MANUAL TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (for AISIN AI Made)


    1. Apply a light coat of gear oil to a new O-ring and install it to the speedometer driven hole cover sub-assembly.

      Note

      Be careful not to damage or twist the O-ring.

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

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }

      Note

      Make sure that the O-ring is not damaged or does not jump out of position during installation.

  2. INSTALL MANUAL TRANSMISSION CASE PLUG (for TMMP Made)


    1. Install a new gasket and manual transaxle case plug to the manual transaxle assembly.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  3. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 2 wire harness clamp brackets to the manual transaxle assembly with the 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  4. INSTALL SHIFT LEVER DAMPER


    1. Install the shift lever damper to the manual transaxle assembly with the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  5. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. B00482H

      Apply clutch spline grease to the input shaft spline.

      Text in Illustration
      B0046MU Clutch Spline Grease
      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
    2. B0045OH

      Confirm that the 2 knock pins are installed on the engine assembly and are not damaged.

    3. B0045WIE01

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

    4. Install the 9 bolts.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note


      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.

      • Do not forcibly pry on the manual transaxle assembly.

      • When mounting the manual transaxle assembly to the engine assembly, make sure to securely fit the knock pins into the knock holes.

      • When tightening the bolts, be sure that the contact surfaces of the engine assembly and manual transaxle assembly are in close contact with one another.

  6. INSTALL ENGINE MOUNTING BRACKET LH


    1. Clean and degrease the bolts and bolt holes.

    2. B0046S7E19
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      To prevent contamination by foreign matter, install immediately after applying adhesive.

    3. B00476EE04
      Text in Illustration
      *a Temporarily Tighten

      Install the engine mounting bracket LH to the manual transaxle assembly with the 4 bolts in the order shown in the illustration.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  7. INSTALL ENGINE MOUNTING INSULATOR LH


    1. B0045WME03
      Text in Illustration
      *a Temporarily Tighten

      Engage the hook to temporarily install the engine mounting insulator LH to the body.

    2. Install the 3 bolts in the order shown in the illustration.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    3. B0045OY

      Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt, through bolt and nut.

      Torque:
      Bolt
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Through Bolt
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

      Note

      Install the bolt first and then the through bolt and nut.

      Tech Tips

      Turn the through bolt while holding the nut.

  8. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. B00468BE04
      Text in Illustration
      *a Temporarily Tighten

      Install the engine moving control rod bracket to the manual transaxle assembly with the 3 bolts in the order shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  9. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  10. INSTALL STARTER ASSEMBLY

    Click here

  11. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  12. INSTALL FRONT DRIVE SHAFT ASSEMBLIES

    Click here

  13. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. B0045PEE02
      Text in Illustration
      *a Temporarily Tighten

      Install the drive shaft heat insulator sub-assembly to the engine assembly with the 2 bolts in the order shown in the illustration.

      Torque:
      24 N*m  { 240 kgf*cm, 17 ft.*lbf }

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  16. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  17. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  18. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  19. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY


    1. B00480XE02

      Install the clutch release cylinder assembly to the manual transaxle assembly with the 4 bolts.

      Torque:
      Bolt A for AISIN AI Made
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }
      Bolt A for TMMP Made
      14 N*m  { 141 kgf*cm, 10 ft.*lbf }
      Bolt B
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  20. INSTALL RELEASE CYLINDER HEAT INSULATOR


    1. Install the release cylinder heat insulator to the clutch release cylinder assembly with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  21. CONNECT ENGINE WIRE


    1. Engage the 2 clamps to install the engine wire to the wire harness clamp brackets.

    2. Connect the back-up light switch assembly connector.

    3. w/ Stop and Start System:


      1. Install the wire harness clamp bracket to the clutch flexible hose bracket with the bolt.

        Torque:
        13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      2. Engage the 2 clamps to install the engine wire to the wire harness clamp bracket.

      3. Connect the neutral position switch connector.

  22. CONNECT NO. 3 ENGINE WIRE


    1. Engage the 2 clamps to install the No. 3 engine wire to the engine mounting bracket LH.

    2. Connect the No. 3 engine wire to the manual transaxle assembly with the bolt.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  23. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B0048ATE04

      Install the transmission control cable assembly to the control cable bracket with 2 new clips B.

    2. Connect the transmission control cable assembly to the manual transaxle assembly with the 2 clips A.

  24. INSTALL BATTERY CARRIER

    Click here

  25. INSTALL BATTERY TRAY

    Click here

  26. INSTALL BATTERY

    Click here

  27. ADD MANUAL TRANSAXLE OIL

    Click here

  28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  29. INSPECT SPEED SENSOR SIGNAL

    Click here

  30. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  31. INSPECT FOR EXHAUST GAS LEAK

  32. INSPECT MANUAL TRANSAXLE OIL LEVEL

    Click here

  33. INSPECT FOR MANUAL TRANSMISSION OIL LEAK

  34. INSTALL ENGINE UNDER COVER RH

    Torque:
    5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  35. INSTALL ENGINE UNDER COVER LH

    Torque:
    5.0 N*m  { 51 kgf*cm, 44 in.*lbf }