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 SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY


    1. A00556X

      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 transaxle case with the bolt.

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

  2. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  3. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  4. INSPECT CLUTCH PIPE LINE

    Click here

  5. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  6. INSTALL CLUTCH FLEXIBLE HOSE BRACKET


    1. A0052T8

      Install the clutch flexible hose bracket to the manual transaxle assembly with the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  7. INSTALL CLUTCH RELEASE BLEEDER TO FLEXIBLE HOSE TUBE


    1. A0054YZ

      for 1ZR-FAE:


      1. Using a union nut wrench, install the clutch release bleeder to flexible hose tube to the clutch release bleeder sub-assembly.

        Torque:
        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.

      2. Install the clamp to the manual transaxle with the bolt.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A0052TN

      for 2ZR-FAE:


      1. Using a union nut wrench, install the clutch release bleeder to flexible hose tube to the clutch release bleeder sub-assembly.

        Torque:
        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.

      2. Install the 2 clamps to the manual transaxle with the 2 bolts.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  8. INSTALL REAR ENGINE MOUNTING BRACKET


    1. A0056YY

      Install the rear engine mounting bracket with the 4 bolts.

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

  9. INSTALL ENGINE MOUNTING BRACKET LH


    1. A0052BP

      Apply adhesive to the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the engine mounting bracket LH with the 4 bolts.

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

  10. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. A00568B

      Install the front engine mounting bracket with the 4 bolts.

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

  11. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Align the input shaft with the clutch disc and install the manual transaxle assembly 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. A00561C

      Install the 7 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 }
    3. A0052PQ

      Connect the neutral position switch connector and install the wire harness to the manual transaxle assembly with the 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    4. A0053E6

      Connect the back-up light switch connector and install the wire harness to the manual transaxle assembly with the bolt.

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

  12. INSTALL ENGINE WIRE


    1. A0055H1

      Install the engine wire with the 2 bolts.

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

  13. INSTALL STARTER ASSEMBLY


    1. for 1ZR-FAE:

      Install the starter assembly Click here.

    2. for 2ZR-FAE:

      Install the starter assembly Click here.

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. for 1ZR-FAE:

      Install the engine assembly with transaxle Click here.

    2. for 2ZR-FAE:

      Install the engine assembly with transaxle Click here.

  15. PERFORM CLUTCH ENGAGEMENT POINT LEARNING

    Click here