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Manual Transaxle Assembly: Disassembly

  1. REMOVE CLUTCH RELEASE FORK AND BEARING 
    NOTE: 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.
    NOTE: At the time of reassembly, please refer to the following item. Apply FIPG to the transmission case cover, as shown in the illustration.
    Fig 1: Removing Transmission Case Cover
    G02575260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    FIPG: 

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

  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 Using Dial Indicator
    G02575261Courtesy 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.) 

    Fig 3: Measuring Radial Clearance Using Dial Indicator
    G02575262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.

  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 And Gasket
    G02575263Courtesy 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: Disengaging Double Meshing Of Gear
    G02575264Courtesy 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.
      NOTE: At the time of reassembly, please refer to the following item. Select a snap ring that allows the minimum axial play.
      SNAP RING MARK - THICKNESS SPECIFICATION

      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 09950-40011

      Fig 6: Removing Clutch Hub Assembly, 5th Gear And Synchronizer Ring Using SST
      G02575265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: 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 the illustration. 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
        G02575266Courtesy 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 09612-22011

      NOTE: Align the synchronizer ring slots with the shifting keys.
    3. Remove the needle roller bearings and spacer.
    Fig 8: Driving In Hub Sleeve Assembly With Shift Fork Using SST And Hammer
    G02575267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE 5th DRIVEN GEAR 

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

    SST 09950-40011

    Fig 9: Removing 5th Driven Gear Using SST And Socket Wrench
    G02575268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: 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 Using SST
    G02575269Courtesy 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.

    NOTE: If it is difficult to remove and install the snap rings, pull up the shafts.
    Fig 11: Removing Snap Rings Using Snap Ring Expander
    G02575270Courtesy 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 And Gasket
    G02575271Courtesy 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 Plug, Seat, Spring And Ball
    G02575272Courtesy 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
    G02575273Courtesy 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
      G02575274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: At the time of reassembly, please refer to the following item.

      Apply FIPG to the transaxle case, as shown in the illustration.

      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
      G02575275Courtesy 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: Setting Pin On Top Of Reverse Shift Arm Into A Groove On Reverse Idler Gear
      G02575276Courtesy 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.
      Fig 18: Installing Reverse Idler Gear, Thrust Washer And Shaft
      G02575277Courtesy 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 Shaft And Shift Head
      G02575278Courtesy 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 
    Fig 20: Removing Balls From Reverse Shift Fork Using Magnetic Finger
    G02575279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 
  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: Identifying Disassemble Clutch Hub Assembly
    G02575280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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