MANUAL TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE

  1. INSTALL MANUAL TRANSAXLE ASSEMBLY

    1. C304094

      Check that the 2 knock pins are installed to the engine assembly before installing the manual transaxle assembly.

    2. C305350C01
      V100135

      Clutch spline grease

      Apply clutch spline grease to the input shaft splines.

      Grease

      Toyota Genuine Clutch Spline Grease or equivalent

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

    4. C304078C03
      V100135

      Bolt
      V100136

      Nut

      Install the 2 bolts and 2 nuts.

      Bolt

      55 N*m

      561 kgf*cm

      41 ft.*lbf

      Nut

      55 N*m

      561 kgf*cm

      41 ft.*lbf

      Note:

      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.

      • Do not forcibly pry on the manual transaxle assembly when installing it to the engine assembly.

      • Do not apply excessive force to the manual transaxle assembly as this will break the input shaft.

      • Make sure that the 2 knock pins fit securely into the holes when installing the manual transaxle assembly to the engine assembly.

      • Make sure that the contact surfaces of the engine assembly and manual transaxle assembly are flat against each other before tightening the bolts and nuts.

      • Be careful not to damage the radiator assembly when installing the manual transaxle assembly.

  2. INSTALL ENGINE MOUNTING BRACKET LH

    1. C304077

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

      30 N*m

      306 kgf*cm

      22 ft.*lbf

  3. INSTALL ENGINE MOUNTING INSULATOR LH

    1. C304076

      Install the engine mounting insulator LH to the vehicle body and engine mounting bracket LH with the 6 bolts.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

    2. Install the clutch release cable clamp to the engine mounting insulator LH with the bolt.

      7 N*m

      71 kgf*cm

      62 in.*lbf

    3. Connect the clutch release cable assembly to the clutch release cable clamp.

  4. INSTALL ENGINE MOVING CONTROL ROD

    1. Install the engine moving control rod to the front suspension crossmember sub-assembly with the bolt.

      110 N*m

      1122 kgf*cm

      81 ft.*lbf

  5. INSTALL ENGINE MOUNTING CONTROL BRACKET

    1. C304085E01

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

      Bolt (A)

      90 N*m

      918 kgf*cm

      66 ft.*lbf

      Bolt (B)

      120 N*m

      1224 kgf*cm

      89 ft.*lbf

    2. C304083

      Install the 3 bolts.

      55 N*m

      561 kgf*cm

      41 ft.*lbf

  6. CONNECT FRONT FENDER LINER LH

    1. C302674C01
      V100135

      Bolt
      V100136

      Screw

      Connect the front fender liner LH with the 2 screws and 3 bolts.

  7. INSTALL STARTER ASSEMBLY

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  8. INSTALL CONTROL CABLE BRACKET

    1. C304126

      Install the 2 bolts and control cable bracket to the manual transmission assembly.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  9. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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  10. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    1. Install the front exhaust pipe assembly to the exhaust pipe support with the nut.

      8 N*m

      82 kgf*cm

      71 in.*lbf

    2. Install the front exhaust pipe assembly to the tail exhaust pipe assembly with the nut.

      22 N*m

      224 kgf*cm

      16 ft.*lbf

    3. Install the front exhaust pipe assembly to the exhaust manifold with the nut.

      22 N*m

      224 kgf*cm

      16 ft.*lbf

  11. INSTALL CLUTCH CABLE BRACKET

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

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  12. CONNECT CLUTCH RELEASE CABLE ASSEMBLY

    1. C305456C01
      V100135

      Lithium soap base glycol grease

      Apply lithium soap base glycol grease to the clevis of the clutch release fork sub-assembly.

    2. Connect the clutch release cable assembly to the manual transaxle assembly.

    3. C305290C01

      *1

      Clutch Release Fork Sub-assembly

      *a

      Push

      *b

      Turn

      While pushing the clutch release fork sub-assembly, tighten the clutch release cable end clamp.

    4. Slowly release the clutch release fork sub-assembly and ensure that the clutch release cable end clamp is correctly located in the groove of the clutch release fork sub-assembly.

    5. Install the clutch release cable grommet to the hole in the vehicle body.

    6. Depress the clutch pedal a few times to ensure the clutch release cable assembly moves smoothly.

  13. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (for LHD)

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  14. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (for RHD)

    Click here

  15. CONNECT NO. 2 RADIATOR HOSE

    1. Connect the No. 2 radiator hose to the clutch cable bracket.

  16. CONNECT WIRE HARNESS

    1. C304061

      Engage the wire harness clamp to connect the No.3 engine wire to the clutch cable bracket.

    2. Install the No. 3 engine wire to the manual transaxle assembly with the bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

    3. C304064

      Install the wire harness bracket to the manual transaxle assembly with the 2 nuts.

    4. Connect the back-up light switch assembly connector.

  17. INSTALL SHIFT & SELECT LEVER BUSH

    1. C308683

      Install the shift and select lever bush to the manual transaxle assembly with the bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  18. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    1. Engage the 3 wire harness clamps to connect the wire harness to the battery clamp sub-assembly.

    2. C304060E01

      Install the 3 bolts.

      Bolt (A)

      7.4 N*m

      75 kgf*cm

      65 in.*lbf

      Bolt (B)

      17.2 N*m

      175 kgf*cm

      13 ft.*lbf

  19. INSTALL NO. 1 ENGINE ROOM RELAY BLOCK

    1. C304059E01

      Engage the claw to install the No. 1 engine room relay block to the battery clamp sub-assembly.

    2. Engage the wire harness clamp to connect the wire harness to the battery clamp sub-assembly.

    3. Install the 2 bolts.

      Bolt (A)

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

      Bolt (B)

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    4. Install the No. 1 engine room relay block cover.

  20. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. C304092C01

      *a

      Transmission Control Shift Cable

      *b

      Transmission Control Select Cable

      *c

      Turn

      Connect the transmission control select cable to the floor shift control lever housing support bracket.

      Note:

      Make sure that the transmission control select cable is securely installed.

    2. Rotate the lever to secure the transmission control select cable.

    3. Connect the transmission control shift cable to the floor shift control lever housing support bracket.

      Note:

      Make sure that the transmission control shift cable is securely installed.

    4. Rotate the lever to secure the transmission control shift cable.

    5. C304091C01

      *a

      Transmission Control Shift Cable

      *b

      Transmission Control Select Cable

      Connect the transmission control select cable to the manual transaxle assembly.

      Note:

      Make sure that the transmission control select cable is securely installed.

    6. Connect the transmission control shift cable to the manual transaxle assembly.

      Note:

      Make sure that the transmission control shift cable is securely installed.

  21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  22. INSTALL BATTERY

    Click here

  23. ADD MANUAL TRANSAXLE OIL

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  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When reconnecting the cable, some systems need to be initialized.

    Click hereClick here

  25. INSPECT FOR OIL LEAK

  26. INSPECT FOR EXHAUST GAS LEAK

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