MANUAL TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE

1. Click here

   PRECAUTION

   Note:

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

2. Click here

   INSTALL CLUTCH FLEXIBLE HOSE BRACKET

   Click here

3. Click here

   INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

   Click here

4. Click here

   REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

   Click here

5. Click here

   INSPECT CLUTCH PIPE LINE

   Click here

6. Click here

   INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

   Click here

7. Click here

   INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

   
   

   1. Apply manual transaxle oil to a new O-ring and install it to the speedometer driven hole cover sub-assembly.

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

      11 N*m

      115 kgf*cm

      8 ft.*lbf

8. Click here

   INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

   Click here

9. Click here

   INSTALL WIRE HARNESS CLAMP BRACKET

   
   
   1. 

      Install the wire harness clamp bracket with the bolt and nut.

      Table 1. Text in Illustration

      *1

      Wire Harness Bracket (w/ Stop and Start System)

      -

      -

      Bolt A
      13 N*m	130 kgf*cm	9 ft.*lbf
      Bolt B
      29 N*m	296 kgf*cm	21 ft.*lbf
      Nut
      8.4 N*m	85 kgf*cm	74 in.*lbf

10. Click here

    INSTALL MANUAL TRANSAXLE ASSEMBLY

    
    
    1. 

       Hook the outer lever to the low fixture lever of the reverse restrict pin to secure it.

       Table 2. Text in Illustration

       *1	Reverse Restrict Pin Assembly
       *2	Outer Select Lever

    2. Make sure that the knock 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.

    3. Using a transmission jack, align the input shaft with the clutch disc and install the manual transaxle assembly to the engine assembly.

    4. 

       Install the 8 bolts.

       Bolt A
       64 N*m	653 kgf*cm	47 ft.*lbf
       Bolt B
       39 N*m	397 kgf*cm	29 ft.*lbf

       Note:
       

       • Be careful not to pinch wire harnesses, etc.

       • To avoid damage to the input shaft, do not forcefully shake the transaxle.

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

11. Click here

    INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

    
    

    1. Clean and degrease the bolt and the bolt installation hole.

    2. 

       Apply adhesive to 2 or 3 threads of the bolt end.

       Table 3. Text in Illustration

       *1	Toyota Genuine Adhesive 1324

       Adhesive
       Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. 

       Install the engine mounting bracket sub-assembly LH with the 4 bolts in several steps.

       64 N*m

       653 kgf*cm

       47 ft.*lbf

       Note:

       Temporarily tighten bolt A, and then fully tighten the 4 bolts in the order of B, D, C and A.

12. Click here

    INSTALL ENGINE MOUNTING INSULATOR LH

    
    
    1. 

       Install the engine mounting insulator LH with the 5 bolts in several steps.

       52 N*m

       530 kgf*cm

       38 ft.*lbf

       Note:

       Temporarily tighten bolt A and B, and then fully tighten the 5 bolts in the order of C, D, E, A and B.

    2. Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

       52 N*m

       530 kgf*cm

       38 ft.*lbf

       Note:

       Turn the bolt while holding the nut.

13. Click here

    INSTALL ENGINE MOVING CONTROL ROD BRACKET

    
    
    1. 

       Install the engine moving control rod bracket with the 3 bolts in several steps.

       45 N*m

       459 kgf*cm

       33 ft.*lbf

       Note:

       Temporarily tighten bolt A, and then fully tighten the 3 bolts in the order of B, C and A.

14. Click here

    INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

15. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY

    (Click here)

16. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLIES

    (Click here)

17. Click here

    INSTALL STARTER ASSEMBLY (w/ Stop and Start System)

    Click here

18. Click here

    INSTALL FLYWHEEL HOUSING SIDE COVER (w/ Stop and Start System)

    Click here

19. Click here

    INSTALL STARTER ASSEMBLY (w/o Stop and Start System)

    Click here

20. Click here

    INSTALL FLYWHEEL HOUSING SIDE COVER (w/o Stop and Start System)

    Click here

21. Click here

    CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    
    

    1. Install the 2 cables to the control cable bracket with 2 new clips.

    2. Connect the 2 cables to the transaxle and install the 2 washers and the 2 clips.

22. Click here

    INSTALL CLUTCH HOSE

    
    

    1. Install the clutch hose to the flexible hose bracket with a new clip.

    2. Using a union nut wrench 10 mm, install the flexible hose tube to the clutch hose.

       15 N*m

       155 kgf*cm

       11 ft.*lbf

       Note:

       Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

23. Click here

    CONNECT WIRE HARNESS (w/ Stop and Start System)

    
    

    1. Engage the 2 clamps and connect the park/neutral position switch connector.

24. Click here

    CONNECT WIRE HARNESS

    
    

    1. Engage the 6 clamps and connect the 2 connectors.

    2. Connect the wire harness to the transaxle assembly with the bolt.

       13 N*m

       130 kgf*cm

       9 ft.*lbf

25. Click here

    CONNECT WATER HOSE SUB-ASSEMBLY

    
    

    1. Engage the 2 hose clamp to the wire harness clamp brackets.

26. Click here

    INSTALL BATTERY CARRIER

    Click here

27. Click here

    INSTALL BATTERY TRAY

28. Click here

    INSTALL BATTERY

    Click here

29. Click here

    ADD TRANSAXLE OIL

    Click here

30. Click here

    INSPECT MANUAL TRANSAXLE OIL LEVEL

    Click here

31. Click here

    INSTALL ENGINE UNDER COVER RH

    Click here

32. Click here

    INSTALL ENGINE UNDER COVER LH

    Click here

33. Click here

    INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY (for LHD)

    Click here

34. Click here

    INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY (for RHD)

    Click here

35. Click here

    INSTALL COLUMN HOLE COVER SILENCER SHEET (for LHD)

    Click here

36. Click here

    INSTALL COLUMN HOLE COVER SILENCER SHEET (for RHD)

    Click here

37. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    5.4 N*m

    55 kgf*cm

    48 in.*lbf

38. Click here

    INSPECT ABS SPEED SENSOR SIGNAL (w/o VSC)

    (Click here)

39. Click here

    INSPECT ABS SPEED SENSOR SIGNAL (w/ VSC)

    (Click here)

40. Click here

    INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    (Click here)

41. Click here

    INSPECT FOR EXHAUST GAS LEAK

    Tip:

    Perform "Inspection After Repairs" after repairing or replacing the exhaust system (Click here).

42. Click here

    INSPECT MANUAL TRANSAXLE OIL LEAK