

SST : 09950-70010

09951-07100

Dimension A:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

(b) Apply gear oil to the lip of the oil seal.

35. INSTALL REAR EXTENSION HOUSING OIL SEAL

(a) Using SST and a hammer, install a new rear extension housing oil seal.

SST : 09612-70100

09612-07210

Installation depth:

4.6 to 5.4 mm (0.1811 to 0.2126 in.)

36. INSTALL EXTENSION HOUSING DUST DEFLECTOR

(a) Using a plastic hammer, install a new extension housing dust deflector.

37. INSTALL EXTENSION HOUSING SUB-ASSEMBLY

(a) Clean the seal packing attached on the center transmission case and extension housing sub-assembly using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

NOTICE:
Do not scratch the fitting surface.

(b) Apply FIPG to the extension housing sub-assembly, as shown in the illustration.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

38. INSTALL SHIFT AND SELECT LEVER SHAFT SUPPORT

(a) Using a pin punch (dia5 mm) and a hammer, install the shift and select lever shaft support and a new slotted spring pin onto the shift and select lever shaft.

Driven in depth:

1.0 to 2.0 mm (0.0394 to 0.0787 in.)

39. INSTALL FLOOR SHIFT CONTROL SHAFT

(a) Install a new control shaft collar onto the shift and select lever shaft.

(b) Install the shift lever damper and floor shift control shaft to the shift and select lever shaft.

(c) Using a pin punch (dia5 mm) and a hammer, align the floor shift control shaft hole and the shift and select lever shaft hole with the cutout of the control shaft collar, and insert the shaft pin from above.

(d) Slide the control shaft collar until it comes into contact with the stopper of the floor shift control shaft, then turn the control shaft collar 90° and stake it to the cutout.

NOTICE:
Be careful to install the floor shift control shaft in the proper direction.

40. INSTALL TRANSMISSION CONTROL CABLE WEIGHT

(a) Install the shift lever boot dust seal to the dust boot plate.

(b) Using a hexagon socket wrench (8 mm), install the dust boot plate, 2 shift arm pivot collars and transmission control cable weight to the extension housing sub-assembly with a new shift arm pivot.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
When tightening the shift arm pivot, position the arrow-shaped portion of the transmission control cable weight up, and insert it to the groove of the shift and select lever shaft support.

(c) Install the control shaft cover.

41. INSTALL CONTROL SHAFT

(a) Install the 2 collars to the floor shift control shaft.

(b) Install the control shaft with a new E-ring.

42. INSTALL SHIFT LEVER RETAINER BUSHING

(a) Install the 4 shift lever bushings.

43. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER

(a) Install the floor shift control shift lever retainer with the 2 shift lever pins.

(b) Secure the shift lever pins to the extension housing.

44. INSTALL SHIFT AND SELECT LEVER BOOT

(a) Install the shift and select lever boot.

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

(a) Install the floor shift lever retainer sub-assembly to the control shift lever retainer in accordance with the dimension specified in the illustration.

Dimension A:

18 mm (0.7087 in.)

46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using SST, install the back-up light switch with a new gasket onto the center transmission case.

SST : 09817-16011

Torque : 44 Nm (450 kgf-cm, 33 ft-lbf)

(b) Install the bracket with the bolt.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(c) Install the wire harness with the 3 clamps.