Install Th Gear

(a) Coat the 5th gear with gear oil and install it onto the input shaft.

Toyota Rav4 5th Gear Repair

36. INSTALL SYNCHRONIZER RING NO.3

(a) Coat synchronizer ring No. 3 with gear oil and install it onto the 5th gear.

Land Cruiser 5th Gear Key

37. INSTALL TRANSMISSION CLUTCH HUB NO.3

(a) Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the transmission clutch hub No. 3, as shown in the illustration. NOTICE:

Do not set the 2 shifting key spring openings in the same position.

(b) Using SST and a hammer, install transmission clutch hub No. 3 onto the input shaft.

SST 09636-20010

NOTICE:

• Do not install transmission clutch hub No. 3 in the wrong direction.

• Install the transmission clutch hub No. 3 with the synchronizer ring No. 3 key groove and synchromesh shifting key No. 3 aligned.

• Check that the 5th gear is rotating.

• Place a suitable sized wooden block to support the input shaft.

(c) Select a clutch hub No. 3 shaft snap ring that will allow minimum axial play. Clearance:

0.1 mm or less Snap ring thickness

Mark

Thickness mm (in.)

Mark

Thickness mm (in.)

A

2.25 (0.0886)

E

2.49 (0.0980)

B

2.31 (0.0909)

F

2.55 (0.1004)

C

2.37 (0.0933)

G

2.61 (0.1028)

Mark

Thickness mm (in.)

Mark

Thickness mm (in.)

D

2.43 (0.0957)

-

-

(d) Using a brass bar and a hammer, install the snap ring onto the input shaft.

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 (0.0039 to 0.0217 in.) Maximum clearance: 0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, replace transmission clutch hub No. 3, 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: KOYO made:

0.015 to 0.058 mm (0.0006 to 0.0023 in.) NSK made: 0.015 to 0.056 mm (0.0006 to 0.0022 in.) Maximum clearance: KOYO made:

0.058 mm (0.0023 in.) NSK made: 0.056 mm (0.0022 in.) If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.

40. INSTALL GEAR SHIFT FORK NO.3

(a) Coat transmission clutch hub sleeve No. 3 with gear oil and install it together with gear shift fork No. 3 onto transmission clutch hub No. 3. HINT:

Set the transmission clutch hub No. 3 in the correct orientation.

(b) Coat the gear shift fork lock bolt with sealant, and install it onto gear shift fork No. 3.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 16 N*m (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 sealant.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

(c) Install the new manual transmission output shaft rear set nut.

(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 FIPG to the manual transaxle case cover subassembly as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE:

Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

(b) Install the manual transmission case cover sub-assembly onto the manual transmission case with the 9 bolts.

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 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 (0.0079 to 0.0472 in.) SST 09950-60010 (09951-00280), 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 sealant. Install a new gasket and control shaft cover onto the manual transmission case with the 4 bolts. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) Sealant:

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 sealant.

(b) Install the washer and shift gate pin. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

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C120744

INSTALL LOCK BALL ASSEMBLY NO.1

(a) Coat lock ball assembly No. 1 with sealant, install it onto the manual transmission case. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

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 N*m (120 kgf*cm, 8.7 ft.*lbf)

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 N*m (120 kgf*cm, 8.7 ft.*lbf)

50. INSTALL SELECTING BELL CRANK ASSEMBLY

(a) Install the selecting bell crank assembly together with the control shift lever bush onto the manual transmission case with the 2 bolts and nut. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) for bolt 12 N*m (120 kgf*cm, 8.7 ft.*lbf) for nut NOTICE:

Apply MP grease to the inside circumferential surface of the control shift lever bush.

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

(b) Install the back-up light switch wire harness into the 2 clamps.

52. INSTALL SPEEDOMETER SENSOR (w/o ABS)

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

(b) Install the speedometer sensor onto the transaxle case with the bolt.

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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Responses

  • eila
    How to repair 5th gear toyota carina?
    8 years ago
  • sarah fikru
    How to install gear position indicator on yaris 2012?
    2 years ago

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