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 transaxle 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 new O-ring to the speedometer driven hole cover sub-assembly.

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

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

  2. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the manual transaxle assembly with the bolt.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 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

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  6. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  7. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

    Click here

  8. INSTALL REAR ENGINE MOUNTING BRACKET


    1. Install the rear engine mounting bracket to the manual transaxle assembly with the 4 bolts.

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

  9. INSTALL ENGINE MOUNTING BRACKET LH


    1. Apply sealant to the 4 bolts.

      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the engine mounting bracket LH to the manual transaxle assembly with the 4 bolts.

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

  10. INSTALL FRONT ENGINE MOUNTING BRACKET


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

      Torque:
      Green Bolt
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Silver Bolt
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  11. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. A00Y7O4

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

    2. A00Y872N01

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

    3. Install the 8 bolts.

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

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


    1. Install the wire harness to the manual transaxle assembly with the nut and bolt.

      Torque:
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Connect the park/neutral position switch assembly connector.

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

    4. Connect the 5 clamps.

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


    1. Install the wire harness to the manual transaxle assembly with the nut and bolt.

      Torque:
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

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

    3. Connect the 3 clamps.

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

    Click here

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

    Click here

  16. INSTALL NO. 1 AIR TUBE


    1. A00Y7TPC01
      *a Hose Clamp

      Install the No. 1 air tube and tighten the hose clamp.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

    2. Install the 4 bolts.

      Torque:
      Bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Bolt B
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
      Bolt C
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the 2 wire harness clamps to the manual transaxle assembly.

  17. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR

    Click here

  18. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

    Click here

  19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here