Part 1

RA62 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSMISSION UNIT: REASSEMBLY

1. INSTALL NO. 1 RELEASE ARM

(a) Install the No. 1 release arm and No. 1 release arm pivot onto the shift interlock bracket.

(b) Install a new E-ring onto the No. 1 release 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 (0.197 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 0.0197 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 (0.197 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 0.0197 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 (0.197 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 0.0197 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 (0.197 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 0.0197 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 a 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 transmission case in accordance with the dimension specified in the illustration.

SST : 09950-60010

09951-00470

SST : 09950-70010

09951-07100

Dimension A:

60.0 to 60.8 mm (2.36 to 2.39 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 transmission 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. REMOVE REVERSE IDLER GEAR RADIAL CLEARANCE Inspection

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 Inspection

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.

Text in Illustration

(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.

Text in Illustration

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

(f) Using a pin punch (5 mm (0.197 in.)) 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.

Text in Illustration

(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 transmission 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.

Text in Illustration

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)