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Manual Transaxle ASSY (MTM): Replacement

WARNING: This page is about a different variant/trim than selected.
  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  2. SEPARATE STEERING INTERMEDIATE SHAFT (See  OVERHAUL  ) 
  3. REMOVE FRONT WHEELS 
  4. REMOVE ENGINE UNDER COVER LH 
  5. REMOVE ENGINE UNDER COVER RH 
  6. REMOVE EXHAUST PIPE (See  REMOVAL & INSTALLATION  in Exhaust (1ZZ-FE) or See  REMOVAL & INSTALLATION  ) in Exhaust (2ZZ-GE) 
  7. DRAIN TRANSAXLE OIL 
  8. REMOVE HOOD SUB-ASSY 
  9. REMOVE CYLINDER HEAD COVER NO. 2 
    1. C59 T/M:

      Remove the 2 nuts caps, clips and No. 2 cylinder head cover.

    2. C60 T/M:

      Remove the 3 bolts, nut and No. 2 cylinder head cover.

  10. REMOVE AIR CLEANER ASSY 
  11. REMOVE BATTERY CLAMP SUB-ASSY 
  12. REMOVE BATTERY 
  13. REMOVE BATTERY TRAY 
  14. REMOVE BATTERY CARRIER 
    1. Remove the 4 bolts and battery carrier.
    Fig 1: Removing Battery Carrier
    G00921638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) (See  REPLACEMENT  ) 
  16. DISCONNECT WIRE HARNESS 
    1. Disconnect the wire harness clamp.
    2. Remove the 2 bolts and disconnect the 2 wire harness brackets.
      Fig 2: Removing Bolts And Disconnecting Wire Harness Brackets
      G00921639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and 2 ground cables.
    Fig 3: Removing Bolts And Ground Cables
    G00921640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT CONNECTOR 
    1. Disconnect the back-up lamp switch connector.
      Fig 4: Disconnecting Back-Up Lamp Switch Connector
      G00921641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o ABS:

      Disconnect the speed sensor connector.

    Fig 5: Disconnecting Speed Sensor Connector
    G00921642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. SEPARATE CLUTCH RELEASE CYLINDER ASSY 
    1. Remove the 5 bolts, separate the release cylinder assy with clutch piping from the transaxle.
    Fig 6: Separating Clutch Release Cylinder Assy
    G00921643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT 
    1. Remove the clip, washer and disconnect the shift cable from the transaxle.
    2. Remove the clip and disconnect the shift cable from the bracket.
    Fig 7: Separating Floor Shift Cable Transmission Control Shift
    G00921644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT 
    1. Remove the clip, washer and disconnect the select cable from the transaxle.
    2. Remove the clip and disconnect the select cable from the bracket.
    Fig 8: Separating Floor Shift Cable Transmission Control Select
    G00921645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE STARTER ASSY 
    1. Remove the nut and disconnect the starter wire.
    2. Disconnect the connector.
    3. Remove the 2 bolts and starter assy.
    Fig 9: Removing Starter Assy
    G00921646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT TIE ROD END SUB-ASSY LH (See  OVERHAUL  ) 

    SST 09628-62011

  23. DISCONNECT TIE ROD END SUB-ASSY RH (See  OVERHAUL  ) 

    SST 09628-62011

  24. DISCONNECT PRESSURE FEED TUBE ASSY (See  OVERHAUL  ) 

    SST 09023-38400

  25. DISCONNECT RETURN TUBE SUB-ASSY (See  OVERHAUL  ) 

    SST 09023-38400

  26. REMOVE FRONT DRIVE SHAFT ASSY LH (See  OVERHAUL  ) 

    SST 09520-01010, 09520-24010 (09520-32040)

  27. REMOVE FRONT DRIVE SHAFT ASSY RH (See  OVERHAUL  ) 

    SST 09520-01010, 09520-24010 (09520-32040)

  28. SUSPEND ENGINE ASSY 
    1. Remove the 2 PCV hoses.
    2. C59 T/M:

      Install the No. 1 and No. 2 engine hangers in the correct direction.

      1. Parts No.: 
        1. No. 1 engine hanger: 12281-22021 
        2. No. 2 engine hanger: 12281-15040 
        1. Bolt: 91512-B1016 
        1. Torque: 38 N.m (387 kgf.cm,28 ft.lbf) 
      Fig 10: Installing No. 1 And No. 2 Engine Hangers (C59 T/M)
      G00921647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. C60 T/M:

      Install the No. 1 and No. 2 engine hangers in the correct direction.

      1. Parts No.: 
        1. No. 1 engine hanger: 12281-88600 
        2. No. 2 engine hanger: 12282-88600 
        1. Bolt: 91512-61020 
        1. Torque: 38 N.m (387 kgf.cm,28 ft.lbf) 
    4. Attach the engine chain hoist to the hangers.
    Fig 11: Installing No. 1 And No. 2 Engine Hangers (C60 T/M)
    G00921648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
  29. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY (See  REPLACEMENT  ) 
  30. SUPPORT MANUAL TRANSAXLE ASSY 
    1. Support the transaxle with a transmission jack.
  31. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR 
    1. Remove the 5 bolts, nut and engine mounting insulator LH from the body.
    Fig 12: Removing Transverse Engine Mounting Insulator
    G00921649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Remove the 3 bolts and engine mounting bracket LH from the transaxle.
    Fig 13: Removing Transverse Engine Mounting Bracket
    G00921650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE MANUAL TRANSAXLE ASSY 
    1. Remove the 6 bolts and transaxle from the engine.
    Fig 14: Removing Bolts And Transaxle From Engine
    G00921651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
    2. Remove the 2 bolts and engine mounting bracket FR from the transaxle.
    Fig 15: Removing Engine Mounting Bracket FR From Transaxle
    G00921652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR.
    2. Remove the 3 bolts and engine mounting bracket RR from the transaxle.
    Fig 16: Removing Engine Mounting Bracket RR From Transaxle
    G00921653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Install the engine mounting bracket RR and 3 bolts to the transaxle.
      1. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 
    2. Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
      1. Torque: 87 N.m (888 kgf.cm, 64 ft.lbf) 
    Fig 17: Installing Engine Mounting Bracket RR
    G00921654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Install the engine mounting bracket FR and 2 bolts to the transaxle.
      1. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 
    2. Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
      1. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 
    Fig 18: Installing Engine Mounting Bracket FR
    G00921655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL MANUAL TRANSAXLE ASSY 
    1. Align the input shaft with the clutch disc and install the transaxle to the engine.
    2. Install the 6 bolts.
      1. Torque: 
        1. Bolt A: 64 N.m (650 kgf.cm, 47 ft.lbf) 
        2. Bolt B: 47 N.m (480 kgf.cm, 35 ft.lbf) 
        3. Bolt C: 23 N.m (230 kgf.cm, 17 ft.lbf) 
    Fig 19: Installing Manual Transaxle Assembly
    G00921656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Install the engine mounting bracket LH to the transaxle with the 3 bolts.
      1. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 
    Fig 20: Installing Engine Mounting Bracket LH
    G00921657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR 
    1. Install the engine mounting insulator LH with the 5 bolts and nut.
      1. Torque: 
        1. Bolt A: 52 N.m (530 kgf.cm, 38 ft.lbf) 
        2. Bolt B: 80 N.m (816 kgf.cm, 59 ft.lbf) 
    Fig 21: Installing Engine Mounting Insulator LH
    G00921658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY (See  REPLACEMENT  ) 

    SST 09670-00010

  42. INSTALL FRONT DRIVE SHAFT ASSY LH (See  OVERHAUL  ) 
  43. INSTALL FRONT DRIVE SHAFT ASSY RH (See  OVERHAUL  ) 
  44. CONNECT RETURN TUBE SUB-ASSY (See  OVERHAUL  ) 

    SST 09023-38400

  45. CONNECT PRESSURE FEED TUBE ASSY (See  OVERHAUL  ) 

    SST 09023-38400

  46. CONNECT TIE ROD END SUB-ASSY LH (See  OVERHAUL  ) 
  47. CONNECT TIE ROD END SUB-ASSY RH (See  OVERHAUL  ) 
  48. INSTALL STARTER ASSY 
    1. Install the starter assy and 2 bolts to the transaxle.
      1. Torque: 37 N.m (378 kgf.cm, 27 ft.lbf) 
    2. Connect the starter connector.
    3. Install the wire and nut to starter assy.
      1. Torque: 9.8 N.m (100 kgf.cm, 87 ft.lbf) 
    Fig 22: Installing Starter Assy
    G00921659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT 
    1. Connect the shift cable end, and install the washer and clip.
    Fig 23: Connecting Floor Shift Cable Transmission Control Shift
    G00921660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT 
    1. Connect the select cable end, and install the washer and clip.
    Fig 24: Connecting Select Cable End
    G00921661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. CONNECT CLUTCH RELEASE CYLINDER ASSY 
    1. Install the release cylinder with the 5 bolts.
      1. Torque: 
        1. Bolt A: 25 N.m (250 kgf.cm, 19 ft.lbf) 
        2. Bolt B: 12 N.m (120 kgf.cm, 9 ft.lbf) 
        3. Bolt C: 5.0 N.m (51 kgf.cm, 44 ft.lbf) 
    Fig 25: Installing Release Cylinder
    G00921662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. CONNECT CONNECTOR 
    1. Connect the back-up lamp switch connector.
      Fig 26: Connecting Back-Up Lamp Switch Connector
      G00921663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o ABS:
      1. Connect the speed sensor connector.
    Fig 27: Connecting Speed Sensor Connector
    G00921664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. CONNECT WIRE HARNESS 
    1. Install the 2 wire harness clamps to the transaxle with the 2 bolts.
      1. Torque: 
        1. Bolt A: 25.5 N.m (260 kgf.cm, 19 ft.lbf) 
        2. Bolt B: 12.8 N.m (131 kgf.cm, 9 ft.lbf) 
        Fig 28: Installing Wire Harness Clamps To Transaxle With Bolts
        G00921665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        1. Connect the wire harness clamp.
    2. Install the 2 bolts and 2 ground cables.
      1. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 
    Fig 29: Installing Bolts And Ground Cables
    G00921666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) (See  REPLACEMENT  ) 
  55. INSTALL BATTERY CARRIER 
    1. Install the battery carrier and 4 bolts.
      1. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 
    Fig 30: Installing Battery Carrier
    G00921667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL BATTERY TRAY 
  57. INSTALL BATTERY 
  58. INSTALL BATTERY CLAMP SUB-ASSY 
    1. Torque: 
      1. Bolt: 5.0 N.m (51 kgf.cm, 44 in.lbf) 
      2. Nut: 3.5 N.m (36 kgf.cm, 31 in.lbf) 
  59. INSTALL AIR CLEANER ASSY 
    1. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 
  60. INSTALL CYLINDER HEAD COVER NO. 2 
    1. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 
  61. INSTALL HOOD SUB-ASSY 
    1. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 
  62. INSPECT HOOD SUB-ASSY 
  63. ADJUST HOOD SUB-ASSY (See  ADJUSTMENT  ) 
  64. ADD TRANSAXLE OIL (See  MANUAL TRANSAXLE OIL (MTM)  
  65. INSPECT TRANSAXLE OIL (See  MANUAL TRANSAXLE OIL (MTM)   ) 
  66. INSTALL FRONT WHEELS 
    1. Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 
  67. INSTALL STEERING COLUMN HOLE COVER SUB-ASSY NO. 1 
  68. CONNECT STEERING INTERMEDIATE SHAFT (See  OVERHAUL  ) 
  69. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  70. CENTER SPIRAL CABLE (See  SPIRAL CABLE  ) 
  71. STEERING WHEEL CENTER POINT (See  OVERHAUL  ) 
  72. INSTALL EXHAUST PIPE (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  in Exhaust (1ZZ-FE) or See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) in Exhaust (2ZZ-GE) 
  73. INSTALL ENGINE UNDER COVER LH 
  74. INSTALL ENGINE UNDER COVER RH 
  75. INSPECT FRONT WHEEL ALIGNMENT (See  FRONT WHEEL ALIGNMENT (MAY, 2003)  ) 
  76. CHECK ABS SPEED SENSOR SIGNAL (See  PRE-CHECK  ) 
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