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 manual transaxle assembly 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 2 wire harness clamp brackets to the manual transaxle assembly with the 2 bolts.

      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 FLEXIBLE HOSE BRACKET

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

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  8. INSTALL BLEEDER CLUTCH RELEASE TUBE

    Click here

  9. 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

  10. 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

  11. 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

  12. INSTALL MANUAL TRANSAXLE ASSEMBLY

    1. C200898

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

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

    3. C191597N01

      Install the 8 bolts.

      Bolt (A)

      64 N*m

      653 kgf*cm

      47 ft.*lbf

      Bolt (B)

      39 N*m

      398 kgf*cm

      29 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.

  13. CONNECT WIRE HARNESS

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

    2. Connect the 2 clamps to the manual transaxle assembly.

  14. INSTALL STARTER ASSEMBLY

    Click here

  15. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR

    Click here

  16. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

    Click here

  17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here