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 TRANSFER AND TRANSAXLE SETTING STUD BOLT



    1. Clean the bolt holes.

    2. Apply adhesive 1324 to 2 or 3 threads on one half of a new transfer and transaxle setting stud bolt A as shown in the illustration.

      A01KAPMC01
      *a Toyota Genuine Adhesive 1324 *b Sealant
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note


      • Do not apply adhesive 1324 to the ends of the stud bolt.

      • Install the stud bolt immediately after applying adhesive to prevent the adherence of foreign matter.

    3. Install the 2 new transfer and transaxle setting stud bolts to the transaxle case positions shown in the illustration.

      Torque:
      39.2 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Install the stud bolt so that the side that has sealant and adhesive is facing the automatic transaxle assembly.

      Tech Tips

      Stud bolt length:

      Stud bolt A: 69 mm (2.72 in.)

      Stud bolt B: 47 mm (1.85 in.)

  2. INSTALL TRANSFER ASSEMBLY

    Click here

  3. 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 transaxle case with the bolt.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  4. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  5. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  6. INSPECT CLUTCH PIPE LINE

    Click here

  7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  8. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

    Click here

  9. INSTALL REAR ENGINE MOUNTING BRACKET

    A01KCS4C01
    *a Temporarily

    1. Temporarily install the rear engine mounting bracket with the 4 bolts.

    2. Tighten the 4 bolts of the rear engine mounting bracket in the order shown in the illustration.

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

  10. INSTALL ENGINE MOUNTING BRACKET LH

    A01KBFGC01
    *a Temporarily

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

    2. Apply adhesive to the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Temporarily install the engine mounting bracket LH with the 4 bolts.

    4. Tighten the 4 bolts of the engine mounting bracket LH in the order shown in the illustration.

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

  11. INSTALL FRONT ENGINE MOUNTING BRACKET

    A01KDGXC01
    *a Temporarily

    1. Temporarily install the front engine mounting bracket with the 4 bolts.

    2. Tighten the 4 bolts of the front engine mounting bracket in the order shown in the illustration.

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

  12. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Align the input shaft with the clutch disc and install the manual transaxle 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. A01KAP5C01
      *a Temporarily

      Temporarily install the manual transaxle assembly with the bolt (*a).

    3. Tighten the 3 bolts labeled A in the order shown in the illustration, and then install the 5 bolts labeled B.

      Torque:
      for Bolt A
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      for Bolt B
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

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

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    5. Connect the clamp with the bolt.

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

  13. INSTALL STARTER ASSEMBLY

    for 3ZR-FE:

    Click here

    for 3ZR-FAE for 1.0 kW Type:

    Click here

    for 3ZR-FAE for 1.3 kW Type:

    Click here

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    for 3ZR-FE:

    Click here

    for 3ZR-FAE:

    Click here