Manual Transaxle Unit: Disassembly

REMOVE MANUAL TRANSMISSION FILLER PLUG
1. Remove the manual transmission filler plug and gasket from the manual transmission case.
  
  Fig 1: Identifying Manual Transmission Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRAIN PLUG SUB-ASSEMBLY
1. Remove the drain plug sub-assembly and gasket from the manual transmission case.
REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
1. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
2. Remove the O-ring from the speedometer driven hole cover sub-assembly.
REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Separate the back-up light switch wire harness from the 2 clamps.
2. Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.
  SST 09817-16011
  
  Fig 3: Locating Back-Up Light Switch With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SELECTING BELL CRANK ASSEMBLY
1. Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.
2. Remove the control shift lever bush.
REMOVE FLOOR SHIFT CONTROL SHIFT LEVER
1. Remove the nut and spring washer.
  
  Fig 5: Locating Floor Shift Control Shift Lever Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, remove the lock pin.
3. Remove the floor shift control shift lever.
  
  Fig 6: Identifying Floor Shift Control Shift Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT LEVER DAMPER
1. Remove the nut and spring washer.
  
  Fig 7: Locating Spring Washer And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, remove the lock pin.
3. Remove the shift lever damper.
FIX MANUAL TRANSAXLE ASSEMBLY
1. Place the manual transaxle assembly on wooden blocks.
  
  Fig 9: Identifying Manual Transaxle Assembly On Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT GUIDE PIN
1. Remove the shift guide pin and washer from the transmission case.
  
  Fig 11: Locating Shift Guide Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL SHAFT COVER
1. Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.
  
  Fig 12: Locating Control Shaft Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL SHAFT COVER OIL SEAL
1. Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.
  
  Fig 13: Removing Control Shaft Cover Oil Seal Of Control Shaft Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Remove the shift and select lever shaft assembly from the transmission case.
  
  Fig 14: Identifying Select Lever Shaft Assembly And Shift
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
1. Remove the 9 bolts.
  
  Fig 15: Identifying Manual Transmission Case Cover Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap the projections of the manual transmission case cover sub-assembly to remove the manual transmission case cover from the manual transmission case.
  NOTE: Do not damage the manual transmission case.
  
  Fig 16: Locating Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
1. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
  
  Fig 17: Removing Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage 2 gears simultaneously to lock the transmission.
3. Remove the manual transmission output shaft rear set nut.
4. Disengage the 2 gears.
REMOVE NO. 3 GEAR SHIFT FORK
1. Remove the gear shift fork lock bolt from the No. 3 gear shift fork.
  
  Fig 19: Locating Gear Shift Fork Lock Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 3 transmission hub sleeve with the No. 3 gear shift fork from the No. 3 transmission clutch hub.
  
  Fig 20: Locating No. 3 Gear Shift Fork Of No. 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 5th gear thrust clearance.
  Standard clearance:
  
  0.10 to 0.55 mm (0.0039 to 0.0217 in.)
  
  Maximum clearance:
  
  0.55 mm (0.0217 in.)
  
  If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.
  
  Fig 21: Measuring 5Th Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 5th gear radial clearance.
  Standard clearance:
  
  KOYO made:
  
  0.015 to 0.058 mm (0.0006 to 0.0023 in.)
  
  NSK made:
  
  0.015 to 0.056 mm (0.0006 to 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 5th gear, 5th gear needle roller bearing or input shaft.
  
  Fig 22: Measuring 5Th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 TRANSMISSION CLUTCH HUB
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
  
  Fig 23: Removing No. 3 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the No. 3 transmission clutch hub, 5th gear and No. 3 synchronizer ring from the input shaft.
  SST 09950-40011 (09951-04020,09952-04010, 09953-04030, 09954-04010, 09955-04011), 09950-60010 (09951-00180)
  
  Fig 24: Removing No. 3 Transmission Clutch Hub With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the No. 3 transmission clutch hub.
  
  Fig 25: Identifying Synchromesh Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH GEAR NEEDLE ROLLER BEARING
1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
  
  Fig 26: Identifying 5th Gear Needle Roller Bearing And 5th Gear Bearing Spacer Of Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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, 09955-03021), 09950-60010 (09951-00180)
  
  Fig 27: Removing 5th Driven Gear Of Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RETAINER REAR
1. Remove the 5 bolts and bearing retainer rear from the manual transmission case.
  
  Fig 28: Locating Bearing Retainer Rear Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 29: Removing Output Shaft Rear Bearing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
  
  Fig 30: Removing Input Shaft Rear Bearing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the reverse idler gear shaft bolt and reverse idler gear shaft gasket from the manual transmission case.
  
  Fig 31: Locating Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 gear shift fork shaft.
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
  
  Fig 32: Identifying No. 2 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT DETENT BALL
1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
  
  Fig 33: Identifying Shift Detent Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the 2 No. 1 shift detent ball spring seats, 2 shift detent ball springs and 2 shift detent balls from the manual transmission case.
  
  Fig 34: Identifying 2 No. 1 Shift Detent Ball Spring Seats
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.
  
  Fig 35: Identifying Shift Detent Ball Plug Of Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.
  
  Fig 36: Identifying Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 LOCK BALL ASSEMBLY
1. Using a hexagon wrench, remove the No. 2 lock ball assembly from the manual transmission case.
  
  Fig 37: Removing No. 2 Lock Ball Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE
1. Remove the 3 bolts from the front transaxle case.
  
  Fig 38: Locating Front Transaxle Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the manual transmission case.
  
  Fig 39: Locating Manual Transmission Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, carefully tap the projections of the manual transmission case to remove the transmission case from the transaxle case.
  NOTE: Do not damage the manual transmission case and transaxle case.
  
  Fig 40: Identifying Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
1. Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the front transaxle case.
  
  Fig 41: Identifying Idler Gear Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case.
  
  Fig 42: Locating Shift Arm Bracket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 GEAR SHIFT FORK SHAFT
1. Remove the 2 bolts from the No. 2 gear shift fork and No. 1 gear shift head.
  
  Fig 43: Locating No. 2 Gear Shift Fork Shaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the front transaxle case.
  
  Fig 44: Identifying No. 2 Gear Shift Fork Shaft And No. 1 Gear Shift Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 GEAR SHIFT FORK SHAFT
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
  
  Fig 45: Removing No. 1 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift fork set bolt and No. 1 gear shift fork shaft from No. 1 gear shift fork.
  
  Fig 46: Identifying No. 1 Gear Shift Fork Shaft And No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 1 gear shift fork.
  
  Fig 47: Removing No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 GEAR SHIFT FORK SHAFT
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.
  HINT:
  
  Use a piece of cloth to keep the snap ring from flying off.
  
  Fig 48: Removing No. 3 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 3 shift fork shaft together with the reverse shift fork and gear shift fork No. 2 from the manual transaxle case.
  
  Fig 49: Identifying No. 3 Shift Fork Shaft And Gear Shift Fork No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.
  
  Fig 50: Identifying Reverse Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using 2 screwdrivers and a hammer, tap the snap ring out of the No. 3 shift fork shaft.
  HINT:
  
  Use a shop rag or piece of cloth to keep the snap ring from flying off.
  
  Fig 51: Tapping Snap Ring Out Of No.3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
REMOVE INPUT SHAFT ASSEMBLY
1. Remove the input shaft assembly and output shaft assembly from the front transaxle case.
  
  Fig 52: Identifying Input Shaft Assembly And Output Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL CASE ASSEMBLY
1. Remove the differential case assembly from the front transaxle case.
  
  Fig 53: Identifying Differential Case Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSAXLE CASE RECEIVER
1. Remove the bolt and manual transaxle case receiver from the front transaxle case.
  
  Fig 54: Locating Manual Transaxle Case Receiver Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE RESTRICT PIN ASSEMBLY
1. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
  
  Fig 55: Removing Reverse Restrict Pin Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch ( 5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.
  
  Fig 56: Identifying Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 No. 1 oil receiver pipe.
  
  Fig 57: Removing No. 1 Oil Receiver Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 No. 2 oil receiver pipe.
  
  Fig 58: Locating No. 2 Oil Receiver Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING LOCK PLATE
1. Remove the bolt and bearing lock plate from the front transaxle case.
  
  Fig 59: Locating Bearing Lock Plate Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the front transaxle case.
  
  Fig 60: Locating Transmission Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING
1. Using SST, remove the input shaft front bearing from the front transaxle case.
  SST 09612-65014 (09612-01050, 09612-01060)
  
  Fig 61: Removing Input Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
  
  Fig 62: Removing Front Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the output shaft front bearing from the front transaxle case.
  SST 09308-00010
  
  NOTE: Do not apply excessive force to the front transaxle case when installing SST.
  
  Fig 63: Removing Output Shaft Front Bearing With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT COVER
1. Remove the output shaft cover from the front transaxle case.
  
  Fig 64: Identifying Output Shaft Cover And Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing (outer race) and plate washer from the front transaxle case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 65: Removing Front Differential Case Front Tapered Roller Bearing And Plate Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.
  SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)
  
  NOTE: Do not damage the bearing.
  
  Fig 66: Removing Front Differential Case Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, remove the transaxle case oil seal from the front transaxle case.
  SST 09950-60010 (09951 -00530), 09950-70010 (09951-07150)
  
  Fig 67: Removing Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 68: Identifying Front Differential Case Rear Tapered Roller Bearing And Plate Washer
  Courtesy 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 09950-40011 (09951 -04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
  
  Fig 69: Identifying Front Differential Case Rear Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case.
  SST 09950-60010 (09951 -00530), 09950-70010 (09951-07150)
  
  Fig 70: Removing Transmission Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT OIL SEAL
1. Using a screwdriver and hammer, remove the shift and select lever shaft oil seal.
  
  Fig 71: Removing Shift And Select Lever Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
1. Using SST and a hammer, remove the shift and select lever shaft slide ball bearing.
  SST 09950-60010 (09951 -00220), 09950-70010 (09951-07200)
  
  Fig 72: Removing Shift And Select Lever Shaft Slide Ball Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002