MANUAL TRANSAXLE ASSEMBLY INSTALLATION

Note

When the transaxle 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, and dust could damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.


  1. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.

    2. A011BWO

      Temporarily tighten the bleeder clutch release tube onto the clutch release with bearing cylinder assembly.

    3. A0119UV

      Install the new clutch release with the bearing cylinder with the 3 new bolts.

      Note


      • The clutch release with bearing cylinder assembly and installation bolts cannot be reused and must be replaced with new ones.

      • Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder assembly fits securely with the transaxle during installation. The first bolt should be tightened by hand the clutch release with bearing cylinder assembly when installing.

      • Ensure that none of the clutch disc spline grease adheres to the clutch release with bearing cylinder assembly.

      • The clutch release with bearing cylinder assembly cannot be disassembled.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    4. Install the clutch tube boot onto the transaxle.

    5. Install the release cylinder bleeder plug onto the clutch release bleeder.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    6. Install the release cylinder bleeder plug cap.

    7. A0119X3E01
      Text in Illustration
      *1 Bleeder clutch release tube
      *2 Clutch release bleeder

      Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.

    8. Temporarily tighten the 2 bolts and install the clutch release bleeder.

    9. A0117M9

      Using a union nut wrench 10 mm, install the bleeder clutch release tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench Click here.

  2. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. Separate the bleeder clutch release tube from the clutch release bleeder.

    2. Remove the 2 bolts and the clutch release bleeder.

  3. INSPECT CLUTCH PIPE LINE

    A0119YKE01

    1. Using SST, apply pressure of 0.1 MPa to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

      SST
      09992-00242

      If the pressure drops, replace the bleeder clutch release tube.

  4. INSTALL CLUTCH FLEXIBLE HOSE BRACKET


    1. Install the clutch flexible hose bracket with the bolt.

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

  5. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A0119X3E01
      Text in Illustration
      *1 Bleeder clutch release tube
      *2 Clutch release bleeder

      Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.

    2. Install the 2 bolts and clutch release bleeder.

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

    3. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench Click here.

  6. INSTALL BLEEDER CLUTCH RELEASE TUBE


    1. Install the bleeder clutch release tube with the bolt.

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

    2. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench Click here.

  7. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover onto the transaxle.

  8. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A0117JV

      Install the wire harness clamp bracket with the bolt as shown in the illustration.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    2. A0119B1

      Install the wire harness clamp bracket with the bolt as shown in the illustration.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    3. A011B5G

      Install the oxygen sensor wire harness clamp bracket with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  9. INSTALL TRANSMISSION CASE PLUG


    1. Install the transmission case plug with the new O-ring.

  10. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET


    1. Coat the threads of the bolts with sealant.

      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

  11. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET


    1. Install the engine mounting control bracket with the 3 bolts.

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

  12. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. A011AXP

      Hook the outer lever to the low fixture lever of the reverse restrict pin to secure it.

    2. Make sure that the knock 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.

    3. Align the input shaft with the clutch disc and install the manual transaxle onto the engine.

    4. A01180ME01

      Install the 10 bolts.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B (for Flange Bolt)
      37 N*m  { 377 kgf*cm, 27 ft.*lbf, }
      Bolt B (for Bolt with Washer)
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
      Bolt C
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Insert knock pins into the knock pin holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.

  13. INSTALL STARTER ASSEMBLY


    1. Install the starter assembly with the 2 bolts.

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

    2. Connect the connector.

    3. Connect terminal 30 with the nut.

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

    4. Close the terminal cap.

  14. INSTALL CONTROL CABLE BRACKET


    1. Install the control cable bracket with the 2 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    2. Install the wire harness clamps onto the control cable bracket.

  15. INSTALL DRIVE SHAFT HEAT INSULATOR BRACKET


    1. Install the drive shaft heat insulator bracket with the 2 bolts.

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine assembly with transaxle Click here.