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Manual Transaxle Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE CLUTCH RELEASE FORK AND BEARING 

    HINT:

    At the time of reassembly, please refer to the following item.

    Apply molybdenum disulphide lithium base grease (See INSTALLATION ).

  2. 4WD: REMOVE TRANSFER ASSEMBLY 
    1. Remove the 2 bolts.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 78.4 N.m (800 kgf.cm, 58 ft.lbf) 

    2. Remove the 6 nuts.

      Torque: 

      78.4 N.m (800 kgf.cm, 58 ft.lbf) for 17 mm nut 

      29.4 N.m (300 kgf.cm, 22 ft.lbf) for 14 mm nut 

    3. Using a plastic hammer, remove the transfer assembly from the transaxle.

    HINT:

    At the time of reassembly, please refer to the following item.

    • Shift into the 4th gear, and install the transfer assembly while turning the input shaft of the transaxle.
    • It is possible to apply FIPG either transaxle side or transfer side. In addition, be sure to apply it on the center of the seal.

      FIPG: 

      Part No. 08826-00100, THREE BOND 1281 or equivalent 

      Fig 1: Applying FIPG To Transaxle Side Or Transfer Side
      G02925835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 4WD: REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT 
  4. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS 

    Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

  5. REMOVE BACK-UP LIGHT SWITCH WITH GASKET 

    Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 

  6. REMOVE BOLT AND VEHICLE SPEED SENSOR 

    Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

  7. REMOVE CONTROL CABLE BRACKET 

    Remove the 3 bolts and control cable bracket.

    Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

  8. REMOVE CLUTCH TUBE BRACKET 

    Remove the bolt and tube bracket.

    Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

  9. REMOVE SELECTING BELLCRANK ASSEMBLY 

    Remove the 2 bolts and the selecting bellcrank assembly.

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

    Fig 2: Removing Selecting Bellcrank Assembly
    G02925836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE CONTROL SHIFT LEVER AND DUST BOOT 
    1. Remove the nut and wave washer.

      Torque: 6.4 N.m (65 kgf.cm, 57 in.lbf) 

      Fig 3: Removing Nut & Wave Washer
      G02925837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and a hammer, tap out the lever lock pin.
      Fig 4: Tapping Out Lever Lock Pin
      G02925838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: At the time of reassembly, please refer to the following item.

      When fixing the lever lock pin, properly position the shaft groove. 

    3. Remove the control shift lever and dust boot.
      NOTE: At the time of reassembly, please refer to the following items.
      • Install the dust boot into a groove in the control shift lever.
      • Be sure to install the dust boot in the correct direction, as shown in Fig 4.
  11. REMOVE LOCK BALL ASSEMBLY AND SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Remove the lock ball assembly.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

    2. Remove the 4 bolts, shift and select lever shaft assembly and gasket.
      Fig 5: Removing Lock Ball Assembly & Shift And Select Lever Shaft Assembly
      G02925839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

  12. REMOVE CONTROL SHAFT COVER 

    Remove the control shaft cover from the shift and select lever shaft assembly.

    NOTE: At the time of reassembly, please refer to the following item.
    Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
  13. REMOVE TRANSMISSION CASE COVER 

    Remove the 10 bolts and transmission case cover.

    Fig 6: Removing Transmission Case Cover & Bolts
    G02925840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    FIPG: 

    Part No. 08826-00100, THREE BOND 1282B or equivalent 

    Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

  14. REMOVE BREATHER PLUG WITH GASKET 

    Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

  15. REMOVE OUTPUT SHAFT LOCK NUT 
    1. Unstake the lock nut.
    2. Engage the gear double meshing.
    3. Remove the lock nut.

      Torque: 123 N.m (1,250 kgf.cm, 90 ft.lbf) 

    4. Disengage the gear double meshing.
      Fig 7: Removing Output Shaft Lock Nut
      G02925841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK 
    1. Remove the No. 3 shift fork set bolt.

      Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) 

    2. Remove the No. 3 hub sleeve and No. 3 shift fork.
  17. REMOVE 5TH DRIVEN GEAR 

    Using SST, remove the 5th driven gear.

    SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03030)

    Fig 8: Removing 5th Driven Gear
    G02925842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance.

      Maximum clearance: 

      0.65 mm (0.0256 in.) 

      Fig 9: Measuring Thrust Clearance
      G02925843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the radial clearance.

      Maximum clearance: 

      0.050 mm (0.0020 in.) 

      3. Fig 10: Measuring Radial Clearance
      G02925844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      At the time of the reassembly, please refer to the following item.

      Select a snap ring that allows the minimum axial play.

      Fig 11: Selecting Snap Ring Allowing Minimum Axial Play
      G02925845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SNAP RING THICKNESS

      Mark Thickness mm (in.)
      a 1.75 (0.0689)
      b 1.80 (0.0709)
      c 1.85 (0.0729)
      d 1.90 (0.0748)
      e 1.95 (0.0768)
      f 2.00 (0.0787)
      g 2.05 (0.0807)
      h 2.10 (0.0827)
      j 2.15 (0.0847)
    2. Using SST, remove the No. 3 clutch hub with the synchronizer ring and 5th gear.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)

      3. Fig 12: Removing No. 3 Clutch Hub With Synchronizer Ring & 5th Gear
      G02925846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NEEDLE ROLLER BEARINGS 
  21. REMOVE REAR BEARING RETAINER 

    Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer.

    Sealant: 

    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    Torque: 42 N.m (430 kgf.cm, 31 ft.lbf) 

  22. REMOVE SNAP RING 
    1. Using a snap ring expander, remove the input shaft rear bearing snap ring.
    2. Using 2 screwdrivers and a hammer, remove the 2 snap rings.
      Fig 13: Removing Snap Ring
      G02925847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE STRAIGHT SCREW PLUG 

    Using a hexagon wrench (6 mm), remove the plug.

    Sealant: 

    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

    Fig 14: Removing Straight Screw Plug
    G02925848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND WASHER 

    Sealant: 

    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

    Fig 15: Removing Reverse Idler Gear Shaft Lock Bolt And Washer
    G02925849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TRANSMISSION CASE 
    1. Transaxle case side:

      Remove the 3 bolts.

    2. Transmission case side:

      Remove the 14 bolts and tap out the case with a plastic hammer.

      Fig 16: Removing Transmission Case Bolts
      G02925850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG: 

      Part No. 08826-00100, THREE BOND 1282B or equivalent 

      Torque: 

      29 N.m (300 kgf.cm, 21 ft.lbf) for transaxle case side 

      30 N.m (306 kgf.cm, 22 ft.lbf) for transmission case side 

      Fig 17: Locating FIPG
      G02925851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE SHIM 

    HINT:

    At the time of reassembly, please refer to the following item. Install the previously selected shim by adjusting output shaft preload (See REASSEMBLY  ).

    Fig 18: Removing Shim
    G02925852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE 

    Using SST and a hammer, remove the output shaft rear bearing outer race.

    SST 09316-6001 1 (09316-00011)

    Fig 19: Removing Output Shaft Rear Rearing Outer Race
    G02925853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY 

    Remove the 2 bolts and pull off the reverse shift arm and bracket.

    Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

    29. Fig 20: Removing Reverse Shift Arm Bracket Assembly
    G02925854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE REVERSE IDLER GEAR AND SHAFT 

    Pull out the shaft, remove the reverse idler gear and thrust washer.

    HINT:

    At the time of reassembly, please refer to the following item.

    Align the matchmarks, as shown in Fig 21.

    Fig 21: Aligning Matchmarks
    G02925855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE STRAIGHT SCREW PLUGS 

    Using a hexagon wrench (6 mm), remove the 2 plugs.

    Sealant: 

    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

    Fig 22: Removing Straight Screw Plugs
    G02925856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE 3 SHIFT FORK SET BOLTS 

    Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) 

  32. REMOVE NO. 1 SHIFT FORK SHAFT 

    Pull up the No. 3 shift fork shaft, remove the No. 1 shift fork shaft.

    HINT:

    At the time of reassembly, please refer to the following item. When it is difficult to push the fork shaft through the reverse shift fork, pull up the No. 3 shift fork shaft.

    Fig 23: Pulling Up No. 3 Shift Fork Shaft
    G02925857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE INTERLOCK ROLLER 

    Using a magnetic finger, remove the interlock roller from the reverse shift fork.

    Fig 24: Removing Interlock Roller
    G02925858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE NO. 2 SHIFT FORK SHAFT, SHIFT HEAD AND NO. 1 SHIFT FORK 
    1. Pull out the No. 2 shift fork shaft.
    2. Remove the shift head and No. 1 shift fork.
      Fig 25: Removing No. 2 Shift Fork Shaft Shift Head & No. 1 Shift Fork
      G02925859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE NO. 3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO. 2 SHIFT FORK 
    1. Pull out the No. 3 shift fork shaft with the reverse shift fork.
    2. Remove the No. 2 shift fork.
      3. Fig 26: Removing No.3 Shift Fork Shaft With Reverse Shift Fork & No. 2 Shift Fork
      G02925860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE SNAP RING 
    1. Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No. 3 shift fork shaft.
    2. Using 2 screwdrivers and a hammer, remove the snap rings from the No. 1, No. 2 and No. 3 shift fork shafts.
  37. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY 
    1. Leaning the output shaft to the differential side, remove the input shaft assembly.
    2. Lift up the differential case assembly, remove the output shaft assembly.
  38. REMOVE DIFFERENTIAL CASE ASSEMBLY 
  39. REMOVE MAGNET FROM TRANSAXLE CASE 
  40. REMOVE 2 BOLTS, NO. 1 AND NO. 2 OIL RECEIVER PIPES 

    Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

  41. REMOVE STRAIGHT SCREW PLUG FROM TRANSAXLE CASE 

    Sealant: 

    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

  42. REMOVE NO. 5 SYNCHRONIZER RING WITH KEY SPRING FROM NO. 3 CLUTCH HUB 
    1. Remove the No. 5 synchronizer ring with the key spring from the No. 3 clutch hub.
      2. Fig 27: Removing No.5 Synchronizer Ring with Key Spring from No.3 Clutch Hub
      G02925861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the snap ring.

      HINT:

      Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.

    3. Remove the synchronizer rings.
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