MULTI-MODE MANUAL TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. 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. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

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  3. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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  4. INSPECT CLUTCH PIPE LINE

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  5. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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  6. 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.

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

  7. 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 }

    2. Connect the shift stroke sensor connector.

  8. INSTALL AIR TUBE SUPPORT


    1. Install the air tube support to the manual transaxle assembly with the 2 bolts.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Make sure that the knock pins are not loose, bent, damaged or scratched and then install the manual transaxle assembly to the engine assembly with the contact surfaces of the engine and transaxle flat against each other.

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

    3. B00484QE01
      Text in Illustration
      *1 Knock Pin Hole

      Install the 8 bolts.

      Torque:
      for Flange Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      for Bolt with Washer
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

      Note


      • Be careful not to pinch wire harnesses, etc.

      • Do not allow the engine and transaxle to interfere with the vehicle body.

      • Do not forcefully pry on the transaxle.

      • 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.

  10. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH


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

    2. B0046CJE07
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B0047TWE02

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

      Torque:
      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, C, D and A.

  11. INSTALL ENGINE MOUNTING INSULATOR LH


    1. B0045SSE02

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

      Torque:
      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.

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

      Note

      Turn the bolt while holding the nut.

  12. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. B0046FLE03

      Install the engine moving control rod bracket with the 4 bolts in several steps.

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

      Note

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

  13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  14. INSTALL OIL PAN COVER

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  15. INSTALL EXHAUST PIPE

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  16. INSTALL FRONT DRIVE SHAFT ASSEMBLIES

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  17. INSTALL STARTER ASSEMBLY (except Cold Area Specification Vehicles)


    1. Install the starter assembly with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    2. Connect the terminal 30 with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the connector and engage the harness clamp.

    4. Close the terminal cap.

  18. INSTALL STARTER ASSEMBLY (for Cold Area Specification Vehicles)


    1. Install the starter assembly with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    2. Connect terminal 30 with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the connector and engage the harness clamp.

    4. Close the terminal cap.

  19. CONNECT WIRE HARNESS


    1. Connect the 2 shift and select actuator connectors.

    2. Engage the wire harness clamp, and connect the back-up light switch connector and the transmission revolution sensor connector.

    3. Engage the 4 wire harness clamps and connect the 5 connectors.

    4. Connect the wire harness to the manual transaxle assembly with the bolt.

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

  20. INSTALL CLUTCH ACTUATOR ASSEMBLY

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  21. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

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

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  23. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

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  24. INSTALL COLUMN HOLE COVER SILENCER SHEET

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  25. INSTALL NO. 1 AIR TUBE

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  26. INSTALL NO. 2 AIR HOSE

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  27. INSTALL BATTERY CARRIER

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  28. INSTALL BATTERY TRAY

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  29. INSTALL BATTERY

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  30. INSTALL AIR CLEANER BRACKET

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  31. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  32. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  33. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  34. ADD MANUAL TRANSAXLE OIL

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  35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  36. INSPECT SPEED SENSOR SIGNAL

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  37. PERFORM INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

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  38. PERFORM LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

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  39. PERFORM SYNCHRONIZATION POSITION CALIBRATION

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  40. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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  41. INSPECT MANUAL TRANSAXLE OIL LEVEL

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  42. INSPECT FOR MANUAL TRANSAXLE OIL LEAK

  43. INSPECT FOR EXHAUST GAS LEAK

  44. INSTALL ENGINE UNDER COVER LH

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  45. INSTALL ENGINE UNDER COVER RH

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  46. INSTALL CENTER ENGINE UNDER COVER

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