MANUAL TRANSAXLE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note:

When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

PROCEDURE

  1. INSTALL WIRE HARNESS CLAMP BRACKET

    1. C341831

      for Rear of Vehicle (w/ Stop and Start System):

      Install the wire harness clamp bracket with the bolt.

      19.1 N*m

      195 kgf*cm

      14 ft.*lbf

    2. C341830

      for Front of Vehicle:

      Install the wire harness clamp bracket with the bolt.

      19.1 N*m

      195 kgf*cm

      14 ft.*lbf

  2. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

    1. Clean the transfer and transaxle setting stud bolt holes.

    2. Apply adhesive 1324 to 2 or 3 threads on one half of a new transfer and transaxle setting stud bolt A as shown in the illustration.

      C299986C01

      *a

      Toyota Genuine Adhesive 1324

      *b

      Sealant

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note:

      • Do not apply adhesive 1324 to the ends of the transfer and transaxle setting stud bolt.

      • Install the transfer and transaxle setting stud bolt immediately after applying adhesive to prevent the adherence of foreign matter.

    3. Install the 2 new transfer and transaxle setting stud bolts to the transaxle case positions shown in the illustration.

      39.2 N*m

      400 kgf*cm

      29 ft.*lbf

      Note:

      Install the transfer and transaxle setting stud bolt so that the side that has sealant and adhesive is facing the automatic transaxle assembly.

      Tip:

      Stud transfer and transaxle setting stud bolt length:

      Stud transfer and transaxle setting stud bolt A: 69 mm (2.72 in.)

      Stud transfer and transaxle setting stud bolt B: 47 mm (1.85 in.)

  3. INSTALL TRANSFER ASSEMBLY

    Click here

  4. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

    1. Coat a new O-ring with gear oil.

    2. Install the O-ring to the speedometer driven hole cover sub-assembly.

    3. Install the speedometer driven hole cover sub-assembly to the manual transaxle case with the bolt.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  5. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

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  6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  7. INSPECT CLUTCH PIPE LINE

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  8. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  9. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

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  10. INSTALL REAR ENGINE MOUNTING BRACKET

    C277913C01

    *a

    Temporarily

    1. Temporarily install the rear engine mounting bracket with the 4 bolts.

    2. Tighten the 4 bolts of the rear engine mounting bracket in the order shown in the illustration.

      45 N*m

      459 kgf*cm

      33 ft.*lbf

  11. INSTALL ENGINE MOUNTING BRACKET LH

    C279718C01

    *a

    Temporarily

    1. Clean the bolts and the installation holes in the engine mounting bracket LH.

    2. Apply adhesive to the 4 bolts.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Temporarily install the engine mounting bracket LH with the 4 bolts.

    4. Tighten the 4 bolts of the engine mounting bracket LH in the order shown in the illustration.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  12. INSTALL FRONT ENGINE MOUNTING BRACKET

    C279719C01

    *a

    Temporarily

    1. Temporarily install the front engine mounting bracket with the 4 bolts.

    2. Tighten the 4 bolts of the front engine mounting bracket in the order shown in the illustration.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  13. INSTALL MANUAL TRANSAXLE ASSEMBLY

    1. Align the input shaft with the clutch disc and install the manual transaxle to the engine.

      Note:

      • Make sure that the dowel pins are not loose, bent, damaged or scratched and then install the transaxle onto the engine with the contact surfaces of the engine and transaxle flat against each other.

      • Insert the dowel pins into the dowel holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.

    2. C277914C01

      *a

      Temporarily

      Temporarily install the manual transaxle assembly with the bolt (*a).

    3. Tighten the 3 bolts labeled A in the order shown in the illustration, and then install the 5 bolts labeled B.

      for Bolt A

      38 N*m

      387 kgf*cm

      28 ft.*lbf

      for Bolt B

      40 N*m

      408 kgf*cm

      30 ft.*lbf

    4. C341829

      Connect the engine wire.

      1. w/ Stop and Start System:

        Connect the neutral position switch connector and 2 clamps.

      2. C341827

        Connect the clamp and back-up light switch connector.

  14. INSTALL STARTER ASSEMBLY (for 3ZR-FE)

  15. INSTALL STARTER ASSEMBLY (for 3ZR-FAE)

    Click here

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE