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Manual Transaxle Assembly: Installation

  1. INSTALL THE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY. 
    1. Coat a new O-ring with gear oil.
    2. Install the O-ring onto the speedometer driven hole cover.
    3. Install the speedometer driven hole cover sub-assembly onto the transaxle case with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in*lbf) 

      4. Fig 1: Identifying Speedometer Driven Hole Cover Sub-Assembly
      G00505161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL THE CLUTCH FLEXIBLE HOSE BRACKET. 
    1. Install the clutch flexible hose bracket with the bolt.

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

      2. Fig 2: Identifying Clutch Flexible Hose Bracket
      G00505162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clutch line to the clutch flexible hose bracket with the bolt.

      Torque: 19 N*m (192 kgf*cm, 14 ft*lbf) 

      3. Fig 3: Identifying Clutch Flexible Hose Bracket
      G00505163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL THE FRONT ENGINE MOUNTING BRACKET WITH THE 3 BOLTS. 

      Torque: 64 N*m (653 kgf*cm, 47 ft*lbf) 

    Fig 4: Identifying Front Engine Mounting Bracket
    G00505164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL THE LOWER (5) TRANSAXLE BOLTS. 

      Bolt A, B: Torque: 46 N*m (469 kgf*cm, 34 ft*lbf) 

      Bolt A = 65 mm (2.56 in.) 

      Bolt B = 32 or 33 mm (1.26 or 1.30 in.) 

    Fig 5: Identifying Lower Transaxle Bolts
    G00505165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. LOWER THE TRANSMISSION JACK AWAY FROM THE ENGINE AND TRANSMISSION. 
  6. INSTALL THE SUB FRAME USING THE SST. 

      SST: 00002-90080 

    1. Install the front frame assembly with the 9 nuts.

      2. Front Side: Torque: 52 N*m (531 kgf*cm, 38 ft*lbf) 

      RH & LH Sides: Torque: 87 N*m (887 kgf*cm, 64 ft*lbf) 

      Fig 6: Identifying Sub Frame Assembly And Fasteners
      G00505122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 5 hole plugs.
      3. Fig 7: Identifying Hole Plugs
      G00505123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine lateral control rod with the 2 nuts, then install the 2 hole plugs.

      Torque: 52 N*m (530 kgf*cm, 38 ft*lbf) 

      Fig 8: Identifying Engine Lateral Control Rod
      G00505159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the power steering link assembly with the 2 bolts and 2 nuts.

      Torque: 70 N*m (714 kgf*cm, 52 ft*lbf) 

      Fig 9: Identifying Power Steering Link Assembly
      G00505124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.

      Nut A: Torque: 85 N*m (867 kgf*cm, 63 ft*lbf) 

      Bolt B: Torque: 32 N*m (329 kgf*cm, 24 ft*lbf) 

    6. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

      Nut C: Torque: 85 N*m (867 kgf*cm, 63 ft*lbf) 

      Bolt D: Torque: 32 N*m (329 kgf*cm, 24 ft*lbf) 

      Fig 10: Identifying Frame Rail Side Plates
      G00505125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: SST 00002-90080 will ensure all engine and transmission mount studs have lined up with their corresponding holes. 
  7. REMOVE THE SECONDARY SAFETY SUPPORT STRAPS. 
  8. INSTALL THE FRONT STABILIZER LINK ASSEMBLY WITH THE NUT. 

    Torque: 74 N*m (755 kgf*cm, 55 ft*lbf) 

    NOTE: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. 
    9. Fig 11: Identifying Front Stabilizer Link Assembly
    G00505126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL THE FRONT EXHAUST PIPE ASSEMBLY BACK ONTO THE VEHICLE. 
    1. Install 2 new gaskets to the front exhaust pipe assembly and center exhaust pipe assembly.
      2. Fig 12: Identifying Front Exhaust Pipe Assembly And Fasteners
      G00505127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front exhaust pipe with the 2 nuts to the exhaust manifold converter sub-assembly.

      Torque: 55 N*m (561 kgf*cm, 40 ft*lbf) 

    3. Install the front exhaust pipe with the 2 nuts and 2 bolts to the center exhaust pipe assembly.

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

    4. Install the bracket with the 2 nuts.

      Torque: 33 N*m (337 kgf*cm, 24 ft*lbf) 

    5. Install the support bracket with the 2 bolts.

      Torque: 33 N*m (337 kgf*cm, 24 ft*lbf) 

      6. Fig 13: Identifying Support Bracket
      G00505128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the connector.
    Fig 14: Identifying Connector
    G00505129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL THE FRONT DRIVE SHAFT ASSEMBLY LH. 
    1. Coat the spline of the inboard joint shaft assembly with ATF.
    2. Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.
      IMPORTANT: * Set the shaft snap ring with the opening side facing down.
      IMPORTANT: * Be careful NOT to damage the drive shaft dust cover, boot, or oil seal.
      IMPORTANT: * Move the drive shaft assembly while keeping it level.
      3. Fig 15: Installing The Front Drive Shaft Assembly LH
      G00505130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL THE FRONT DRIVE SHAFT ASSEMBLY RH. 
    1. Coat the spline of the inboard joint shaft assembly with ATF.
    2. Install the front drive shaft assembly RH.
    3. Using a screwdriver, install a new bearing bracket hole snap ring.
    4. Install a new bolt.

      Torque: 32 N*m (330 kgf*cm, 24 ft*lbf) 

      IMPORTANT: * Do NOT damage the boot and oil seal.
      IMPORTANT: * Move the drive shaft assembly while keeping it level.
    Fig 16: Identifying Bearing Bracket Hole Snap Ring And Bolt
    G00505131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL THE FRONT AXLE ASSEMBLY 
    1. Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly
    Fig 17: Identifying Matchmarks
    G00505132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL THE FRONT SUSPENSION LOWER NO. 1 ARM. 
    1. Install the lower ball joint to the front suspension lower No. 1 arm with the bolt and 2 nuts.

      Torque: 75 N*m (765 kgf*cm, 55 ft*lbf) 

      2. Fig 18: Identifying Front Suspension Lower No. 1 Arm And Fasteners
      G00505133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL THE FRONT AXLE HUB NUT. 
    1. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.
    2. Using a socket wrench (30 mm) and applying the brakes, install a new front axle hub nut.

      Torque: 294 N*m (3, 000 kgf*cm, 217 ft*lbf) 

    3. Using a chisel and hammer, stake the front axle hub nut.
    Fig 19: Staking Front Axle Hub Nut
    G00505134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL THE FRONT WHEELS. 
  16. INSTALL THE FRONT WHEEL OPENING EXTENSION PAD LH. 
  17. INSTALL THE ENGINE UNDER COVER LH. 
  18. INSTALL THE FRONT WHEEL OPENING EXTENSION PAD RH 
  19. INSTALL THE FRONT FENDER APRON SEAL LH. 
  20. INSTALL THE FRONT FENDER APRON SEAL RH. 
  21. REMOVE THE ENGINE SUPPORT BAR. 
  22. INSTALL THE UPPER (5) TRANSAXLE BOLTS 

    Bolt A: Torque: 46 N*m (469 kgf*cm, 34 ft*lbf) 

    Bolt 1, 2, and 3: Torque: 64 N*m (653 kgf*cm, 47 ft*lbf) 

    Bolt A, 1, and 2 = 60 mm (2.36 in.) 

    Bolt 3 = 74.5 mm (2.93 in.) 

    23. Fig 20: Identifying Upper Transaxle Bolts
    G00505166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL THE CLUTCH HOSE. 
    1. Using a union nut wrench (10 mm), install the flexible hose tube.

      Torque: 15 N*m (155 kgf*cm, 11 ft*lbf) 

    2. Add fluid to the clutch reservoir.
    3. Bleed air out of the clutch line.
    Fig 21: Identifying Clutch Hose
    G00505167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. CONNECT THE TRANSMISSION CONTROL CABLE ASSEMBLY. 
    1. Install the 2 transmission control cables to the control cable bracket with the 2 new clips (1).
    2. Install the 2 clips (2).

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

      3. Fig 22: Identifying Transmission Control Cable Assembly
      G00505168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. CONNECT THE WIRE HARNESS. 
    1. Connect the 2 connectors and install the 2 cables with the 2 bolts.

      Torque: 12 N*m (123 kgf*cm, 9 ft*lbf) 

    2. Install the wire harness to the manual transaxle with the clamp and nut.

      Torque: 8.4 N*m (85 kgf*cm, 74 in*lbf) 

      3. Fig 23: Identifying Wire Harness
      G00505169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL THE STARTER ASSEMBLY. 
    1. Install the starter assembly with the 2 bolts.

      Torque: 37 N*m (377 kgf*cm, 27 ft*lbf) 

      2. Fig 24: Identifying Starter Assembly And Fasteners
      G00505063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the wire harness to terminal 30 and install the nut. Then attach the terminal cap.

      Torque: 9.8 N*m (100 kgf*cm, 87 in*lbf) 

    3. Connect the terminal 50 connector to the starter assembly.
    Fig 25: Identifying Terminal 50 Connector And Starter Assembly
    G00505062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL THE AIR CLEANER CASE SUB-ASSEMBLY. 
    1. Install the air cleaner case with the 3 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf) 

    2. Connect the wire harness clamp.
    Fig 26: Identifying Air Cleaner Case Sub-Assembly
    G00505061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL THE AIR CLEANER CAP SUB-ASSEMBLY. 
    1. Connect the air cleaner cap sub-assembly with the hose clamp.
      2. Fig 27: Identifying Air Hose And Clamp
      G00505059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the hose with the hose clamp.
      3. Fig 28: Identifying Hose Clamp
      G00505058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the hose with the hose clamp.
      4. Fig 29: Identifying Air Cleaner Cap Sub-Assembly
      G00505057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the vacuum switching valve connector and 2 hoses.
      5. Fig 30: Identifying Vacuum Switching Valve And Hoses
      G00505056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the mass air flow meter connector and wire harness clamp to the air cleaner cap sub-assembly.
      6. Fig 31: Identifying Mass Air Flow Meter And Harness
      G00505055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. For PZEV vehicles:  Connect the hose and engage the hose to the clips on the air cleaner hose.
      7. Fig 32: Identifying Vacuum Hose And Air Hose
      G00505054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the air cleaner cap sub-assembly with the 2 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf) 

      8. Fig 33: Identifying Air Cleaner Cap Sub-Assembly And Bolts
      G00505060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL THE INLET AIR CLEANER ASSEMBLY WITH THE 2 BOLTS. 

    Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf) 

    30. Fig 34: Identifying Inlet Air Cleaner Assembly And Fasteners
    G00505053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. FIT THE 3 RETAINERS AND INSTALL THE NO. 1 ENGINE COVER SUB-ASSEMBLY. 
    31. Fig 35: Identifying No. 1 Engine Cover Assembly
    G00505052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL THE BATTERY. 
    1. Install the battery and battery tray.
    2. Install the battery clamp with the bolt and nut.

      Bolt: Torque: 9.0 N*m (92 kgf*cm, 80 in*lbf) 

      Nut: Torque: 3.5 N*m (36 kgf*cm, 31 in*lbf) 

    3. Connect the battery terminals.

      Torque: 6.9 N*m (70 kgf*cm, 61 in*lbf) 

      4. Fig 36: Identifying Battery, Hold Down Clamp And Tray
      G00505051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. FILL TRANSMISSION TO CORRECT LEVEL 
  33. CHECK FOR EXHAUST LEAKS. 
  34. CHECK FOR FLUID LEAKS. 
  35. CHECK SHIFT LEVER POSITION. 
  36. INSTALL THE ENGINE UNDER COVERS. 
  37. RE-INITIALIZE AUTO-POWER WINDOWS AND MOON ROOF (IF EQUIPPED). 
  38. TEST DRIVE VEHICLE, INSURING PROPER OPERATION. 
  39. ADJUST WHEEL ALIGNMENT AS NEEDED. 
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