Part 2

R155 MANUAL TRANSMISSION: MANUAL TRANSMISSION UNIT: REASSEMBLY - Continued

26. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

(a) Install the shift interlock pin (ball) and shift interlock No. 1 roller into the intermediate plate.

(b) Install the gear shift fork No. 2 onto the transmission hub sleeve No. 2.

(d) Install the new shift fork set bolt onto the gear shift fork No. 2.

Torque : 19.5 Nm (199 kgf-cm, 14 ft-lbf)

(e) Using a brass bar and a hammer, install the shift fork shaft snap ring onto the gear shift fork shaft No. 2.

27. INSTALL NO. 1 SHIFT DETENT BALL SPRING SEAT

(a) Install the 2 shift detent ball low side compression springs and 2 shift detent balls into the intermediate plate.

(b) Using a "Torx" socket wrench T40, install the 3 shift detent ball spring seats No. 1 onto the intermediate plate.

Torque : 18.5 Nm (189 kgf-cm, 14 ft-lbf)

(c) Install the shift detent ball and the shift detent ball low side compression spring into the intermediate plate.

(d) Using a "Torx" socket wrench T40, install the shift detent ball spring seat No. 1 onto the intermediate plate.

Torque : 18.5 Nm (189 kgf-cm, 14 ft-lbf)

28. INSTALL TRANSMISSION MAGNET

(a) Clean the transmission magnet, and install it onto the intermediate plate.

29. INSTALL MANUAL TRANSMISSION CASE

(a) Apply seal packing 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

(b) Using a plastic hammer, tap the manual transmission case to attach it to the intermediate plate.

30. INSTALL NO. 1 COUNTER GEAR FRONT BEARING SNAP RING

(a) Using a snap ring expander, install the counter gear front bearing snap ring No. 1 onto the transmission case.

31. INSTALL FRONT BEARING SHAFT SNAP RING

(a) Using a snap ring expander, install the front bearing shaft snap ring onto the transmission case.

32. INSTALL TRANSMISSION FRONT BEARING RETAINER OIL SEAL

(a) Using SST and a hammer, install the new transmission front bearing retainer oil seal onto the transmission front bearing retainer.

SST : 09950-60010

09951-00300

09951-00520

09952-06010

SST : 09950-70010

09951-07100

Drive in depth:

11.2 to 12.2 mm (0.4409 to 0.4803 in.)

(b) Coat the lip of the oil seal with MP grease.

33. INSTALL FRONT BEARING RETAINER

(a) Apply seal packing to the bearing retainer front as shown in the illustration.

Text in Illustration

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(b) Install the front bearing retainer onto the transmission case with the 8 bolts.

Torque : 16.5 Nm (168 kgf-cm, 12 ft-lbf)

(c) Check that the input shaft and output shaft rotate smoothly.

34. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

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

SST : 09710-30050

SST : 09950-70010

09951-07100

Drive in depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

NOTICE:
Be careful not to damage the oil seal lip.

(b) Lightly apply MP grease to the tip of the oil seal.

35. INSTALL REVERSE RESTRICT PIN ASSEMBLY

(a) Install the reverse restrict pin into the extension housing.

(b) Using a pin punch (5 mm) and a hammer, install the reverse restrict slotted pin into the extension housing.

(c) Using a "Torx" socket wrench T40, install the reverse restrict pin plug onto the extension housing.

Torque : 18.5 Nm (189 kgf-cm, 14 ft-lbf)

36. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

(a) Install the oil receiver pipe with the bolt.

37. INSTALL OIL RECEIVER

(a) Install the oil receiver onto the extension housing.

38. INSTALL EXTENSION HOUSING SUB-ASSEMBLY

(a) Apply seal packing to the extension housing as shown in the illustration.

Text in Illustration

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(b) Insert the shift and select lever to the extension housing.

(c) Connect the shift and select lever to the fork shaft and put in the shift lever housing.

(d) Align shift and select lever to the extension housing installation hole and push in the extension housing.

(e) Install the extension housing, onto the transmission case with the 10 bolts.

Torque : 37 Nm (380 kgf-cm, 27 ft-lbf)

(f) Install the shift lever housing set bolt.

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

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

(a) Install the floor shift control shift lever retainer and the extension housing oil deflector onto the transfer adapter with the 6 bolts.

Torque : 18 Nm (185 kgf-cm, 13 ft-lbf)

40. INSTALL REVERSE RESTRICT PIN ASSEMBLY

(a) Install the 2 reverse restrict pins into the extension housing or transfer adapter.

Torque : 37 Nm (380 kgf-cm, 27 ft-lbf)

41. INSTALL SPEEDOMETER SENSOR

(a) Install a new O-ring onto the speedometer sensor.

(b) Install the speedometer sensor with the bolt.

Torque : 11.5 Nm (117 kgf-cm, 8 ft-lbf)

42. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using SST, install the back-up light switch assembly and the gasket onto the transmission case.

SST : 09817-16011

Torque : 44 Nm (450 kgf-cm, 32 ft-lbf)

43. INSTALL CLUTCH HOUSING

(a) Install the clutch housing onto the transmission case with the 9 bolts.

Torque : 36 Nm (370 kgf-cm, 27 ft-lbf)

44. INSTALL CLUTCH RELEASE FORK BOOT

(a) Install the clutch release fork boot onto the clutch housing.

45. INSTALL RELEASE FORK SUPPORT

(a) Install the clutch release fork support onto the clutch housing.

Torque : 47 Nm (480 kgf-cm, 35 ft-lbf)

46. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

(a) Apply clutch release hub grease to the clutch release bearing, and install it onto the clutch release fork.

47. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

(a) Install the clutch release fork.

(b) Apply the clutch spline grease to the spline of the input shaft.

48. INSTALL DRAIN PLUG SUB-ASSEMBLY

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

Torque : 37 Nm (380 kgf-cm, 27 ft-lbf)

49. INSTALL MANUAL TRANSMISSION FILLER PLUG

(a) Install the filler plug onto the transmission case through a new gasket.

Torque : 37 Nm (380 kgf-cm, 27 ft-lbf)