FixVault
Home › Scion › 2009 › xB Standard › Repair and Diagnosis › Transmission › E351 Manual Transaxle › Manual Transaxle Unit › Disassembly

Manual Transaxle Unit: Disassembly

  1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Remove the bolt and hole cover.
    2. Remove the O-ring from the hole cover.
  2. REMOVE SELECTING BELLCRANK ASSEMBLY 
    1. Remove the 2 bolts and selecting bellcrank from the transaxle case.
    2. Remove the shift and select lever bush from the selecting bellcrank.
      Fig 1: Removing Bolts And Selecting Bellcrank Assembly From Transmission Case
      G05388794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE CONTROL SHIFT LEVER 
    1. Remove the nut and spring washer.
      Fig 2: Removing Nut And Spring Washer
      G05388795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and hammer, tap out the shift outer lever lock pin.
    3. Remove the control shift lever.
      Fig 3: Removing Shift Outer Lever Lock Pin
      G05388796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE CONTROL SHAFT COVER 
    1. Remove the 4 bolts, control shift cover and gasket from the transaxle case.
      Fig 4: Removing Bolts, Control Shift Cover And Gasket From Transmission Case
      G05388797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. FIX MANUAL TRANSAXLE ASSEMBLY 
    1. Place the transaxle on wooden blocks.
      Fig 5: Placing Transaxle On Wooden Blocks
      G05388798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 1 LOCK BALL ASSEMBLY 
    1. Remove the lock ball from the transaxle case.
      Fig 6: Identifying Lock Ball To Transaxle Case
      G05388799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE SHIFT GATE PIN 
    1. Remove the shift gate pin and gasket.
      Fig 7: Identifying Shift Gate Pin And Gasket
      G05388800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Remove the shift and select lever shaft from the transaxle case.
      Fig 8: Removing Shift And Select Lever Shaft Assembly
      G04977230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Remove the back-up light switch and gasket from the transaxle case.
      Fig 9: Removing Back-Up Light Switch And Gasket From Transmission Case
      G05388802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the filler plug and gasket from the transaxle case.
      Fig 10: Removing Filler Plug And Gasket From Transmission Case
      G05388803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE DRAIN PLUG SUB-ASSEMBLY 
    1. Remove the drain plug and gasket from the transaxle case.
      Fig 11: Removing Drain Plug And Gasket From Transmission Case
      G05388804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE MANUAL TRANSAXLE CASE COVER SUB-ASSEMBLY 
    1. Remove the 10 bolts and transaxle case cover from the transaxle case.
      Fig 12: Identifying Transaxle Case Cover To Transaxle Case
      G05388805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE REAR MANUAL TRANSAXLE OUTPUT SHAFT SET NUT 
    1. Engage the 2 gears simultaneously to lock the transaxle.
      Fig 13: Engaging Gears Simultaneously To Lock Transmission
      G05388806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, unstake the rear set nut.

      SST 09930-00010 

      Fig 14: Unstaking Rear Set Nut
      G05388807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the shaft rear set nut from the output shaft.

      SST 09229-55010 

    4. Disengage the 2 gears.
      Fig 15: Removing Shaft Rear Set Nut From Output Shaft
      G05388808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT 5TH GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the thrust clearance.

      Standard clearance: 0.10 to 0.65 mm (0.0039 to 0.0256 in.) 

      If the clearance is out of the specification, replace the No. 3 transaxle clutch hub, 5th gear or input shaft rear radial ball bearing.

      Fig 16: Measuring Thrust Clearance
      G05388809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 5TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the radial clearance.

      Standard clearance: 0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

      If the clearance is out of the specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.

      Fig 17: Measuring Radial Clearance
      G05388810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 3 TRANSAXLE CLUTCH HUB 
    1. Using 2 screwdrivers and a hammer, tap out the No. 3 transaxle clutch hub shaft snap ring from the input shaft.

      HINT:

      Cover with a piece of cloth to keep the snap ring from flying off.

      Fig 18: Removing No 3 Transmission Clutch Hub Shaft Snap Ring From Input Shaft
      G05388811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the shift fork set bolt from the No. 3 gear shift fork.
      Fig 19: Removing Shift Fork Set Bolt From No. 3 Gear Shift Fork
      G05388812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the No. 3 transaxle clutch hub, No. 3 transaxle hub sleeve 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 20: Removing No 3 Transmission Clutch Hub, No 3 Transmission Hub Sleeve
      G04977240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE 5TH GEAR 
    1. Remove the 5th gear from the input shaft.
      Fig 21: Removing 5Th Gear From Input Shaft
      G05388814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE 5TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the needle roller bearing from the input shaft.
      Fig 22: Removing Needle Roller Bearing From Input Shaft
      G05388815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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), 09950-60010 (09951-00180, 09955-03011), 09950-50013 

      Fig 23: Removing 5Th Driven Gear From Output Shaft
      G05388816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE REAR BEARING RETAINER 
    1. Using a T45 "TORX" socket, remove the 7 "TORX" screws and bearing retainer from the transaxle case.
      Fig 24: Removing "Torx" Screws And Bearing Retainer Rear (MTM) From Manual Transmission Case
      G04977244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE OUTPUT SHAFT REAR BEARING SHIM 
    1. Remove the rear bearing shim from the output shaft.
      Fig 25: Removing Rear Bearing Shim From Output Shaft
      G05388818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    1. Using a snap ring expander, remove the shaft snap ring from the input shaft.
      Fig 26: Removing Shaft Snap Ring From Input Shaft
      G05388819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE SHIFT FORK SHAFT SNAP RING 
    1. Using 2 screwdrivers and a hammer, tap out the shaft snap ring from the No. 1 gear shift fork shaft.

      HINT:

      Cover with a piece of cloth to keep the snap ring from flying off.

      Fig 27: Removing Shaft Snap Ring From No 1 Gear Shift Fork Shaft
      G05388820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, tap out the shaft snap ring from the No. 2 gear shift fork shaft.

      HINT:

      Cover with a piece of cloth to keep the snap ring from flying off.

      Fig 28: Removing Shaft Snap Ring From No. 2 Gear Shift Fork Shaft
      G05388821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    1. Remove the reverse idler gear shaft bolt and gasket.
  25. REMOVE CLUTCH TUBE BRACKET 
    1. Remove the bolt and clutch tube bracket.
      Fig 29: Removing Bolt And Clutch Tube Bracket
      G05388822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE MANUAL TRANSMISSION CASE 
    1. Remove the 3 bolts from the transaxle case side.
      Fig 30: Removing Bolts From Transaxle Case Side
      G05388823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 14 bolts from the transaxle case side.
    3. Remove the transaxle case by tapping it using a plastic-faced hammer.
      Fig 31: Removing Bolts From Transmission Case Side
      G05388824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 2 OIL RECEIVER PIPE 
    1. Remove the bolt and oil receiver pipe from the transaxle case.
      NOTE: Do not damage the pipe.
      Fig 32: Removing No. 2 Oil Receiver Pipe
      G04977255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 1 OIL RECEIVER PIPE 
    1. Remove the bolt and oil receiver pipe from the transaxle case.
      NOTE: Do not damage the pipe.
      Fig 33: Removing No. 1 Oil Receiver Pipe
      G04977256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE REVERSE RESTRICT PIN ASSEMBLY 
    1. Using a 6 mm hexagon wrench, remove the restrict pin plug from the transaxle case.
      Fig 34: Removing Reverse Restrict Pin Plug From Transmission Case
      G05388827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 5 mm pin punch and hammer, tap out the slotted pin.
      Fig 35: Removing Slotted Pin
      G05388828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, transmission oil baffle and reverse restrict pin.
      Fig 36: Removing Bolt, Transmission Oil Baffle And Reverse Restrict Pin Assembly
      G04977254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TRANSAXLE MAGNET 
    1. Remove the magnet from the transaxle case.
      Fig 37: Removing Transmission Magnet From Transaxle Case
      G05388830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY 
    1. Remove the reverse idler gear with the reverse idler gear shaft from the transaxle case.
      Fig 38: Removing Reverse Idler Gear With Reverse Idler Gear Shaft
      G05388831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the reverse idler gear and reverse idler thrust washer from the gear shaft.
      Fig 39: Removing Reverse Idler Gear And Reverse Idler Thrust Washer
      G05388832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY 
    1. Remove the 2 bolts and arm bracket from the transaxle case.
      Fig 40: Removing Bolts And Reverse Shift Arm Bracket From Transaxle Case
      G05388833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 1 GEAR SHIFT FORK SHAFT 
    1. Remove the shift fork set bolt from the No. 1 gear shift fork.
      Fig 41: Removing Shift Fork Set Bolt From No. 1 Gear Shift Fork
      G05388834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shift is pulled up.
      Fig 42: Pulling Out No 1 Gear Shift Fork Shaft
      G05388835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring from the No. 1 gear shift fork shaft.

      HINT:

      Cover with a piece of cloth to keep the snap ring from flying off.

      Fig 43: Tapping Shift Fork Shaft Snap Ring And No. 1 Gear Shift Fork Shaft
      G05388836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE REVERSE SHIFT FORK ROLLER 
    1. Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
      Fig 44: Removing Reverse Shift Fork Roller From Reverse Shift Fork
      G05388837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. 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 45: Removing Shift Fork Set Bolt And Shift Head Set Bolt
      G05388838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 gear shift fork shaft head and No. 1 gear shift head from the transaxle case.
      Fig 46: Removing No. 2 Gear Shift Fork Shaft Head
      G05388839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO. 1 GEAR SHIFT FORK 
    1. Remove the No. 1 gear shift fork from the output shaft.
      Fig 47: Removing No 1 Gear Shift Fork
      G05388840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 3 GEAR SHIFT FORK SHAFT 
    1. Remove the No. 3 gear shift fork shaft from the transaxle case.
      Fig 48: Removing No. 3 Gear Shift Fork Shaft From Transaxle Case
      G05388841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, tap out the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.

      HINT:

      Cover with a piece of cloth to keep the snap ring from flying off.

    3. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
      Fig 49: Removing Shift Fork Shaft Snap Rings
      G05388842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 2 GEAR SHIFT FORK 
    1. Remove the No. 2 gear shift fork from the input shaft.
      Fig 50: Removing No. 2 Gear Shift Fork From Input Shaft
      G05388843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE INPUT SHAFT ASSEMBLY 
    1. Tilt the output shaft, then remove the input shaft from the transaxle case.
      Fig 51: Removing Input Shaft And Transaxle Case
      G05388844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE OUTPUT SHAFT ASSEMBLY 
    1. Slightly lift up on the differential case with the output shaft at an angle.
    2. Remove the output shaft from the transaxle case.
      Fig 52: Identifying Differential Case And Output Shaft
      G05388845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    1. Remove the differential case from the transaxle case.
      Fig 53: Removing Differential Case From Transaxle Case
      G05388846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE MANUAL TRANSAXLE CASE RECEIVER 
    1. Remove the 3 bolts and receiver from the transaxle case.
      Fig 54: Removing Bolts And Transaxle Case Receiver From Transaxle Case
      G05388847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE INPUT SHAFT FRONT BEARING 
    1. Using SST, remove the input shaft front bearing (outer race) from the transaxle case.

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

      Fig 55: Removing Input Shaft Front Bearing
      G05388848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST, remove the oil seal from the transaxle case.

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

      Fig 56: Removing Oil Seal From Transaxle Case
      G05388849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using SST, remove the front bearing (outer race) from the transaxle case.

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

      Fig 57: Removing Front Bearing
      G05388850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE OUTPUT SHAFT COVER 
    1. Remove the output shaft cover from the transaxle case.
      Fig 58: Removing Output Shaft Cover From Transaxle Case
      G05388851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE OUTPUT SHAFT REAR BEARING 
    1. Using SST, tap out the rear bearing from the transaxle case (outer race).

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

      Fig 59: Tapping Out Rear Bearing From Transmission Case
      G05388852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE TRANSMISSION CASE OIL SEAL 
    1. Using SST, tap out the oil seal from the transaxle case.

      SST 09308-00010 

      Fig 60: Tapping Out Oil Seal From Transmission Case
      G05388853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE TRANSAXLE CASE OIL SEAL 
    1. Using a screwdriver, pry out the cover oil seal.

      HINT:

      Tape the screwdriver tip before use to avoid damage.

      Fig 61: Prying Out Cover Oil Seal
      G05388854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using a brass bar and hammer, tap out the front tapered roller bearing (outer race) from the transaxle case.
      Fig 62: Tapping Out Front Tapered Roller Bearing
      G05388855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the case front tapered roller bearing from the front differential case.

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

      Fig 63: Removing Case Front Tapered Roller Bearing
      G05388856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a hammer, tap out the rear tapered roller bearing (outer race) and rear shim from the transaxle case.

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

      Fig 64: Tapping Out Rear Tapered Roller Bearing
      G05388857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the rear tapered roller bearing (inner race) from the front differential case.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490) 

      Fig 65: Removing Rear Tapered Roller Bearing
      G05388858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE NO. 3 TRANSAXLE HUB SLEEVE 
    1. Remove the No. 3 transaxle hub sleeve from the No. 3 transaxle clutch hub.
      Fig 66: Removing No. 3 Transmission Hub Sleeve
      G05388859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING 
    1. Remove the 2 No. 3 synchromesh shifting key springs and synchronizer ring set from the No. 3 transaxle clutch hub while pushing on the No. 3 synchromesh shifting key spring.
      Fig 67: Removing No 3 Synchromesh Shifting Key Springs And Synchronizer Ring Set
      G05388860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. 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.
      Fig 68: Removing Synchronizer Pulling Ring Snap Ring
      G05388861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
About FixVault