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Manual Transaxle Assembly: Disassembly

  1. REMOVE FILLER PLUG AND DRAIN PLUG WITH GASKETS 

    Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

  2. REMOVE BACK-UP LIGHT SWITCH WITH GASKET 

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

  3. REMOVE CONTROL CABLE BRACKET 

    Remove the 2 bolts and control cable bracket.

    1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
  4. REMOVE CONTROL SHAFT ASSEMBLY 
    1. Remove the (A) nut and wave washer.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

    2. Remove the (B) nut and the control shaft assembly.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

    Fig 1: Identifying Control Shaft Assembly Nuts
    G02631348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE SELECTING BELLCRANK ASSEMBLY 

    Remove the 2 bolts and the selecting bellcrank assembly.

    1. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 
    NOTE: At the time of reassembly, please refer to the following item.
    Fit the selecting bellcrank assembly pin part with the dust cover into a groove in the control shift lever.
    Fig 2: Identifying Selecting Bellcrank Assembly Bolts
    G02631349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE SHIFTING BELLCRANK ASSEMBLY 

    Remove the 2 bolts and the shifting bellcrank assembly.

    1. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 
    Fig 3: Identifying Shifting Bellcrank Assembly Bolts
    G02631350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CONTROL SHIFT LEVER AND DUST BOOT 
    1. Remove the nut and wave washer.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

      Fig 4: Identifying Nut And Washer
      G02631351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and a hammer, tap out the lever lock pin.
      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 the illustration.
    Fig 5: Removing Lever Lock Pin Using Pin Punch And A Hammer
    G02631352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSMISSION CASE COVER 
    1. Remove the 9 bolts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    2. Using a brass bar and a hammer, carefully tap the projection of the transmission case cover to remove the transmission case cover from the transmission case.

    HINT:

    At the time of reassembly, please refer to the following item. Apply FIPG to the transmission case cover as shown in the illustration.

    1. FIPG: 
    2. Part No. 08826-00090, THREE BOND 1281 or equivalent 
    Fig 6: Applying FIPG To Transmission Case Cover
    G02631353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE LOCK BALL ASSEMBLY AND CONTROL SHAFT COVER 
    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, control shaft cover and gasket.
      Fig 7: Identifying Bolts, Control Shaft Cover And Gasket
      G02631354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
      3. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 
  10. REMOVE 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.
    Fig 8: Removing Lock Nut Using A Chisel And Hammer
    G02631355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE LOCK NUT 
    1. Engage the gear double meshing.
    2. Using a chisel and a hammer, loosen the staked part of the nut.
    3. Remove the lock nut.

      Torque: 118 N.m (1,200 kgf.cm, 87 ft.lbf) 

    4. Disengage the gear double meshing.
    Fig 9: Identifying Lock Nut
    G02631356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 3 HUB SLEEVE AND NO. 3 GEAR SHIFT FORK 
    1. Remove the bolt from the No. 3 gear shift fork.

      Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

      Sealant: 

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

    2. Remove the No. 3 hub sleeve and 3 shifting keys with the No. 3 gear shift fork.

    HINT:

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

    • Assemble the No. 3 hub sleeve and No. 3 clutch hub. Install the No. 3 clutch hub and 3 shifting key springs to the No. 3 hub sleeve.
    • Install the 2 shifting key springs under the 3 shifting keys.
    NOTE: Position the key springs so that their end gaps are not aligned.

    HINT:

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

    • Before driving in the No. 3 hub sleeve and No. 3 clutch hub assembly, place the suitable sized wooden block on the rear side of the input shaft, as shown in the illustration. When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear radial ball bearing is overloaded, it might be damaged.
      Fig 10: Placing Wooden Block On Rear Side Of Input Shaft
      G02631357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Using SST and a hammer, tap in the No. 3 hub sleeve and No. 3 clutch hub assembly together with the No. 3 gear shift fork.

      SST 09636-20010

      NOTE:
      • Be sure to install the No. 3 hub sleeve and No. 3 clutch hub assembly in the correct direction, as shown in the illustration.
      • Align the No. 3 synchronizer ring slots with the No. 3 shifting keys.
    Fig 11: Tapping In Hub Sleeve And Clutch Hub Assembly Using SST And A Hammer
    G02631358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT 5TH GEAR THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance.

    1. Standard clearance: 
    2. 0.10 to 0.57 mm (0.0039 to 0.0224 in.) 
    3. Maximum clearance: 0.57 mm (0.0224 in.) 
    Fig 12: Measuring Thrust Clearance Using A Dial Indicator
    G02631359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT 5TH GEAR RADIAL CLEARANCE 

    Using a dial indicator, measure the radial clearance.

    Standard clearance: 

    5TH GEAR - STANDARD CLEARANCE TABLE

    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: 

    5TH GEAR - MAXIMUM CLEARANCE TABLE

    KOYO made 0.058 mm (0.0023 in.)
    NSK made 0.056 mm (0.0022 in.)

    If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

    Fig 13: Measuring Radial Clearance Using A Dial Indicator
    G02631360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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 reassembly, please refer to the following item. Select a snap ring from the table below that will make the thrust clearance of the No. 3 clutch hub less than 0.1 mm (0.0039 in.).

      SNAP RING SPECIFICATION TABLE

      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)
      D 2.43(0.0957) - -
    2. Using a screwdriver, pry out the shifting key spring from the No. 3 clutch hub.
      Fig 14: Tapping Out Snap Ring Using 2 Screwdrivers And A Hammer
      G02631361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a bolt and washer to the tip of the input shaft and using SST, remove the No. 3 clutch hub.

      SST 09950-30012

      HINT:

      Select a bolt whose outer diameter is smaller than the screw hole of the input shaft so that it can be turned easily.

    4. Using a screwdriver, pry out the shifting key spring from the other side of the No. 3 clutch hub.
    5. Remove the No. 3 synchronizer ring, 5th gear, needle roller bearing and spacer.
    Fig 15: Removing Clutch Hub Using SST
    G02631362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE 5TH DRIVEN GEAR 

    Using SST, remove the 5th driven gear.

    SST 09628-62011, 09950-40011 (09957-04010), 09950-60010 (09951-00230)

    Fig 16: Removing 5Th Driven Gear Using SST
    G02631363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    At the time of reassembly, please refer to the following item. Using SST, install the 5th driven gear.

    SST 09309-12020

    Fig 17: Installing 5Th Driven Gear Using SST
    G02631364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REAR BEARING RETAINER 

    Remove the 5 bolts and rear bearing retainer.

    Sealant: 

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

    Torque: 27 N.m (280 kgf.cm, 20 ft.lbf) 

  18. REMOVE BEARING SNAP RING 

    Using a snap ring expander, remove the 2 snap rings.

    HINT:

    If it is difficult to remove and install the snap rings, pull up the shafts.

    Fig 18: Removing Snap Rings Using A Snap Ring Expander
    G02631365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET 

    Sealant: 

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

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

  20. REMOVE SNAP RING FROM NO. 2 SHIFT FORK SHAFT 

    Using 2 screwdrivers and a hammer, tap out the snap ring.

    Fig 19: Removing Snap Ring Using A Screwdriver
    G02631366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND BALL 
    1. Using a hexagon wrench, remove the 3 straight screw plugs.

      Sealant: 

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

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

    2. Using a magnetic finger, remove the 3 seats, springs and balls.
    Fig 20: Removing Straight Screw Plugs Using A Hexagon Wrench
    G02631367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE LOCK BALL ASSEMBLY 

    Using a hexagon wrench, remove the lock ball assembly.

    Sealant: 

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

    Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

    Fig 21: Removing Lock Ball Assembly Using A Hexagon Wrench
    G02631368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TRANSMISSION CASE 
    1. Remove the 16 bolts.

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

    2. Using a plastic-faced hammer, carefully tap the projection of the transmission case to remove the transmission case from the transaxle case.
    Fig 22: Removing Transmission Case Using A Plastic-Faced Hammer
    G02631369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of reassembly, please refer to the following item. Apply FIPG to the transaxle case as shown in the illustration.

    1. FIPG: 
    2. Part No. 08826-00090, THREE BOND 1281 or equivalent 
    Fig 23: Applying FIPG To Transaxle Case
    G02631370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE OIL RECEIVER PIPE 

    Remove the 2 bolts and 2 oil receiver pipes from the transmission case.

    1. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 
    NOTE: At the time of reassembly, please refer to the following items.
    • Prevent the oil receiver pipes from being deformed.
    • Install the oil receiver pipes while placing it against the transmission case, as shown in the illustration.
    Fig 24: Removing Oil Receiver Pipe
    G02631371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT 
  26. REMOVE REVERSE SHIFT ARM BRACKET 

    Remove the 2 bolts and reverse shift arm bracket.

    1. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 
    NOTE: At the time of reassembly, please refer to the following items.
    • Set the pin on the top of the reverse shift arm into a groove on the reverse idler gear.
    • Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing.
      Fig 25: Removing Reverse Shift Arm Bracket
      G02631372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Install the reverse idler gear, thrust washer and shaft, as shown in the illustration.
    Fig 26: Aligning Alignment Mark
    G02631373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK SHAFT 
    1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from each gear shift fork shaft.
    2. Remove the 3 bolts from the No. 1 gear shift head, No. 1 and No. 2 gear shift forks.

      Sealant: 

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

      Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

    3. Pull up the No. 3 gear shift fork shaft, remove the No. 2 gear shift fork shaft.
      Fig 27: Removing Snap Rings Using 2 Screwdrivers
      G02631374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: At the time of reassembly, please refer to the following item.
      To avoid the interference of the 2 balls, lift up the No. 3 gear shift fork shaft at the position shown in the illustration.
      Fig 28: Lifting Up No. 3 Gear Shift Fork Shaft
      G02631375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the No. 1 gear shift head.
      Fig 29: Removing No. 1 Gear Shift Head
      G02631376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
    6. Remove the No. 3 gear shift fork shaft and reverse shift fork.
    7. Pull out the No. 1 gear shift fork shaft.
    8. Remove the No. 1 and No. 2 gear shift forks.
    Fig 30: Removing Balls From Reverse Shift Fork Using A Magnetic Finger
    G02631377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE 
  29. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    NOTE: At the time of reassembly, please refer to the following item.
    Before reassembly, inspect the differential tapered roller bearing preload (See REASSEMBLY ).
  30. REMOVE MAGNET FROM TRANSAXLE CASE 
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