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Manual Transaxle Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Remove the bolt and speedometer driven hole cover sub-assembly.
    2. Remove the O-ring from the speedometer driven hole cover sub-assembly.
  2. 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 1: Removing Clutch Release Fork Sub-Assembly
      G04464285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE CLUTCH RELEASE BEARING ASSEMBLY 
    1. Remove the clutch release bearing hub clip and clutch release bearing assembly from the clutch release fork sub-assembly.
      Fig 2: Removing Clutch Release Bearing Assembly
      G04464286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE RELEASE FORK SUPPORT 
    1. Remove the release fork support from the transaxle case.
      Fig 3: Removing Release Fork Support
      G04464287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CLUTCH RELEASE FORK BOOT 
    1. Remove the clutch release fork boot from the transaxle case.
      Fig 4: Removing Clutch Release Fork Boot
      G04464288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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 5: Removing Floor Shift Control Lever Housing Support Bracket
      G04464289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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 6: Removing Selecting Bell Crank Assembly
      G04464290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. FIX MANUAL TRANSAXLE ASSEMBLY 
    1. Place the manual transaxle assembly on wooden blocks.
      Fig 7: Placing Manual Transaxle Assembly On Wooden Blocks
      G04464291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the manual transmission filler plug and gasket from the manual transmission case cover.
      Fig 8: Removing Manual Transmission Filler Plug
      G04464292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY 
    1. Remove the drain (MTM) plug sub-assembly and gasket from the manual transmission case.
      Fig 9: Removing Drain (MTM) Plug Sub-Assembly
      G04464293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY 
    1. Remove the 9 bolts.
      Fig 10: Removing Manual Transmission Case Cover Sub-Assembly Bolts
      G04464294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the manual transmission case cover sub-assembly.
      NOTE: Do not damage the manual transmission case cover sub-assembly.
  12. INSPECT 6TH GEAR THRUST CLEARANCE (See INSPECTION  )
  13. INSPECT 5TH GEAR THRUST CLEARANCE (See INSPECTION  )
  14. INSPECT 6TH GEAR RADIAL CLEARANCE (See INSPECTION  )
  15. INSPECT 5TH GEAR RADIAL CLEARANCE (See INSPECTION  )
    Fig 11: Removing Manual Transmission Case Cover Sub-Assembly
    G04464295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE COUNTER GEAR 6TH 
    1. Using 2 screwdrivers and a hammer, remove the output shaft RR snap ring from the output shaft.

      HINT:

      Use a shop rag to keep the snap ring from flying.

      Fig 12: Removing Output Shaft RR Snap Ring From Output Shaft
      G04464296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the output shaft RR bearing with the counter gear 6th from the output shaft.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011), 09950-60010 (09951-00190) 

      Fig 13: Removing Output Shaft RR Bearing With Counter Gear 6th From Output Shaft
      G04464297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE OUTPUT GEAR SPACER 
    1. Remove the output gear spacer from the output shaft.
      Fig 14: Removing Output Gear Spacer
      G04464298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE 6TH GEAR SUB-ASSEMBLY 
    1. Using 2 screwdrivers and a hammer, remove the input shaft snap ring from the input shaft.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 15: Removing Input Shaft Snap Ring From Input Shaft
      G04464299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the input shaft radial ball bearing RR with the 6th gear sub-assembly from the input shaft.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011) 

      Fig 16: Removing 6th Gear Sub-Assembly
      G04464300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE 6TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 6th gear needle roller bearing from the input shaft.
      Fig 17: Removing 6th Gear Needle Roller Bearing
      G04464301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE SYNCHRONIZER RING NO. 3 (for 6th Gear) 
    1. Remove the synchronizer ring No. 3 from the input shaft.
      Fig 18: Removing Synchronizer Ring No.3 (For 6th Gear)
      G04464302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSMISSION CLUTCH HUB NO. 3 
    1. Remove the 6th gear spacer.
    2. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 19: Removing Snap Ring
      G04464303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the shift fork lock bolt from the shift fork No. 3.
      Fig 20: Removing Shift Fork Lock Bolt From Shift Fork No. 3
      G04464304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, remove the transmission clutch hub No. 3 with the gear shift fork No. 3 from the input shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09957-04010), 09950-50013 (09954-05040) 

      Fig 21: Removing Transmission Clutch Hub No. 3 With Gear Shift Fork No. 3 From Input Shaft
      G04464305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE SYNCHRONIZER RING NO. 3 (for 5th Gear) 
    1. Remove the synchronizer ring No. 3 from the 5th gear.
      Fig 22: Removing Synchronizer Ring No.3 (For 5th Gear)
      G04464306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE 5TH GEAR 
    1. Remove the 5th gear from the input shaft.
      Fig 23: Removing 5th Gear
      G04464307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE 5TH GEAR NEEDLE ROLLER BEARING 
    1. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 24: Removing Snap Ring
      G04464308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5th gear needle roller bearing and two 5th gear bearing spacers from the input shaft.
      Fig 25: Removing 5th Gear Needle Roller Bearing And 5th Gear Bearing Spacers From Input Shaft
      G04464309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. 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 26: Removing 5th Driven Gear
      G04464310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE SHIFT FORK SHAFT SNAP RING 
    1. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the shift fork shaft No. 2.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 27: Removing Shift Fork Shaft Snap Ring
      G04464311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE BEARING RETAINER REAR (MTM) 
    1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.
      Fig 28: Removing Bearing Retainer Rear (MTM)
      G04464312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE LOCK BALL ASSEMBLY NO. 1 
    1. Remove the lock ball assembly No. 1 from the manual transmission case.
      Fig 29: Removing Lock Ball Assembly No.1
      G04464313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Remove the 4 bolts and shift & select lever shaft assembly and gasket from the manual transmission case.
      Fig 30: Removing Shift And Select Lever Shaft Assembly
      G04464314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE BACK UP LIGHT SWITCH ASSEMBLY 
    1. Using SST, remove the back up light switch assembly and gasket from the manual transmission case.

      SST 09817-16011 

      Fig 31: Removing Back Up Light Switch Assembly
      G04464315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE SHIFT DETENT BALL 
    1. Using a socket hexagon wrench (6 mm), remove the 2 shift detent ball plugs from the manual transmission case.
      Fig 32: Removing Shift Detent Ball Plugs From Manual Transmission Case
      G04464316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a magnetic finger, remove the 2 shift detent ball compression spring seats, 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.
      Fig 33: Removing Shift Detent Ball Compression Spring Seats, Compression Springs And Balls
      G04464317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. 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 34: Removing Output Shaft Rear Bearing Hole Snap Ring
      G04464318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring.
      Fig 35: Removing Input Shaft Rear Bearing Hole Snap Ring
      G04464319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE MANUAL TRANSMISSION CASE PLUG 
    1. Using a socket hexagon wrench (6 mm), remove the manual transmission case plug from the manual transmission case.
      Fig 36: Removing Manual Transmission Case Plug
      G04464320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE REVERSE RESTRICT PIN PLUG 
    1. Using a socket hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.
      Fig 37: Removing Reverse Restrict Pin Plug
      G04464321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
      Fig 38: Removing Reverse Idler Gear Shaft Bolt
      G04464322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE MANUAL TRANSMISSION CASE 
    1. Remove the 3 bolts from the transaxle case side.
      Fig 39: Removing Bolts From Transaxle Case Side
      G04464323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 13 bolts from manual transmission case side.
      Fig 40: Removing Bolts From Manual Transmission Case Side
      G04464324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, remove the manual transmission case from the transaxle case.
      Fig 41: Removing Manual Transmission Case From Transaxle Case
      G04464325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE OIL RECEIVER PIPE NO. 1 (MTM) 
    1. Remove the bolt and oil receiver pipe No. 1 from the manual transmission case.
      NOTE: Be careful not to damage the oil receiver pipe No. 1.
      Fig 42: Removing Oil Receiver Pipe No.1 (MTM)
      G04464326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE OIL RECEIVER PIPE NO. 2 (MTM) 
    1. Remove the bolt and oil receiver pipe No. 2 from the manual transmission case.
      NOTE: Be careful not to damage the oil receiver pipe No. 2.
      Fig 43: Removing Oil Receiver Pipe No.2 (MTM)
      G04464327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE SHIFT DETENT BALL 
    1. Using a socket hexagon wrench (6 mm), remove the shift detent ball plug from the transaxle case.
      Fig 44: Removing Shift Detent Ball Plug From Transaxle Case
      G04464328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a magnetic finger, remove the shift detent ball spring seat, shift detent ball compression spring and shift detent ball from the transaxle case.
      Fig 45: Removing Shift Detent Ball Spring Seat, Compression Spring And Ball From Transaxle Case
      G04464329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE GEAR SHIFT FORK SHAFT SUBASSEMBLY NO. 1 
    1. Using 2 screwdrivers and a hammer, remove the shaft snap ring.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 46: Removing Gear Shift Fork Shaft Snap Ring
      G04464330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assembly No. 1.
      Fig 47: Removing Gear Shift Fork Shaft Subassembly No.1
      G04464331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE GEAR SHIFT FORK SHAFT NO. 3 
    1. Remove the shift fork shaft No. 3 from the transaxle case.
      Fig 48: Removing Shift Fork Shaft No. 3 From Transaxle Case
      G04464332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, remove the shaft snap ring from the shift fork shaft No. 3.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 49: Removing Shaft Snap Ring From Shift Fork Shaft No. 3
      G04464333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE GEAR SHIFT FORK SHAFT NO. 2 
    1. Remove the 2 gear shift fork lock bolts from the gear shift fork No. 2 and gear shift head No. 1.
      Fig 50: Removing Gear Shift Fork Lock Bolts From Gear Shift Fork No. 2 And Gear Shift Head No. 1
      G04464334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gear shift fork shaft No. 2, gear shift fork No. 2, gear shift fork No. 1, gear shift head No. 1 and reverse shift fork.
      Fig 51: Removing Gear Shift Fork Shaft No.2
      G04464335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Remove the reverse idler gear shaft, thrust washer and reverse idler gear sub-assembly from the transaxle case.
      Fig 52: Removing Reverse Idler Gear Sub-Assembly
      G04464336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE INPUT SHAFT ASSEMBLY 
    1. Remove the input shaft assembly with the output shaft assembly from the transaxle case.
      Fig 53: Removing Input Shaft Assembly
      G04464337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Remove the 2 bolts and reverse shift arm bracket assembly from the transaxle case.
      Fig 54: Removing Reverse Shift Arm Bracket Assembly
      G04464338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    1. Remove the differential case assembly from the transaxle case.
      Fig 55: Removing Differential Case Assembly
      G04464339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE MANUAL TRANSAXLE CASE RECEIVER 
    1. Remove the bolt and manual transaxle case receiver from the transaxle case.
      Fig 56: Removing Manual Transaxle Case Receiver
      G04464340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE BEARING LOCK PLATE 
    1. Remove the bolt and bearing lock plate from the transaxle case.
      Fig 57: Removing Bearing Lock Plate
      G04464341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE TRANSMISSION MAGNET 
    1. Remove the transmission magnet from the transaxle case.
      Fig 58: Removing Transmission Magnet
      G04464342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using SST, remove the input shaft front bearing (outer race) from the transaxle case.

      SST 09612-24014 (09613-22011) 

      Fig 59: Removing Output Shaft Front Bearing
      G04464343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST, remove the front transaxle case oil seal from the transaxle case.

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

      Fig 60: Removing Front Transaxle Case Oil Seal
      G04464344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using SST, remove the output shaft front bearing from the transaxle case.

      SST 09308-00010 

      NOTE: Do not apply excessive force to the transaxle case when installing it.
      Fig 61: Removing Output Shaft Front Bearing
      G04464345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.

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

      Fig 62: Removing FR Differential Case Rear Tapered Roller Bearing (Outer Race)
      G04464346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.

      SST 09612-65014 (09612-01040, 09612-01050), 09950-40011 (09951-00390, 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 

      Fig 63: Removing FR Differential Case Rear Tapered Roller Bearing (Inner Race)
      G04464347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. 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 (09951-00530), 09950-70010 (09951-07150) 

      Fig 64: Removing Transmission Case Oil Seal
      G04464348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case front tapered roller bearing (outer race) and front differential case front plate washer from the transaxle case.

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

      Fig 65: Removing FR Differential Case Front Tapered Roller Bearing (Outer Race)
      G04464349Courtesy 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 (09951-00390) 

      Fig 66: Removing FR Differential Case Front Tapered Roller Bearing (Inner Race)
      G04464350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, remove the transaxle case oil seal from the transaxle case.

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

      Fig 67: Removing Transaxle Case Oil Seal
      G04464351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE OUTPUT SHAFT (MTM) COVER 
    1. Remove the output (MTM) shaft cover from the transaxle case.
      Fig 68: Removing Output Shaft (MTM) Cover
      G04464352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE TRANSMISSION HUB SLEEVE NO. 3 
    1. Remove the transmission hub sleeve No. 3, 3 synchromesh shifting key No. 3 and 2 synchromesh shifting key spring No. 3.
      NOTE: Use a shop rag to keep the synchromesh shifting keys and springs from flying.
      Fig 69: Removing Transmission Hub Sleeve No.3
      G04464353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSPECT TRANSMISSION HUB SLEEVE NO. 3 (See INSPECTION  )
  61. INSPECT SYNCHRONIZER RING NO. 3 (for 6th Gear) (See INSPECTION  )
  62. INSPECT 6TH GEAR SUB-ASSEMBLY (See INSPECTION  )
  63. INSPECT SYNCHRONIZER RING NO. 3 (for 5th Gear) (See INSPECTION  )
  64. INSPECT 5TH GEAR (See INSPECTION  )
  65. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY (See INSPECTION  )
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