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 RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  2. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  3. INSPECT CLUTCH PIPE LINE

    Click here

  4. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  5. INSTALL AIR TUBE SUPPORT

    Install the air tube support with the 2 bolts onto the manual transaxle assembly.

    Torque:
    20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  6. 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. A005JS3E02
      Text in Illustration
      *1 Knock Pin Hole

      Install the 8 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 }

      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.

  7. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH


    1. A005IU8E25
      Text in Illustration
      *1 Adhesive

      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 }

  8. 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 }

  9. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. Install the engine moving control rod bracket with the 4 bolts

      Torque:
      45 N*m  { 4593 kgf*cm, 33 ft.*lbf }

  10. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  11. INSTALL OIL PAN COVER

    Click here

  12. INSTALL FRONT DRIVE SHAFT ASSEMBLES

    Click here

  13. INSTALL STARTER ASSEMBLY (for 1.6 kW Type)

    Click here

  14. INSTALL STARTER ASSEMBLY (for 2.0 kW Type)

    Click here

  15. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

    Click here

  16. CONNECT CONNECTOR


    1. Connect the back-up light switch connector.

  17. CONNECT WIRE HARNESS


    1. Connect the wire harness with the bolt.

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

  18. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    A005JMO

    1. Connect the 2 cables and install the 2 clips.

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

  19. INSTALL NO. 2 AIR HOSE

    Click here

  20. INSTALL AIR PIPE SUB-ASSEMBLY

    Click here

  21. INSTALL BATTERY CARRIER

    Click here

  22. INSTALL BATTERY TRAY

    Click here

  23. INSTALL BATTERY

    Click here

  24. INSTALL AIR CLEANER BRACKET

    Click here

  25. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  26. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  27. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  28. ADD TRANSAXLE OIL

    Click here

  29. INSPECT TRANSAXLE OIL

    Click here

  30. INSTALL ENGINE UNDER COVER RH

    Click here

  31. INSTALL ENGINE UNDER COVER LH

    Click here

  32. INSTALL CENTER ENGINE UNDER COVER

    Click here

  33. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  34. INSTALL STEERING SLIDE YOKE SUB-ASSEMBLY

    Click here

  35. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  37. INSPECT SPEED SENSOR SIGNAL (w/o VSC)

    Click here

  38. INSPECT SPEED SENSOR SIGNAL (w/ VSC)

    Click here

  39. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  40. CHECK FOR EXHAUST GAS LEAKAGE

  41. CHECK FOR TRANSAXLE OIL LEAKAGE