Transaxle Disassembly: Notes
- Remove filler plug and drain plug with 2 gaskets. See Fig 1. Remove bolt and vehicle speed sensor. Using a small screwdriver, remove clip from vehicle speed sensor. Remove vehicle speed sensor driven gear from speed sensor. Using a small screwdriver, remove "O" ring from speed sensor. See Fig 2.
- Remove back-up light switch with gasket. Remove 3 bolts and control lever housing support bracket. See Fig 2. Remove 2 bolts and selecting bellcrank assembly. Remove control bellcrank dust cover from selecting bellcrank assembly. See Fig 1. Remove clutch release fork and release bearing. Remove release fork boot and release fork support. See Fig 2.
- Remove 9 transaxle case cover bolts. See Figure. Using a brass drift and a hammer, carefully tap projection of transaxle case cover to remove case cover from transaxle case.
- Using a dial indicator, measure 5th gear thrust clearance. See Fig 3. Standard clearance is .0039-.0224" (.100-.570 mm). Service limit is .0224" (.570 mm). Measure 5th gear radial clearance. See Fig 4. For clearance specifications, see 5TH GEAR RADIAL CLEARANCE SPECIFICATIONS table. If clearances exceed specification, replace gear, needle roller bearing or shaft.5TH GEAR RADIAL CLEARANCE SPECIFICATIONS
Application In. (mm) 5th Gear Radial Clearance KOYO Standard .0006-.0023 (.015-.058) Service Limit .0023 (.058) NSK Standard .0006-.0022 (.015-.056) Service Limit .0022 (.056) - Remove lock bolt and gasket. Remove 4 bolts, and pull out shift and select lever shaft assembly with gasket. See Fig 1. Engage gear double meshing. Using a chisel and a hammer, loosen staked part of lock nut on output shaft. Remove lock nut. See Fig 5. Disengage gear double meshing. Remove bolt from No. 3 gear shift fork. Remove No. 3 hub sleeve and 3 shifting keys with No. 3 gear shift fork. See Fig 6.
- Using 2 screwdrivers and a hammer, tap out 5th gear snap ring. Using Puller Set (09950-40011), remove No. 3 clutch hub assembly, 5th gear and synchronizer ring. Remove needle roller bearing and spacer. Using Puller Set (09950-40011), remove 5th driven gear.
- Remove 5 bolts and rear bearing retainer. See Fig 16. Using snap ring expander, remove 2 snap rings while pulling up on shafts. See Fig 7.
- Remove reverse idler gear shaft lock bolt and gasket. Using 2 screwdrivers and a hammer, remove snap ring from No. 2 shift fork shaft. See Fig 8. Using hexagon wrench, remove 3 straight screw plugs. See Fig 9. Using magnetic finger, remove 3 seats, springs and balls. Using hexagon wrench, remove lock ball assembly. See Fig 10.
- Remove 16 transaxle case bolts. See Fig 11. Using a plastic-faced hammer, carefully tap projection of transaxle case to separate case halves. Remove 2 bolts and oil receiver pipes from transaxle case. See Figure. Remove reverse idler gear, thrust washer and shaft. Remove 2 bolts and reverse shift arm bracket. See Fig 12.
- Using 2 screwdrivers and a hammer, tap out 3 snap rings from each gear shift fork shaft. Remove No. 1 gear shift head, No. 1 and No. 2 gear shift fork set bolts. See Fig 13. Pull up No. 3 gear shift fork shaft, and remove No. 2 gear shift fork shaft. Remove No. 1 gear shift head. See Fig 14. Using magnetic finger, remove 2 balls from reverse shift fork. See Fig 15. Remove No. 3 gear shift fork shaft and reverse shift fork. Pull out No. 1 gear shift fork shaft from transaxle case.
- Remove No. 1 and No. 2 gear shift forks. Remove input and output shafts from transaxle case. Remove differential case assembly. See Fig 2. Remove magnet from transaxle case. Remove bolt and transaxle case receiver from transaxle case. See Fig 2. Using a screwdriver, remove 2 shifting key springs from No. 3 clutch hub. Remove No. 3 shifting keys (3) from No. 3 clutch hub.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002