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Manual Transaxle Assembly: Disassembly

  1. REMOVE CLUTCH RELEASE FORK AND BEARING 

    HINT:

    At the time of reassembly, please refer to the following item . Apply molybdenum disulfide lithium base grease (See INSTALLATION ).

  2. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS 

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

  3. REMOVE VEHICLE SPEED SENSOR 
    1. Remove the bolt and vehicle speed sensor.

      Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 

    2. Using a small screwdriver, remove the clip from the vehicle speed sensor.
    3. Remove the vehicle speed sensor driven gear from the vehicle speed sensor.
    4. Using a small screwdriver, remove the O-ring from the vehicle speed sensor.
  4. REMOVE BACK-UP LIGHT SWITCH WITH GASKET 

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

  5. REMOVE CONTROL LEVER HOUSING SUPPORT BRACKET 

    Remove the 3 bolts and control lever housing support bracket.

    Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 

  6. REMOVE SELECTING BELLCRANK ASSEMBLY 
    1. Remove the 2 bolts and selecting bellcrank assembly.

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

    2. Remove the control bellcrank dust cover from the selecting bellcrank assembly.
  7. REMOVE TRANSMISSION CASE COVER 
    1. Remove the 9 bolts.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 

      242 or equivalent 

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

    2. Carefully tap the projection of the transmission case cover with a brass bar and hammer and remove it.

      HINT:

      At the time of reassembly, please refer to the following item . Apply FIPG to the transmission case cover, as shown in Fig 1 .

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 1: Removing Transmission Case Cover
      G02906347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT 5TH GEAR THRUST CLEARANCE 

    Using a dial indicator, measure the thrust clearance.

    Standard clearance: 

    0.10 - 0.57 mm (0.0039 - 0.0224 in.) 

    Maximum clearance: 

    0.57 mm (0.0224 in.) 

    Fig 2: Measuring Thrust Clearance
    G02906348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT 5TH GEAR RADIAL CLEARANCE 

    Using a dial indicator, measure the radial clearance.

    Standard clearance: 

    KOYO made: 

    0.015 - 0.058 mm (0.0006 - 0.0023 in.) 

    NSK made: 

    0.015 - 0.056 mm (0.0006 - 0.0022 in.) 

    Maximum clearance: 

    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 3: Measuring Radial Clearance
    G02906349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Remove the lock bolt and gasket.

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

    2. Remove the 4 bolts and pull out the shift and select lever shaft assembly with the gasket.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 

      242 or equivalent 

      Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

      Fig 4: Removing Lock Bolt
      G02906350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE LOCK NUT 
    1. Engage the gear to the double meshing.
    2. Using a chisel and 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 double meshing of the gear.
      Fig 5: Removing Lock Nut
      G02906351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK 
    1. Remove the bolt from the No. 3 shift fork.

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

    2. Remove the No. 3 hub sleeve and No. 3 shift fork.
  13. 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 that allows the minimum axial play.

      SNAP RING SPECIFICATIONS

      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 SST, remove the No. 3 clutch hub assembly, 5th gear and synchronizer ring.

      SST 09950-4001 1

      Fig 6: Removing No. 3 Clutch Hub Assembly
      G02906352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

      • Install the No. 3 clutch hub assembly to the No. 3 hub sleeve.
      • Before driving in the No. 3 clutch hub assembly, place the suitable sized wooden block on the rear side of the input shaft, as shown in Fig 7 . When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is overloaded, it might be damaged.
        Fig 7: Placing Suitable Sized Wooden Block On Rear Side Of Input Shaft
        G02906353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Using SST and a hammer, drive in the No. 3 hub sleeve assembly with the No. 3 shift fork.

        SST 09612-2201 1

        NOTE: Align the synchronizer ring slots with the shifting keys.
    3. Remove the needle roller bearings and spacer.
      Fig 8: Driving In No. 3 Hub Sleeve Assembly With No. 3 Shift Fork
      G02906354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE 5TH DRIVEN GEAR 

    Using SST and a socket wrench, remove the 5th driven gear.

    SST 09950-4001 1

    Fig 9: Removing 5Th Driven Gear
    G02906355Courtesy 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 10: Installing 5Th Driven Gear
    G02906356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR BEARING RETAINER 

    Remove the 5 bolts and rear bearing retainer.

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

  16. 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 11: Removing Snap Rings
    G02906357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET 

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

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

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

    Fig 12: Removing Reverse Idler Gear Shaft Lock Bolt
    G02906358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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 13: Removing Straight Screw Plugs
      G02906359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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 14: Removing Lock Ball Assembly
    G02906360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSMISSION CASE 
    1. Remove the 16 bolts.

      Sealant: 

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

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

    2. Carefully tap the transmission case with a plastic hammer and remove it.
      Fig 15: Removing Transmission Case
      G02906361Courtesy 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 Fig 16 .

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

    3. Remove the 2 bolts, No. 1 and No. 2 oil receiver pipes from the transmission case.

      Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

      Fig 16: Applying FIPG To Transaxle Case
      G02906362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT 
  23. REMOVE REVERSE SHIFT ARM BRACKET 

    Remove the 2 bolts and reverse shift arm bracket.

    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.
      Fig 17: Removing Reverse Shift Arm Bracket
      G02906363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing.
    • Install the reverse idler gear, thrust washer and shaft, as shown in Fig 18.
      Fig 18: Aligning Alignment Mark
      G02906364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE SHIFT FORK AND SHIFT FORK SHAFT 
    1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings.
    2. Remove the 3 set bolts.

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

    3. Remove the No. 2 shift fork shaft and shift head.
      Fig 19: Removing Shift Fork And Shift Fork Shaft
      G02906365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
    5. Remove the No. 3 shift fork shaft and reverse shift fork.
    6. Pull out the No. 1 shift fork shaft.
    7. Remove the No. 1 and No. 2 shift forks.
  25. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE 
  26. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    NOTE: At the time of reassembly, please refer to the following item.
    Before reassembly, inspect the differential side bearing preload (See REASSEMBLY  ).
  27. REMOVE MAGNET FROM TRANSAXLE CASE 
    Fig 20: Removing Balls From Reverse Shift Fork
    G02906366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY 
    1. Using a screwdriver, remove the 2 shifting key springs from the No. 3 clutch hub.
      NOTE: At the time of reassembly, please refer to the following item.
      Position the shifting key springs so that their end gaps are not aligned.
    2. Remove the 3 shifting keys from the No. 3 clutch hub.
      Fig 21: Removing 3 Shifting Keys From No. 3 Clutch Hub
      G02906367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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