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Manual Transaxle Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY 
    1. Remove the clutch release fork sub-assembly together with the clutch release bearing assembly from the manual transaxle case.
  2. REMOVE CLUTCH RELEASE BEARING ASSEMBLY 
    1. Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork sub-assembly.
      Fig 1: Removing Clutch Release Fork Sub-Assembly
      G04977150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE RELEASE FORK SUPPORT 
    1. Remove the release fork support from the manual transaxle case.
  4. REMOVE CLUTCH RELEASE FORK BOOT 
    1. Remove the clutch release fork boot from the manual transaxle case.
  5. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Remove the bolt and speedometer driven hole cover sub-assembly.
    2. Remove the O-ring.
      Fig 2: Locating Release Fork Support
      G04977161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CONTROL CABLE BRACKET 
    1. Remove the 3 bolts and control cable bracket.
      Fig 3: Locating Control Cable Bracket Bolts
      G06045508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE SELECTING BELLCRANK ASSEMBLY 
    1. Remove the 2 bolts and selecting bellcrank assembly from the manual transmission case.
      Fig 4: Locating Selecting Bellcrank Assembly Bolts
      G04977222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CONTROL SHIFT LEVER 
    1. Remove the nut and spring washer.
      Fig 5: Locating Nut And Spring Washer
      G04977223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the shift outer lever lock pin.
    3. Remove the control shift lever.
      Fig 6: Removing Shift Outer Lever Lock Pin
      G06013111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CONTROL SHAFT COVER 
    1. Remove the 4 bolts and control shaft cover from the manual transmission case.
      Fig 7: Locating Control Shaft Cover Bolts
      G06013117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 2 CLUTCH TUBE BRACKET 
    1. Remove the bolt and No. 2 clutch tube bracket.
      Fig 8: Locating No. 2 Clutch Tube Bracket Bolt
      G06013112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. SECURE MANUAL TRANSAXLE ASSEMBLY 
    1. Place the manual transaxle assembly on wooden blocks.
      Fig 9: Placing Manual Transaxle Assembly On Wooden Blocks
      G06013113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 LOCK BALL ASSEMBLY 
    1. Remove the No. 1 lock ball assembly from the manual transmission case.
      Fig 10: Locating No. 1 Lock Ball Assembly
      G04977227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE SHIFT GATE PIN 
    1. Remove the shift gate pin from the manual transmission case.
      Fig 11: Locating Shift Gate Pin
      G04977228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE MANUAL TRANSMISSION BREATHER PLUG 
    1. Remove the manual transmission breather plug.
      Fig 12: Locating Manual Transmission Breather Plug
      G04977229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Remove the shift and select lever shaft assembly from the manual transmission case.
      Fig 13: Identifying Shift And Select Lever Shaft Assembly
      G06013118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Remove the back-up light switch assembly and gasket from the manual transmission case.
      Fig 14: Locating Back-Up Light Switch Assembly
      G06013119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the manual transmission filler plug and gasket from the manual transmission case.
      Fig 15: Locating Manual Transmission Filler Plug
      G06013120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE DRAIN PLUG SUB-ASSEMBLY 
    1. Remove the drain plug sub-assembly and gasket from the manual transmission case.
      Fig 16: Locating Drain Plug Sub-Assembly
      G04977233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Remove the 10 bolts and manual transmission case cover from the manual transmission case.
      Fig 17: Locating Manual Transmission Case Cover Bolts
      G04977234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT 
    1. Engage the 1st and 2nd gears simultaneously.
      Fig 18: Engaging 1st And 2nd Gears Simultaneously
      G06013123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, unstake the manual transmission output shaft rear set nut.

      SST 09930-00010 

      Fig 19: Unstaking Manual Transmission Output Shaft Rear Set Nut
      G04977236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the manual transmission output shaft rear set nut from the output shaft.

      SST 09229-55010 

    4. Disengage the gears.
      Fig 20: Removing Manual Transmission Output Shaft Rear Set Nut From Output Shaft
      G04977237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 3 TRANSMISSION CLUTCH HUB 
    1. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.

      HINT:

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

      Fig 21: Removing Transmission Clutch Hub No. 3 Shaft Snap Ring From Input Shaft
      G04977238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the shift fork set bolt from the No. 3 gear shift fork.
      Fig 22: Locating Shift Fork Set Bolt
      G04977239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the No. 3 transmission clutch hub and No. 3 gear shift fork from the input shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951-00280) 

      Fig 23: Removing No. 3 Transmission Clutch Hub And No. 3 Gear Shift Fork From Input Shaft
      G04977240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE 5TH GEAR 
    1. Remove the 5th gear from the input shaft.
      Fig 24: Identifying 5th Gear
      G04977241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE 5TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 5th gear needle roller bearing from the input shaft.
      Fig 25: Identifying 5th Gear Needle Roller Bearing
      G04977242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. 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, 09957-04010), 09950-50013, 09950-60010 (09951-00180, 09955-03011) 

      Fig 26: Removing 5th Driven Gear From Output Shaft
      G04977243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR BEARING RETAINER 
    1. Using a "TORX" socket wrench (T45), remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case.
      Fig 27: Removing "Torx" Screws
      G04977244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE OUTPUT SHAFT REAR BEARING SHIM 
    1. Remove the output shaft rear bearing shim from the output shaft.
      Fig 28: Identifying Output Shaft Rear Bearing Shim
      G04977245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    1. Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
      Fig 29: Removing Input Shaft Rear Bearing Shaft Snap Ring From Input Shaft
      G04977246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE SHIFT FORK SHAFT SNAP RING 
    1. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.

      HINT:

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

      Fig 30: Removing Shift Fork Shaft Snap Ring From No. 1 Gear Shift Fork Shaft
      G04977247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 2 gear shift fork shaft.

      HINT:

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

      Fig 31: Removing Shift Fork Shaft Snap Ring From No. 2 Gear Shift Fork Shaft
      G04977248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    1. Remove the reverse idler gear shaft bolt and gasket.
      Fig 32: Locating Reverse Idler Gear Shaft Bolt
      G04977249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE MANUAL TRANSMISSION CASE 
    1. Remove the 3 bolts from the manual transaxle case.
      Fig 33: Locating Manual Transaxle Case Bolts
      G04977250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 14 bolts from the manual transmission case.
    3. Tapping with a plastic hammer, remove the manual transmission case.
      Fig 34: Locating Manual Transmission Case Bolts
      G04977251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE REVERSE RESTRICT PIN ASSEMBLY 
    1. Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.
      Fig 35: Locating Reverse Restrict Pin Plug
      G04977252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch ( 5 mm) and a hammer, remove the slotted pin.
      Fig 36: Removing Slotted Pin
      G04977253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, transmission oil baffle and reverse restrict pin assembly.
      Fig 37: Locating Bolt, Transmission Oil Baffle And Reverse Restrict Pin Assembly
      G04977254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 2 OIL RECEIVER PIPE 
    1. Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.
      NOTE: Do not damage the pipe.
      Fig 38: Locating No. 2 Oil Receiver Pipe Bolt
      G04977255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 1 OIL RECEIVER PIPE 
    1. Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.
      NOTE: Do not damage the pipe.
      Fig 39: Locating No. 1 Oil Receiver Pipe Bolt
      G04977256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE TRANSMISSION MAGNET 
    1. Remove the transmission magnet from the manual transaxle case.
      Fig 40: Removing Transmission Magnet From Manual Transaxle Case
      G04977257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Remove the reverse idler gear sub-assembly from the manual transaxle case.
      Fig 41: Removing Reverse Idler Gear Sub-Assembly From Manual Transaxle Case
      G05130370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.
      Fig 42: Removing Reverse Gear And Reverse Idler Thrust Washer From Reverse Idler Gear Shaft
      G04977259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Remove the 2 bolts and reverse shift arm bracket assembly from the manual transaxle case.
      Fig 43: Locating Reverse Shift Arm Bracket Assembly Bolts
      G04977260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 1 GEAR SHIFT FORK SHAFT 
    1. Remove the shift fork set bolt from the No. 1 gear shift fork.
      Fig 44: Locating Shift Fork Set Bolt
      G04977261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull out the No. 1 gear shift fork shaft while pulling up the No. 3 gear shift fork shaft.
      Fig 45: Identifying No. 1 Gear Shift Fork Shaft
      G06013150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.

      HINT:

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

      Fig 46: Removing Shift Fork Shaft Snap Ring From No. 1 Gear Shift Fork Shaft
      G04977263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE REVERSE SHIFT FORK ROLLER 
    1. Using a magnetic pick-up tool, remove the reverse shift fork roller from the reverse shift fork.
      Fig 47: Removing Reverse Shift Fork Roller From Reverse Shift Fork
      G04977264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 2 GEAR SHIFT FORK SHAFT 
    1. Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.
      Fig 48: Locating Shift Fork Set Bolt And Shift Head Set Bolt
      G04977265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the manual transaxle case.
      Fig 49: Identifying No. 2 Gear Shift Fork Shaft And No. 1 Gear Shift Head
      G06013154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 1 GEAR SHIFT FORK 
    1. Remove the No. 1 gear shift fork.
      Fig 50: Identifying No. 1 Gear Shift Fork
      G06013155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 3 GEAR SHIFT FORK SHAFT 
    1. Remove the No. 3 gear shift fork shaft from the manual transaxle case.
      Fig 51: Identifying No. 3 Gear Shift Fork Shaft
      G06013156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.

      HINT:

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

    3. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
      Fig 52: Removing Shift Fork Shaft Snap Rings From No. 3 Gear Shift Fork Shaft
      G04977269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 2 GEAR SHIFT FORK 
    1. Remove the No. 2 gear shift fork from the input shaft assembly.
      Fig 53: Identifying No. 2 Gear Shift Fork
      G06013158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE INPUT SHAFT ASSEMBLY 
    1. Tilt the output shaft, and then remove the input shaft from the manual transaxle case.
      Fig 54: Tilting Output Shaft
      G04977271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE OUTPUT SHAFT ASSEMBLY 
    1. Lift the differential case assembly with the output shaft assembly leaned.
    2. Remove the output shaft assembly from the manual transaxle case.
      Fig 55: Removing Output Shaft Assembly
      G04977272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    1. Remove the differential case assembly from the manual transaxle case.
      Fig 56: Identifying Differential Case Assembly
      G04977273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE MANUAL TRANSAXLE CASE RECEIVER 
    1. Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.
      Fig 57: Locating Manual Transaxle Case Receiver Bolts
      G04977274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE INPUT SHAFT FRONT BEARING 
    1. Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case.

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

      Fig 58: Removing Input Shaft Front Bearing (Outer Race) From Manual Transaxle Case
      G04977275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL 
    1. Using SST, remove the front transaxle case cover oil seal from the manual transaxle case.

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

      Fig 59: Removing Front Transaxle Case Cover Oil Seal From Manual Transaxle Case
      G04977276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case.

      SST 09387-00041 (09387-02020, 09387-02010) 

      Fig 60: Removing Output Shaft Front Bearing (Outer Race) From Manual Transaxle Case
      G04977277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE OUTPUT SHAFT COVER 
    1. Remove the output shaft cover from the manual transaxle case.
      Fig 61: Identifying Output Shaft Cover
      G04977278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE OUTPUT SHAFT REAR BEARING 
    1. Using SST and a hammer, remove the output shaft rear bearing from the manual transmission case (outer race).

      SST 09950-60010 (09951-00680), 09950-70010 (09951-07100) 

      Fig 62: Removing Output Shaft Rear Bearing From Manual Transmission Case (Outer Race)
      G04977279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE TRANSMISSION CASE OIL SEAL 
    1. Using SST, remove the transmission case oil seal from the manual transmission case.

      SST 09308-00010 

      Fig 63: Removing Transmission Case Oil Seal From Manual Transmission Case
      G04977280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE TRANSAXLE CASE OIL SEAL 
    1. Using a screwdriver, remove the transaxle case oil seal.

      HINT:

      Tape the screwdriver tip before use to avoid damage.

      Fig 64: Removing Transaxle Case Oil Seal
      G04977281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using a brass bar and a hammer, remove the front differential case front tapered roller bearing (outer race) from the manual transaxle case.
      Fig 65: Removing Front Differential Case Front Tapered Roller Bearing (Outer Race) From Manual Transaxle Case
      G05130394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the front differential case front tapered roller bearing from the front differential case.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560) 

      Fig 66: Removing Front Differential Case Front Tapered Roller Bearing From Front Differential Case
      G06013171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a hammer, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.

      SST 09950-60020 (09951-00790), 09950-70010 (09951-07100) 

      Fig 67: Removing Front Differential Case Rear Tapered Roller Bearing (Outer Race) And Front Differential Case Rear Shim
      G04977284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.

      SST 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490), 09950-60020 (09951-00790) 

      Fig 68: Removing Front Differential Case Rear Tapered Roller Bearing (Inner Race) From Front Differential Case
      G04977285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE NO. 3 TRANSMISSION HUB SLEEVE 
    1. Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.
      Fig 69: Identifying No. 3 Transmission Hub Sleeve
      G06013174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING 
    1. Remove the 2 No. 3 synchromesh shifting key springs from the No. 3 transmission clutch hub while pushing on the No. 3 synchromesh shifting key spring.
      Fig 70: Removing No. 3 Synchromesh Shifting Key Spring
      G04977287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE SYNCHRONIZER PULL RING 
    1. Using a screwdriver, remove the synchronizer pull ring snap ring.
    2. Remove the synchronizer pull ring, No. 5 synchronizer ring outer, No. 5 synchronizer ring inner, and No. 5 synchronizer ring middle from the No. 5 synchronizer ring inner.
      Fig 71: Removing Synchronizer Pull Ring Snap Ring
      G04977288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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