MANUAL TRANSAXLE ASSEMBLY INSTALLATION

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.


  1. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY


    1. A00OJIU

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

  2. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. A00OMAZ

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

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

    3. A00OKMH

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

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

      Note


      • The clutch release with bearing cylinder 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 fits securely with the transaxle during installation. The first bolt should be tightened by hand while holding the clutch release with bearing cylinder.

      • Make sure that none of the clutch spline grease adheres to the clutch release with bearing cylinder.

      • The clutch release with bearing cylinder cannot be disassembled.

    4. A00OKS2

      Install the clutch tube boot to the manual transaxle assembly.

    5. A00OMHD

      Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

    6. Temporarily install the clutch release bleeder sub-assembly with the 2 bolts.

    7. A00OKKV

      Using a union nut wrench, install the clutch release cylinder to bleeder tube.

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

      Note

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

    8. A00OMXQE02
      Text in Illustration
      *1 Clutch spline grease

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent

  3. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A00OMHD

      Separate the clutch release cylinder to bleeder tube from the clutch release bleeder sub-assembly.

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

  4. INSPECT CLUTCH PIPE LINE

    A00OI5ME01

    1. Using SST, apply a pressure of 100 kPa (1.0 kgf/cm2, 15 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 clutch release cylinder to bleeder tube.

  5. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY


    1. A00OMHD

      Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

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

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

    3. Using a union nut wrench, install the clutch release cylinder to bleeder tube.

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

      Note

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

  6. INSTALL CLUTCH FLEXIBLE HOSE BRACKET


    1. A00ONGR

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

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

  7. INSTALL CLUTCH RELEASE BLEEDER TO FLEXIBLE HOSE TUBE


    1. A00OKWX

      for 1ZR-FAE:


      1. Using a union nut wrench, install the clutch release bleeder to flexible hose 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 where a union nut wrench is combined with a torque wrench Click here.

      2. Install the clamp to the manual transaxle with the bolt.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A00OM3Z

      for 2ZR-FAE:


      1. Using a union nut wrench, install the clutch release bleeder to flexible hose 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 where a union nut wrench is combined with a torque wrench Click here.

      2. Install the 2 clamps to the manual transaxle with the 2 bolts.

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

  8. INSTALL REAR ENGINE MOUNTING BRACKET


    1. A00OJO2

      Install the rear engine mounting bracket with the 4 bolts.

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

  9. INSTALL ENGINE MOUNTING BRACKET LH


    1. A00OLOD

      Apply adhesive to the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

  10. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. A00ON09

      Install the front engine mounting bracket with the 4 bolts.

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

  11. 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. A00OO0J

      Install the 7 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 }
    3. A00OMT1

      Connect the neutral position switch connector and install the wire harness to the manual transaxle with the 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    4. A00OMF5

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

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

  12. INSTALL ENGINE WIRE


    1. A00OI3A

      Install the engine wire with the 2 bolts.

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

  13. INSTALL STARTER ASSEMBLY


    1. for 1ZR-FAE:

      Install the starter assembly Click here.

    2. for 2ZR-FAE:

      Install the starter assembly Click here.

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. for 1ZR-FAE:

      Install the engine assembly with transaxle Click here.

    2. for 2ZR-FAE:

      Install the engine assembly with transaxle Click here.

  15. PERFORM CLUTCH ENGAGEMENT POINT LEARNING

    Click here