MANUAL TRANSAXLE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. 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 front transaxle case with the bolt.

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

  2. INSTALL NO. 1 HEATER BRACKET SUB-ASSEMBLY


    1. Install the No. 1 heater bracket sub-assembly to the manual transmission case with the bolt.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  3. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  4. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  5. INSPECT CLUTCH PIPE LINE

    Click here

  6. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  7. INSTALL CLUTCH FLEXIBLE HOSE BRACKET


    1. Install the clutch flexible hose bracket to the manual transmission case with the bolt.

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

  8. INSTALL BLEEDER CLUTCH RELEASE TUBE

    Click here

  9. INSTALL REAR ENGINE MOUNTING BRACKET


    1. Install the rear engine mounting bracket to the front transaxle case with the 4 bolts.

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

  10. INSTALL ENGINE MOUNTING BRACKET LH


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

    2. A002ZSXC21
      *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

      In order to ensure proper installation of the 4 bolts, apply adhesive to the 4 bolts and install them within 10 minutes of adhesive application.

    3. Install the engine mounting bracket LH to the manual transmission case with the 4 bolts.

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

  11. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. Install the front engine mounting bracket to the front transaxle case with the 4 bolts.

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

  12. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. A002ZSQC01
      *1 Knock Pin

      Check that the 2 knock pins are installed on the engine assembly before installing the manual transaxle assembly.

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

    3. A0030EQN01

      Temporarily install the bolt (A).

    4. Install the bolt (B), then fully tighten the bolt (A).

      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 }

    5. Install the 5 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


      • 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 installing it to the engine assembly.

      • Do not apply excessive force to the manual transaxle assembly as this will break the input shaft.

      • Make sure that the knock pins fit securely into the holes when installing the manual transaxle assembly to the engine assembly.

      • Make sure that the contact surfaces of the engine assembly and manual transaxle assembly are flat against each other before tightening the bolts.

  13. INSTALL MANIFOLD SUPPORT BRACKET

    Click here

  14. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  15. CONNECT WIRE HARNESS (w/ Stop And Start System)


    1. Engage the 3 clamps to connect the wire harness to the manual transaxle assembly.

    2. Connect the neutral position switch connector.

    3. Connect the fuel pressure sensor connector.

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

  16. CONNECT WIRE HARNESS (w/o Stop And Start System)


    1. Engage the 2 clamps to connect the wire harness to the manual transaxle assembly.

    2. Connect the fuel pressure sensor connector.

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

  17. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  18. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  19. INSTALL FLYWHEEL HOUSING SIDE COVER (w/ Stop And Start System)

    Click here

  20. INSTALL FLYWHEEL HOUSING SIDE COVER (w/o Stop And Start System)

    Click here

  21. INSTALL WATER HOSE

    Click here

  22. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

    Click here

  23. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

    Click here

  24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here