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Manual Transaxle Assembly: Replacement

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. REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL 
    1. Remove the 3 bolts and transaxle case receiver.
    2. Using SST, pull out the bearing.

      SST 09612-65014 (09612-01040, 09612-01050)

      3. Fig 1: Pulling Out Bearing
      G02925865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, remove the oil seal.
    4. Using SST, drive in a new oil seal.

      SST 09608-00081, 09950-70010 (09951-07150)

      5. Fig 2: Driving In New Oil Seal
      G02925866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Coat the lip of seal with MP grease.
    6. Using SST, drive in a new bearing.

      SST 09950-60010 (09951-00580), 09950-70010 (09951-07150)

      7. Fig 3: Driving In New Bearing
      G02925867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the transaxle case receiver.
    8. Install and torque the 3 bolts.

      Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

  2. REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT COVER 
    1. Using SST, pull out the output shaft front bearing outer race.

      SST 09308-00010

      2. Fig 4: Removing Output Shaft Front Bearing Outer Race
      G02925868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the output shaft cover.
    3. Install a new output shaft cover.
      Fig 5: Installing New Output Shaft Cover
      G02925869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Install the output shaft cover projection into the case side groove.

    4. Using SST and a hammer, drive in a new output shaft front bearing outer race.

      SST 09316-6001 1 (09316-00011, 09316-00021)

      Fig 6: Installing New Output Shaft Front Bearing Outer Race
      G02925870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REPLACE REVERSE RESTRICT PIN 
    1. Using a hexagon wrench (6 mm), remove the screw plug.
      2. Fig 7: Removing Screw Plug
      G02925871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (5 mm) and hammer, drive out the slotted spring pin.
    3. Replace the reverse restrict pin.
    4. Using a pin punch (5 mm) and hammer, drive in the slotted spring pin.
      5. Fig 8: Driving In Slotted Spring Pin
      G02925872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply sealant to the screw plug threads.

      Sealant: 

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

    6. Using a hexagon wrench (6 mm), install and torque the screw plug.

      Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 

  4. REPLACE CONTROL SHAFT COVER OIL SEAL AND BUSHING 
    1. Using a screwdriver, pry out the oil seal.
      Fig 9: Prying Out Oil Seal
      G02925873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press out the bushing.

      SST 09950-60010 (09951-00200, 09951-00210), 09950-70010 (09951-07150)

      Fig 10: Pressing Out Bushing
      G02925874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press in a new bushing.

      SST 09950-60010 (09951-00200), 09950-70010 (09951-07150)

      Depth: 0.65 +/- 0.25 mm (0.0256 +/- 0.0098 in.) 

      Fig 11: Pressing In New Bushing
      G02925875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a plastic-faced hammer, carefully tap in a new oil seal.

      SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)

      Depth: 0.70 +/- 0.50 mm (0.0276 +/- 0.0197 in.) 

      Fig 12: Tapping In New Oil Seal
      G02925876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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