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. TEMPORARILY TIGHTEN BLEEDER CLUTCH RELEASE TUBE


    1. Temporarily tighten the bleeder clutch release tube to a new clutch release with bearing cylinder assembly.

  2. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. Install the clutch release with bearing cylinder assembly to the manual transaxle assembly with 3 new bolts.

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

      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 spline grease adheres to the clutch release with bearing cylinder assembly.

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

    2. Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  3. INSTALL CLUTCH TUBE BOOT


    1. Install the clutch tube boot to the manual transaxle assembly.

  4. TEMPORARILY TIGHTEN CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. Temporarily tighten the bleeder clutch release tube to the clutch release bleeder sub-assembly.

    2. Temporarily install the clutch release bleeder sub-assembly to the manual transaxle assembly with the 2 bolts.

  5. FULLY TIGHTEN BLEEDER CLUTCH RELEASE TUBE


    1. Using a union nut wrench 10 mm, fully tighten the bleeder clutch release tube to the clutch release with bearing cylinder assembly.

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

      Note

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

  6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. Separate the bleeder clutch release tube from the clutch release bleeder sub-assembly.

    2. Remove the 2 bolts and the clutch release bleeder sub-assembly from the manual transaxle assembly.

  7. INSPECT CLUTCH PIPE LINE


    1. A0119YKE01

      Using SST, apply pressure of 0.1 MPa (1.02 kgf/ cm2, 14.5 psi) 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.

  8. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. Temporarily tighten the bleeder clutch release tube to the clutch release bleeder sub-assembly.

    2. Install the clutch release bleeder sub-assembly to the manual transaxle assembly with the 2 bolts.

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

    3. Using a union nut wrench 10 mm, fully tighten the bleeder clutch release 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 when the union nut wrench is combined with a torque wrench Click here.

  9. INSTALL CLUTCH FLEXIBLE HOSE BRACKET


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

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

  10. INSTALL BLEEDER CLUTCH RELEASE TUBE


    1. Install the bleeder clutch release tube to the manual transaxle assembly 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 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 when the union nut wrench is combined with a torque wrench Click here.

  11. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. Install the No. 1 clutch housing cover to the manual transaxle assembly.

  12. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 2 wire harness clamp brackets to the manual transaxle assembly with the 2 bolts.

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

    2. Install the oxygen sensor wire harness clamp bracket to the manual transaxle assembly with the bolt.

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

  13. INSTALL TRANSMISSION CASE PLUG


    1. Coat a new O-ring with gear oil, and install it to the transmission case plug.

    2. Install the transmission case plug to the manual transaxle assembly.

  14. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET


    1. A0116YRE21
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads on the end of the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

  15. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET


    1. Install the transverse engine engine mounting control bracket to the manual transaxle assembly with the 3 bolts.

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

  16. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. A011AXPE01
      Text in Illustration
      *1 Reverse Restrict Pin
      *2 Outer Select Lever

      Hook the outer select 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 manual transaxle assembly to the engine assembly 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 assembly to the engine assembly.

    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


      • Be careful not to pinch wire harnesses, etc.

      • Do not forcefully pry on the manual transaxle assembly.

      • To avoid damage to the input shaft, do not forcefully shake the manual transaxle assembly.

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

  17. 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.

  18. INSTALL CONTROL CABLE BRACKET


    1. Install the control cable bracket to the manual transaxle assembly with the 2 bolts.

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

    2. Engage the wire harness clamps and connector to the control cable bracket.

  19. INSTALL DRIVE SHAFT HEAT INSULATOR BRACKET


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

      Torque:
      16 N*m  { 166 kgf*cm, 12 ft.*lbf }

  20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here