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 CLUTCH FLEXIBLE HOSE BRACKET

    Click here

  2. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  3. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  4. INSPECT CLUTCH PIPE LINE

    Click here

  5. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  6. INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

    Click here

  7. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt and nut.

      A005ITZE04
      Text in Illustration
      *1 w/ Stop and Start System - -
      Torque:
      Bolt A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Bolt B
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Nut
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  8. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. A005KZ3

      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 assembly onto the engine.

    4. A005J7HE02

      Install the 8 bolts.

      Torque:
      Part A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Part B
      39 N*m  { 397 kgf*cm, 29 ft.*lbf }

      Note

      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.

  9. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH


    1. A005IU8E25
      Text in Illustration
      *1 Toyota Genuine Adhesive 1324

      Coat the threads of the bolts with sealant.

      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the engine mounting bracket sub-assembly LH with the 4 bolts.

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

  10. INSTALL ENGINE MOUNTING INSULATOR LH


    1. Install the engine mounting insulator LH with the 5 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    2. Install the engine mounting bracket sub-assembly LH and engine mounting insulator LH with the bolt and nut.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  11. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. Install the engine moving control rod bracket with the 3 bolts.

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

  12. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  13. INSTALL FRONT DRIVE SHAFT ASSEMBLES

    Click here

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

    Click here

  15. INSTALL FLYWHEEL HOUSING SIDE COVER (w/ Stop and Start System)

    Click here

  16. INSTALL STARTER ASSEMBLY (w/o Stop and Start System)

    Click here

  17. INSTALL FLYWHEEL HOUSING SIDE COVER (w/o Stop and Start System)

    Click here

  18. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    A005IBUE01

    1. Connect the 2 cable ends and install the 2 washers and the 2 clips.

    2. Install 2 new clips onto the control cable bracket.

  19. INSTALL CLUTCH HOSE


    1. Install the clutch hose into the flexible hose bracket with a new clip.

    2. Using a union nut wrench (10 mm), install the flexible hose tube into the clutch hose.

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

      Note

      This torque value can be obtained by using a torque wrench with a fulcrum length of 250 mm (9.84 in.) and a union nut wrench with a fulcrum length of 22 mm (0.866 in.) Click here

  20. CONNECT CONNECTOR (w/ Stop and Start System)


    1. Attach the 2 clamps and connect the park/neutral position switch connector.

  21. CONNECT WIRE HARNESS


    1. Attach the 6 clamps and connect the 2 connectors.

    2. Connect the wire harness with the bolt.

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

  22. CONNECT WATER HOSE SUB-ASSEMBLY


    1. Attach the 2 hose clamp to the wire harness clamp brackets.

  23. INSTALL BATTERY CARRIER

    Click here

  24. INSTALL BATTERY TRAY

    Click here

  25. INSTALL BATTERY

    Click here

  26. ADD TRANSAXLE OIL

    Click here

  27. INSPECT TRANSAXLE OIL

    Click here

  28. INSTALL ENGINE UNDER COVER RH

    Click here

  29. INSTALL ENGINE UNDER COVER LH

    Click here

  30. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  31. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  32. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  34. INSPECT ABS SPEED SENSOR SIGNAL (w/o VSC)

    Click here

  35. INSPECT ABS SPEED SENSOR SIGNAL (w/ VSC)

    Click here

  36. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  37. INSPECT FOR EXHAUST GAS LEAK

  38. INSPECT FOR TRANSAXLE OIL LEAK