Manual Transmission Assembly: Installation: Installation

1. Install the transmission upper cover sub-assembly with the 2 bolts.
   Fig 1: Identifying Transmission Upper Cover Sub-Assembly

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   Torque: 12 N.m (120 kgf cm, 9 ft. lbf) 

1. Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.
   Fig 2: Identifying Rear No. 1 Engine Mounting Insulator Bolts

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   Torque: 25 N.m (255 kgf cm, 18 ft. lbf) 

1. Apply release hub grease to the contact surface between the release fork and release bearing hub, the contact surface between the release fork and push rod, and the release fork pivot points as shown in the illustration.
   Fig 3: Identifying Grease Application Area

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   Grease

   Toyota Genuine Release Hub Grease or equivalent

2. Install the clutch release fork sub-assembly to the release fork support.
   NOTE:

   • Do not use excess force to install the clutch release fork sub-assembly.
   • After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.

1. Make sure that the knock pins are not loose, bent, damaged or scratched and then install the manual transmission onto the engine with the contact surfaces of the engine and manual transmission flat against each other.
   Fig 4: Identifying Manual Transmission Assembly Knock Pins

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2. Install the manual transmission to the engine with the 9 bolts.
   Fig 5: Identifying Manual Transmission To Engine With Bolts

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   Bolt A 

   Torque: 72 N.m (730 kgf cm, 53 ft. lbf) 

   Bolt B 

   Torque: 37 N.m (380 kgf cm, 28 ft. lbf) 

   NOTE:

   • Temporarily tighten bolt A*1, fully tighten bolt A*2, lift the rear end of the transmission, and fully tighten bolt A*1 and the other bolts. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.
   • Do not apply excessive force to the transmission assembly as this will break the input shaft
   • Insert dowel pins into the dowel holes securely so that the end face of the transmission assembly fits close against the engine assembly before tightening the bolts.

1. Install the engine rear mounting member with the 4 bolts and 4 nuts.
   Fig 6: Identifying Engine Rear Mounting Member Bolts & Nuts

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   Nut 

   Torque: 13 N.m (130 kgf cm, 10 ft. lbf) 

   Bolt 

   Torque: 26 N.m (265 kgf cm, 19 ft. lbf) 

1. Install the 2 bushings to the shift lever assembly.
   Fig 7: Identifying Washer & Floor Shift Lever Assembly

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2. Install the washer to the floor shift lever assembly.
3. Install the shift lever assembly with a new E-ring.
   Fig 8: Identifying Shift & Select Lever Boot

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4. Install the shift and select lever boot.

1. Install the floor shift control shift lever retainer sub-assembly with the 2 nuts.
   Fig 9: Identifying Floor Shift Control Shift Lever Retainer Sub-Assembly Nuts

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   Torque: 20 N.m (204 kgf cm, 15 ft. lbf) 

1. Align the matchmarks on the clutch cover assembly and the flywheel sub-assembly.
   Fig 10: Aligning Matchmarks On Clutch Cover Assembly & Flywheel Sub-Assembly

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2. Install the clutch cover to the flywheel sub-assembly with the 6 new bolts.

   Torque: 19 N.m (195 kgf cm, 14 ft. lbf) 

   NOTE:

   Tighten the bolts a little at a time in a diagonal pattern until they are all tightened.

1. Install the No. 1 clutch housing cover with the 4 bolts.
   Fig 11: Identifying Bolts & No. 1 Clutch Housing Cover

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   Torque: 18 N.m (184 kgf cm, 13 ft. lbf) 

   Bolt length

   20 mm (0.787 in.)

1. Install the No. 2 clutch housing cover with the 4 bolts.
   Fig 12: Identifying No. 2 Clutch Housing Cover & Bolts

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   Torque: 18 N.m (184 kgf cm, 13 ft. lbf) 

   Bolt length

   16 mm (0.630 in.)

1. Connect the back-up light switch connector and install the wire harness.
   Fig 13: Identifying Back-Up Light Switch Connector & Wire Harness

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1. Connect the ground cable with the bolt.
   Fig 14: Identifying Ground Cable Bolt

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   Torque: 5.4 N.m (55 kgf cm, 48 in. lbf) 

1. Install the clutch release cylinder assembly with the 2 bolts.
   Fig 15: Identifying Clutch Release Cylinder Assembly Bolts

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   Torque: 12 N.m (120 kgf cm, 9 ft. lbf) 

1. Install the clutch accumulator assembly with the 3 bolts and nut.
   Fig 16: Identifying Clutch Accumulator Assembly Bolts

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   Bolt 

   Torque: 12 N.m (120 kgf cm, 9 ft. lbf) 

   Nut 

   Torque: 5.4 N.m (55 kgf cm, 48 in. lbf) 

Refer to INSTALLATION

1. Install the engine under cover air guide bracket with the 2 bolts.
   Fig 17: Identifying Engine Under Cover Air Guide Bracket Bolts

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   Torque: 26 N.m (260 kgf cm, 19 ft. lbf) 

1. Temporarily install the shift lever cap with the 4 bolts.
   Fig 18: Identifying Shift Lever Cap Bolts

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2. Move the shift lever to the 2nd gear position. Adjust the shift lever cap by pushing it towards neutral until dimension A is as shown in the illustration.

   Dimension A

   0.3 to 0.6 mm (0.0118 to 0.0236 in.)

3. Fully tighten the 4 bolts.

   Torque: 10 N.m (102 kgf cm, 7 ft. lbf) 

1. Install the No. 1 shift and select lever boot with the 4 bolts.
   Fig 19: Identifying No. 1 Shift & Select Lever Boot Bolts

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   Torque: 12 N.m (122 kgf cm, 9 ft. lbf)