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Manual Transaxle Unit: Disassembly

  1. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the manual transmission filler plug and gasket from the manual transmission case.
      Fig 1: Identifying Manual Transmission Filler Plug
      G04831683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY 
    1. Remove the drain (MTM) plug sub-assembly and gasket from the manual transmission case.
    Fig 2: Identifying Drain (MTM) Plug Sub-Assembly
    G04831684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE SPEEDOMETER SENSOR (w/o ABS) 
    1. Remove the bolt and speedometer sensor from the transaxle case.
    2. Remove the O-ring from the speedometer sensor.
  4. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (w/ ABS) 
    1. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
    2. Remove the O-ring from the speedometer driven hole cover.
  5. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY 
    1. Remove the clutch release fork sub-assembly with the clutch release bearing assembly from the transaxle case.
      Fig 3: Removing Clutch Release Fork Sub-Assembly
      G05194283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CLUTCH RELEASE BEARING ASSEMBLY 
    1. Remove the clutch release bearing clip and clutch release bearing assembly from the clutch release fork sub-assembly.
      Fig 4: Identifying Clutch Release Bearing Assembly
      G05234627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE RELEASE FORK SUPPORT 
    1. Remove the clutch release fork support from the transaxle case.
      Fig 5: Identifying Release Fork Support
      G05194285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CLUTCH RELEASE FORK BOOT 
    1. Remove the clutch release fork boot from the transaxle case.
      Fig 6: Identifying Clutch Release Fork Boot
      G05194286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BACK UP LIGHT SWITCH ASSEMBLY 
    1. Remove the back up light switch assembly and gasket from the manual transmission case.
      Fig 7: Locating Back Up Light Switch Assembly
      G05194287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET 
    1. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.
      Fig 8: Locating Floor Shift Control Lever Housing Support Bracket
      G05194288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE SELECTING BELL CRANK ASSEMBLY 
    1. Remove the 2 bolts and selecting bell crank assembly from the manual transmission case.
    2. Remove the control shift lever bush.
      Fig 9: Locating Selecting Bell Crank Assembly And Bolts
      G05234632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. FIX MANUAL TRANSAXLE ASSEMBLY 
    1. Place the manual transaxle assembly on wooden blocks.
      Fig 10: Identifying Manual Transaxle Assembly On Wooden Blocks
      G05194290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE LOCK BALL ASSEMBLY NO. 1 
    1. Remove the lock ball assembly No. 1 from the manual transmission case.
      Fig 11: Locating Lock Ball Assembly No. 1
      G05194291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Remove the 4 bolts, shift & select lever shaft assembly and gasket from the manual transmission case.
      Fig 12: Identifying Shift And Select Lever Shaft Assembly
      G05194292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Remove the 9 bolts.
      Fig 13: Identifying Manual Transmission Case Cover Sub-Assembly
      G05194293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assembly to remove it from the manual transmission case.
      NOTE: Do not damage the manual transmission case.
      Fig 14: Locating Manual Transmission Case Cover Sub-Assembly
      G05194294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
      Fig 15: Loosening Staked Part Of Manual Transmission Output Shaft Rear Set Nut
      G04831699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage two gears simultaneously to lock the transmission.
    3. Remove the manual transmission output shaft rear set nut.
    4. Disengage the two gears.
      Fig 16: Removing Manual Transmission Output Shaft Rear Set Nut
      G04831700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE GEAR SHIFT FORK NO. 3 
    1. Remove the gear shift fork lock bolt from the gear shift fork No. 3.
      Fig 17: Locating Gear Shift Fork Lock Bolt From Gear Shift Fork No. 3
      G04831701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the transmission hub sleeve No. 3 with the gear shift fork No. 3 from the transmission clutch hub No. 3.
      3. Fig 18: Removing Transmission Hub Sleeve No. 3
      G04831702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT 5TH GEAR THRUST CLEARANCE (See  INSPECTION   ) 
  19. INSPECT 5TH GEAR RADIAL CLEARANCE (See  INSPECTION   ) 
  20. REMOVE TRANSMISSION CLUTCH HUB NO. 3 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      Use a shop rag or piece of cloth to keep the snap ring from flying.

      Fig 19: Removing 5Th Gear Needle Roller Bearing
      G05234642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the transmission clutch hub No. 3, 5th gear and synchronizer ring No. 3 from the input shaft.

      SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010), 09950-60010 (09951-00200) 

      Fig 20: Removing Transmission Clutch Hub No. 3, 5Th Gear And Synchronizer Ring No. 3 From Input Shaft
      G05194300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No. 3.
      Fig 21: Identifying Synchromesh Shifting Keys
      G04831707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE 5TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
      Fig 22: Identifying 5Th Gear Needle Roller Bearing
      G05234645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE 5TH DRIVEN GEAR 
    1. Using SST, remove the 5th driven gear from the output shaft.

      SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190) 

      Fig 23: Identifying 5Th Driven Gear
      G05194303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE BEARING RETAINER REAR (MTM) 
    1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.
      Fig 24: Locating Bearing Retainer Rear (MTM)
      G05194304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
      Fig 25: Removing Output Shaft Rear Bearing Hole Snap Ring
      G04831711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
      Fig 26: Removing Input Shaft Rear Bearing Hole Snap Ring
      G04831712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
      Fig 27: Locating Reverse Idler Gear Shaft Bolt
      G04831713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE SHIFT FORK SHAFT, SHAFT SNAP RING 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 2.

      HINT:

      Use a shop rag or piece of cloth to keep the snap ring from flying.

      Fig 28: Identifying Shift Fork Shaft, Shaft Snap Ring
      G04831714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE SHIFT DETENT BALL 
    1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
      Fig 29: Identifying Shift Detent Ball Plugs
      G04831715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a magnetic finger, remove the 2 seats, 2 springs and 2 shift detent balls from the manual transmission case.
      Fig 30: Removing Seats, Springs And Shift Detent Balls From Manual Transmission Case
      G04831716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.
      Fig 31: Identifying Shift Detent Ball Plug
      G04831717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a magnetic finger, remove the seat, spring and shift detent ball from the transaxle case.
      Fig 32: Identifying Seat, Spring And Ball
      G04831718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE LOCK BALL ASSEMBLY NO. 1 
    1. Using a hexagon wench, remove the lock ball assembly No. 1 from the manual transmission case.
      Fig 33: Identifying Lock Ball Assembly No. 1
      G04831719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE MANUAL TRANSMISSION CASE 
    1. Remove the 3 bolts from the transaxle case side.
      Fig 34: Locating Transaxle Case Side And Bolts
      G05234657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 13 bolts from the manual transmission case side.
      Fig 35: Removing Bolts To Manual Transmission Side
      G04831721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, carefully tap the projection of the manual transmission case to remove it from the transaxle case.
      NOTE: Do not damage the manual transmission case and transaxle case.
      Fig 36: Identifying Manual Transmission Case And Transaxle Case
      G05234659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the transaxle case.
      Fig 37: Identifying Reverse Idler Gear Sub-Assembly
      G04831723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Remove the 2 bolts and reverse shift arm bracket assembly from the transaxle case.
      Fig 38: Locating Reverse Shift Arm Bracket Assembly
      G04831724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE GEAR SHIFT FORK SHAFT NO. 2 
    1. Remove the 2 bolts from the gear shift fork No. 2 and gear shift head No. 1.
      Fig 39: Locating Gear Shift Fork No. 2 And Bolts
      G05234662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gear shift fork shaft No. 2 and gear shift head No. 1 from the transaxle case.
      Fig 40: Identifying Gear Shift Fork Shaft No. 2 And Gear Shift Head No. 1
      G05194320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE GEAR SHIFT FORK SHAFT SUB-ASSEMBLY NO. 1 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      HINT:

      Use a shop rag or piece of cloth to keep the snap ring from flying.

      Fig 41: Removing Snap Ring
      G04831727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assembly No. 1 from the gear shift fork No. 1.
      Fig 42: Locating Gear Shift Fork Lock Bolt And Gear Shift Fork Shaft Sub-Assembly No. 1
      G05194322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the gear shift fork No. 1.
      Fig 43: Identifying Gear Shift Fork No. 1
      G05194323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE GEAR SHIFT FORK SHAFT NO. 3 
    1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 3.

      HINT:

      Use a shop rag or piece of cloth to keep the snap ring from flying.

      Fig 44: Removing Snap Ring
      G04831730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the shift fork shaft No. 3 with the reverse shift fork and gear shift fork No. 2 from the transaxle case.
      Fig 45: Identifying Gear Shift Fork No. 1 And Gear Shift Fork No. 2
      G05234668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
      Fig 46: Identifying Reverse Shift Fork
      G04831732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using 2 screwdrivers and a hammer, tap out the snap ring.
      Fig 47: Removing Snap Ring
      G04831733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a shop rag or piece of cloth to keep the snap ring from flying.

    5. Remove the reverse shift fork from the gear shift fork shaft No. 3.
  36. REMOVE INPUT SHAFT ASSEMBLY 
    1. Remove the input and output shaft assembly from the transaxle case.
      Fig 48: Identifying Input Shaft Assembly
      G04831734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    1. Remove the differential case assembly from the transaxle case.
      Fig 49: Identifying Differential Case Assembly And Transaxle Case
      G05234672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE MANUAL TRANSAXLE CASE RECEIVER 
    1. Remove the bolt and manual transaxle case receiver from the transaxle case.
      Fig 50: Locating Manual Transaxle Case Receiver
      G04831736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE REVERSE RESTRICT PIN ASSEMBLY 
    1. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
      Fig 51: Removing Reverse Restrict Pin Assembly
      G04831737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (ø 5 mm) and a hammer, drive out the slotted pin and remove the reverse restrict pin assembly from the manual transmission case.
      Fig 52: Removing Reverse Restrict Pin Assembly From Manual Transmission Case
      G04831738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE OIL RECEIVER PIPE NO. 1 (MTM) 
    1. Remove the bolt and oil receiver pipe No. 1 (MTM) from the manual transmission case.
      NOTE: Be careful not to damage the oil receiver pipe No. 1 (MTM).
      Fig 53: Locating Oil Receiver Pipe No. 1 And Bolts
      G05234676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE OIL RECEIVER PIPE NO. 2 (MTM) 
    1. Remove the bolt and oil receiver pipe No. 2 (MTM) from the manual transmission case.
      NOTE: Be careful not to damage the oil receiver pipe No. 2 (MTM).
      Fig 54: Locating Bolt And Oil Receiver Pipe No. 2
      G04831740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE BEARING LOCK PLATE 
    1. Remove the bolt and bearing lock plate from the transaxle case.
      Fig 55: Locating Bearing Lock Plate
      G04831741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE TRANSMISSION MAGNET 
    1. Remove the transmission magnet from the transaxle case.
      Fig 56: Locating Transmission Magnet
      G05194336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE INPUT SHAFT FRONT BEARING 
    1. Using SST, remove the input shaft front bearing from the transaxle case.

      SST 09612-65014 (09612-01050, 09612-01060) 

      Fig 57: Removing Input Shaft Front Bearing
      G05194337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    1. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
      Fig 58: Removing Front Transaxle Case Oil Seal
      G04831744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using SST, remove the output shaft front bearing from the transaxle case.

      SST 09308-00010 

      Fig 59: Identifying Output Shaft Front Bearing
      G05194339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE OUTPUT SHAFT (MTM) COVER 
    1. Remove the output shaft (MTM) cover from the transaxle case.
      Fig 60: Identifying Output Shaft (MTM) Cover
      G04831746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST, remove the FR differential case front tapered roller bearing (outer race) and shim from the transaxle case.

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

      Fig 61: Identifying FR Differential Case Front Tapered Roller Bearing (Outer Race) And Shim From Transaxle Case
      G05194341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360) 

      NOTE: Be careful not to damage the bearing.
      Fig 62: Removing FR Differential Case Front Tapered Roller Bearing (Inner Race) From Front Differential Case
      G05194342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, drive out the transaxle case oil seal from the transaxle case.

      SST 09950-60010 (09951 -00530), 09950-70010 (09951-07150) 

      Fig 63: Removing Transaxle Case Oil Seal
      G05194343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the FR differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.

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

      Fig 64: Removing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
      G05234687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360) 

      NOTE: Be careful not to damage the bearing.
      Fig 65: Removing FR Differential Case Rear Tapered Roller Bearing (Inner Race) From Front Differential Case
      G05194345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.

      SST 09950-60010 (09951 -00600), 09950-70010 (09951-07100) 

      Fig 66: Identifying Transmission Case Oil Seal
      G05194346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSPECT SYNCHRONIZER RING NO. 3 (See  INSPECTION   ) 
  53. INSPECT TRANSMISSION HUB SLEEVE NO. 3 (See  INSPECTION   ) 
  54. INSPECT 5TH GEAR (See  INSPECTION   ) 
  55. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY (See  INSPECTION   ) 
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