Manual Transaxle Unit: Disassembly: Disassembly
- REMOVE MANUAL TRANSMISSION FILLER PLUG
- Remove the manual transmission filler plug and gasket from the manual transmission case.
- REMOVE DRAIN PLUG SUB-ASSEMBLY
- Remove the drain plug sub-assembly and gasket from the manual transmission case.
- REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
- Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
- Remove the O-ring from the speedometer driven hole cover sub-assembly.
- REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
- Separate the back-up light switch wire harness from the 2 clamps.
- Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.
- SST: 09817-16011
- REMOVE SELECTING BELL CRANK ASSEMBLY
- Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.
- Remove the control shift lever bush.
- REMOVE FLOOR SHIFT CONTROL SHIFT LEVER
- Remove the nut and spring washer.
- Using a brass bar and a hammer, remove the lock pin.
- Remove the floor shift control shift lever.
- REMOVE SHIFT LEVER DAMPER
- Remove the nut and spring washer.
- Using a brass bar and a hammer, remove the lock pin.
- Remove the shift lever damper.
- FIX MANUAL TRANSAXLE ASSEMBLY
- Place the manual transaxle assembly on wooden blocks.
- REMOVE NO. 1 LOCK BALL ASSEMBLY
- Remove the No. 1 lock ball assembly from the manual transmission case.
- REMOVE SHIFT GUIDE PIN
- Remove the shift guide pin and washer from the transmission case.
- REMOVE CONTROL SHAFT COVER
- Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.
- REMOVE CONTROL SHAFT COVER OIL SEAL
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.
- REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the shift and select lever shaft assembly from the transmission case.
- REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the 9 bolts.
- 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.
- REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
- Engage 2 gears simultaneously to lock the transmission.
- Remove the manual transmission output shaft rear set nut.
- Disengage the 2 gears.
- REMOVE NO. 3 GEAR SHIFT FORK
- Remove the gear shift fork lock bolt from the No. 3 gear shift fork.
- Remove the No. 3 transmission hub sleeve with the No. 3 gear shift fork from the No. 3 transmission clutch hub.
- INSPECT 5TH GEAR THRUST CLEARANCE
- 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.
- Using a dial indicator, measure the 5th gear thrust clearance.
- INSPECT 5TH GEAR RADIAL CLEARANCE
- Using a dial indicator, measure the 5th gear radial clearance.
Standard clearance
JTEKT 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
JTEKT 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.
- Using a dial indicator, measure the 5th gear radial clearance.
- REMOVE NO. 3 TRANSMISSION CLUTCH HUB
- 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.
- Using a screwdriver, remove the synchromesh shifting key spring from the No. 3 transmission clutch hub.
- Using SST, remove the No. 3 transmission clutch hub, 5th gear, and No. 3 synchronizer ring from the input shaft.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-50013
- 09951-05010
- 09952-05010
- 09953-05020
- 09954-05031
- 09957-04010
- SST: 09950-60010
- 09951-00200
- SST: 09950-50013
- Remove the 3 synchromesh shifting keys and synchromesh shifting key spring from the No. 3 transmission clutch hub.
- Using 2 screwdrivers and a hammer, tap out the snap ring.
- REMOVE 5TH GEAR NEEDLE ROLLER BEARING
- Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
- REMOVE 5TH DRIVEN GEAR
- Using SST, remove the 5th driven gear from the output shaft.
- SST: 09950-30012
- 09951-03010
- 09953-03010
- 09954-03010
- 09955-03021
- SST: 09950-60010
- 09951-00180
- SST: 09950-30012
- Using SST, remove the 5th driven gear from the output shaft.
- REMOVE BEARING RETAINER REAR
- Remove the 5 bolts and bearing retainer rear from the manual transmission case.
- REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
- REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
- REMOVE REVERSE IDLER GEAR SHAFT BOLT
- Remove the reverse idler gear shaft bolt and reverse idler gear shaft gasket from the manual transmission case.
- REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
- 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.
- Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 gear shift fork shaft.
- REMOVE SHIFT DETENT BALL
- Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
- 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.
- Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.
- Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.
- REMOVE NO. 2 LOCK BALL ASSEMBLY
- Using a hexagon wrench, remove the No. 2 lock ball assembly from the manual transmission case.
- REMOVE MANUAL TRANSMISSION CASE
- Remove the 3 bolts from the front transaxle case.
- Remove the 13 bolts from the manual transmission case.
- 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.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Do not damage the manual transmission case and transaxle case.
- REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
- Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the front transaxle case.
- REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case.
- REMOVE NO. 2 GEAR SHIFT FORK SHAFT
- Remove the 2 bolts from the No. 2 gear shift fork and No. 1 gear shift head.
- Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the front transaxle case.
- REMOVE NO. 1 GEAR SHIFT FORK SHAFT
- 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.
- Remove the shift fork set bolt and No. 1 gear shift fork shaft from No. 1 gear shift fork.
- Remove the No. 1 gear shift fork.
- Using 2 screwdrivers and a hammer, tap out the snap ring.
- REMOVE NO. 3 GEAR SHIFT FORK SHAFT
- 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.
- Remove the No. 3 shift fork shaft together with the reverse shift fork and gear shift fork No. 2 from the manual transaxle case.
- Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.
- Using 2 screwdrivers and a hammer, tap the snap ring out of the No. 3 shift fork shaft.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:
Use a piece of cloth to keep the snap ring from flying off.
- Remove the reverse shift fork from the No. 3 gear shift fork shaft.
- Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.
- REMOVE INPUT SHAFT ASSEMBLY
- Remove the input shaft assembly and output shaft assembly from the front transaxle case.
- REMOVE DIFFERENTIAL CASE ASSEMBLY
- Remove the differential case assembly from the front transaxle case.
- REMOVE MANUAL TRANSAXLE CASE RECEIVER
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the bolt and manual transaxle case receiver from the front transaxle case.
- REMOVE REVERSE RESTRICT PIN ASSEMBLY
- Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
- 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.
- REMOVE NO. 1 OIL RECEIVER PIPE
- Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.NOTE:
Do not damage the No. 1 oil receiver pipe.
- Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.
- REMOVE NO. 2 OIL RECEIVER PIPE
- Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.NOTE:
Do not damage the No. 2 oil receiver pipe.
- Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.
- REMOVE BEARING LOCK PLATE
- Remove the bolt and bearing lock plate from the front transaxle case.
- REMOVE TRANSMISSION MAGNET
- Remove the transmission magnet from the front transaxle case.
- REMOVE INPUT SHAFT FRONT BEARING
- Using SST, remove the input shaft front bearing from the front transaxle case.
- SST: 09612-65014
- 09612-01050
- 09612-01060
- SST: 09612-65014
- Using SST, remove the input shaft front bearing from the front transaxle case.
- REMOVE FRONT TRANSAXLE CASE OIL SEAL
- Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
- REMOVE OUTPUT SHAFT FRONT BEARING
- 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.
- Using SST, remove the output shaft front bearing from the front transaxle case.
- REMOVE OUTPUT SHAFT COVER
- Remove the output shaft cover from the front transaxle case.
- REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- 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
- SST: 09612-65014
- Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-00020
- SST: 09950-00030
- SST: 09950-40011
- 09957-04010
- SST: 09950-60010
- 09951-00360
NOTE:Do not damage the bearing.
- Using SST, remove the front differential case front tapered roller bearing (outer race) and plate washer from the front transaxle case.
- REMOVE TRANSAXLE CASE OIL SEAL
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Using SST and a hammer, remove the transaxle case oil seal from the front transaxle case.
- SST: 09950-60010
- 09951-00530
- SST: 09950-70010
- 09951-07150
- SST: 09950-60010
- Using SST and a hammer, remove the transaxle case oil seal from the front transaxle case.
- REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- 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
- SST: 09612-65014
- Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-40011
- 09951-04010
- 09952-04010
- 09953-04020
- 09954-04010
- 09955-04061
- 09957-04010
- 09958-04011
- SST: 09950-60010
- 09951-00360
- SST: 09950-40011
- Using SST, remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
- REMOVE TRANSMISSION CASE OIL SEAL
- Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case.
- SST: 09950-60010
- 09951-00530
- SST: 09950-70010
- 09951-07150
- SST: 09950-60010
- Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case.
- REMOVE SHIFT AND SELECT LEVER SHAFT OIL SEAL
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Using a screwdriver and hammer, remove the shift and select lever shaft oil seal.
- REMOVE SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Using SST and a hammer, remove the shift and select lever shaft slide ball bearing.
- SST: 09950-60010
- 09951-00220
- SST: 09950-70010
- 09951-07200
- SST: 09950-60010
- Using SST and a hammer, remove the shift and select lever shaft slide ball bearing.