MANUAL TRANSAXLE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note:

When the manual transaxle assembly 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. Dust from the moving section may damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.

PROCEDURE

  1. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

    1. 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 manual transaxle assembly with the bolt.

      11.3 N*m

      115 kgf*cm

      8 ft.*lbf

  2. INSTALL WIRE HARNESS CLAMP BRACKET

    1. Install the wire harness clamp bracket to the manual transaxle assembly with the bolt.

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

  3. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  4. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  5. INSPECT CLUTCH PIPE LINE

    Click here

  6. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  7. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

    Click here

  8. INSTALL REAR ENGINE MOUNTING BRACKET

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

      45 N*m

      459 kgf*cm

      33 ft.*lbf

  9. INSTALL ENGINE MOUNTING BRACKET LH

    1. Clean the bolts and installation holes in the engine mounting bracket LH.

    2. P000601C21

      *a

      Adhesive

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

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note:

      In order to ensure proper installation of the 4 bolts, apply adhesive to the 4 bolts and install them within 10 minutes of adhesive application.

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

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  10. INSTALL FRONT ENGINE MOUNTING BRACKET

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

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  11. INSTALL MANUAL TRANSAXLE ASSEMBLY

    1. C202942

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

    2. C278310N01

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

    3. Install the 8 bolts.

      Bolt (A) for Flange Bolt

      37 N*m

      377 kgf*cm

      27 ft.*lbf

      Bolt (A) for Bolt with Washer

      33 N*m

      337 kgf*cm

      24 ft.*lbf

      Bolt (B)

      37 N*m

      377 kgf*cm

      27 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 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.

  12. CONNECT WIRE HARNESS (w/ Stop And Start System)

    1. Connect the wire harness to the manual transaxle assembly with the nut and bolt.

      Nut

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

      Bolt

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

    2. Connect the park/neutral position switch assembly connector.

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

    4. Engage the 5 clamps.

  13. CONNECT WIRE HARNESS (w/o Stop And Start System)

    1. Connect the wire harness to the manual transaxle assembly with the nut and bolt.

      Nut

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

      Bolt

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

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

    3. Engage the 3 clamps.

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

    Click here

  15. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  16. INSTALL NO. 1 AIR TUBE

    1. C279690C01

      *a

      Hose Clamp

      Install the No. 1 air tube and tighten the hose clamp.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

    2. Install the 4 bolts.

      Bolt (A)

      20 N*m

      204 kgf*cm

      15 ft.*lbf

      Bolt (B)

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

      Bolt (C)

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    3. Connect the 2 wire harness clamps to the manual transaxle assembly.

  17. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR

    Click here

  18. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

    Click here

  19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here