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Transaxle Disassembly

  1. Remove clutch release fork assembly with bearing. See Fig 1 and Fig 2 . Remove back-up light switch with gasket. See Fig 3. Remove vehicle speed sensor and sensor drive gear. Remove breather plug. Remove lock ball assembly No. 1.
  2. Remove selecting bellcrank with support. Remove shift and select lever shaft assembly with gasket.
  3. Remove transaxle case cover. Unstake output shaft lock nut. See Fig 4. Lock transaxle in 2 gears (double meshing). See Fig 5. Remove output shaft lock nut. Unlock transaxle.
  4. Measure 5th gear clearances, and record for reassembly reference. Using dial indicator, measure 5th gear thrust clearance. See Fig 6. Standard clearance is .004-.022" (.10-.57 mm). Service limit is .026" (.65 mm). Measure radial clearance (oil clearance) of 5th gear. Standard clearance is .0004-.0020" (.009-.05 mm).
  5. Remove No. 3 shift fork set bolt. Remove No. 3 hub sleeve and the No. 3 shift fork. Using appropriate puller, remove 5th driven gear from output shaft.
  6. Remove input shaft snap ring. Using appropriate puller, remove No. 3 clutch hub with synchronizer ring assembly and 5th gear. Remove needle bearing. Remove 7 Torx screws (T45) and rear bearing retainer.
  7. Remove output shaft rear bearing shim. Remove input shaft snap ring. Remove shift fork shaft snap rings. Remove reverse idler gear shaft retaining bolt. See Fig 4.
    8. NOTE: Three bolts must be removed from transaxle case (clutch housing) side.
  8. Remove bolts holding transaxle case to clutch housing. Use a plastic hammer to loosen case to housing seal. Remove No. 2 oil receiver pipe. See Fig 3.
  9. Remove plug. Remove and inspect reverse restrict pin. See Fig 7. Replace pin if worn or damaged. Remove magnet.
  10. Remove bolts and remove reverse shift arm bracket. Remove reverse idler gear, thrust washer and shaft. Remove all remaining plugs, seats, springs and detent balls.
  11. Remove No. 1 shift fork shaft by pulling up No. 3 shift fork shaft. Remove interlock roller from reverse shift fork. Remove No. 2 shift fork shaft, shift head and No. 1 shift fork. Remove No. 3 shift fork shaft with reverse shift fork and No. 2 shift fork. Remove snap ring and reverse shift fork from No. 3 shift fork shaft. Remove snap rings from No. 1, No. 2 and No. 3 shift fork shafts. See Fig 3.
  12. Move output shaft toward differential and remove input shaft assembly. Lift differential case and remove output shaft assembly. Remove oil pump drive gear and remove differential assembly. Remove oil pipe and oil pump assembly (4WD). If necessary, replace input shaft bearing and oil seal. Remove transaxle case receiver (2WD). See Fig 3. Remove input shaft bearing and oil seal. Install NEW bearing and oil seal. Install transaxle case receiver. Tighten receiver bolts to 65 INCH lbs. (7.4 N.m). Remove No. 5 synchronizer ring and key spring from No. 3 clutch hub. Remove snap rings. See Fig 4.
Fig 1: Exploded View Of Transaxle Case Components (2WD)
G00085363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Exploded View Of Transaxle Case Components (4WD)
G00085362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Exploded View Of Transaxle Internal Components (Shift Fork Assemblies)
G00085361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Exploded View Of Transaxle Internal Components (Geartrain Assemblies)
G00085364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Locking Transaxle Into 2 Gears
G00085366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Measuring 5th Gear Clearances
G93I23562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 7: Removing Reverse Restrict Pin Assembly
G00085365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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