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 SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

    1. C194489

      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 transaxle case with the bolt.

      11 N*m

      115 kgf*cm

      8 ft.*lbf

  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 FLEXIBLE HOSE BRACKET

    1. C201660

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

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  7. INSTALL CLUTCH RELEASE BLEEDER TO FLEXIBLE HOSE TUBE

    C199298

    1. Using a union nut wrench, install the clutch release bleeder to flexible hose tube to the clutch release bleeder sub-assembly.

      15 N*m

      155 kgf*cm

      11 ft.*lbf

      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

    2. Install the clamp to the manual transaxle assembly with the bolt.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  8. INSTALL REAR ENGINE MOUNTING BRACKET

    1. C210233

      Install the rear engine mounting bracket with the 4 bolts.

      45 N*m

      459 kgf*cm

      33 ft.*lbf

  9. INSTALL ENGINE MOUNTING BRACKET LH

    1. C197751

      Apply adhesive to the 4 bolts.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the engine mounting bracket LH with the 4 bolts.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  10. INSTALL FRONT ENGINE MOUNTING BRACKET

    1. C197750

      Install the front engine mounting bracket with the 4 bolts.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  11. INSTALL MANUAL TRANSAXLE ASSEMBLY

    1. C208258

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

      Note:

      • Make sure that the dowel 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.

      • Insert the dowel pins into the dowel holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.

    2. C197747

      Install the 7 bolts.

      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

    3. C207455

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

      13 N*m

      130 kgf*cm

      9 ft.*lbf

    4. C197746

      Connect the back-up light switch connector and install the wire harness to the manual transaxle assembly with the bolt.

      13 N*m

      130 kgf*cm

      9 ft.*lbf

  12. INSTALL ENGINE WIRE

    1. C197745

      Install the engine wire with the 2 bolts.

      13 N*m

      130 kgf*cm

      9 ft.*lbf

  13. INSTALL STARTER ASSEMBLY

    1. Install the starter assembly (Click here).

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    1. Install the engine assembly with transaxle (Click here).