MULTI-MODE MANUAL TRANSAXLE UNIT DISASSEMBLY

CAUTION / NOTICE / HINT

Note:

When replacing any tapered roller bearing outer race, replace both the tapered roller bearing and tapered roller bearing outer race with new ones.

PROCEDURE

  1. REMOVE CLUTCH RELEASE BEARING ASSEMBLY

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  2. REMOVE CLUTCH RELEASE FORK LEVER

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  3. REMOVE CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

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  4. REMOVE NO. 1 CLUTCH HOUSING COVER

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  5. INSPECT NEUTRAL POSITION

    1. C304357

      Remove the plug from the shift and select actuator assembly.

    2. Look through the plug and check that the slit of the shift and select actuator assembly is in the position shown in the illustration.

      C304358C01

      *a

      Shift Slit Position

      *b

      N

      *c

      2nd, 4th or R

      *d

      1st, 3rd or 5th

      If not, turn it with a screwdriver.

      Note:

      Make sure that the slit is in position *b and not in position *c or *d shown in the illustration when removing the shift and select actuator assembly, otherwise the shift and select actuator assembly, No. 1 gear shift head, No. 2 gear shift fork shaft or No. 3 gear shift head may be deformed.

    3. Clean and degrease the plug and installation hole in the shift and select actuator assembly.

    4. C303558C01

      *a

      Adhesive

      Apply adhesive to the plug threads.

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note:

      In order to ensure proper installation of the plug, apply adhesive to the plug and install it within 10 minutes of adhesive application.

    5. C304357

      Install the plug to the shift and select actuator assembly.

      40.2 N*m

      410 kgf*cm

      30 ft.*lbf

  6. REMOVE MANUAL TRANSAXLE CASE PLUG

    1. F100310

      Remove the manual transaxle case plug and gasket from the front transaxle case.

  7. REMOVE DRAIN PLUG

    1. C304366

      Remove the drain plug and gasket from the manual transmission case.

  8. REMOVE FILLER PLUG

    1. C304364

      Remove the filler plug and gasket from the manual transmission case.

  9. REMOVE NO. 1 LOCK BALL ASSEMBLY

    1. C112762

      Using a 18 mm socket wrench, remove the No. 1 lock ball assembly from the manual transmission case.

  10. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    1. C114061N01

      Using SST, remove the park/neutral position switch assembly and gasket from the manual transmission case.

      09817-16011

  11. REMOVE SHIFT AND SELECT ACTUATOR ASSEMBLY

    1. C303569

      Remove the 6 bolts, 2 wire harness clamp brackets and shift and select actuator assembly from the manual transmission case.

  12. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

    1. C112765N01

      Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.

      09817-16011

  13. REMOVE TRANSMISSION REVOLUTION SENSOR

    1. C303549

      Remove the bolt and transmission case protector from the manual transmission case.

    2. C303550

      Remove the bolt and transmission revolution sensor from the manual transmission case.

  14. REMOVE REVERSE IDLER GEAR SHAFT BOLT

    1. C112767

      Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.

  15. REMOVE MANUAL TRANSMISSION CASE

    1. F100320

      Remove the 5 bolts from the front transaxle case side.

    2. F100319

      Remove the 8 bolts from the manual transmission case side.

    3. Using a plastic hammer, remove the manual transmission case from the front transaxle case.

  16. REMOVE REVERSE IDLER GEAR SHAFT

    1. G020851

      Remove the reverse idler gear shaft from the front transaxle case.

  17. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY

    1. C303228

      Remove the reverse idler gear sub-assembly from the front transaxle case.

  18. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

    1. C112777

      Remove the 2 bolts and reverse shift arm bracket assembly from the front transaxle case.

  19. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

    1. C112771

      Remove the bolt from the No. 1 gear shift fork.

    2. G020854

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 1 gear shift head.

    3. G020855

      Remove the No. 1 gear shift fork shaft, No. 1 gear shift head and No. 1 gear shift fork from the front transaxle case.

    4. G020856

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 1 gear shift fork shaft.

      Tip:

      Use a piece of cloth to keep the snap ring from flying off.

  20. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

    1. C303209

      Using a Magnet Hand, remove the straight pin from the No. 3 gear shift fork.

    2. G020858

      Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 3 gear shift head.

    3. G020859

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 3 gear shift fork shaft.

      Tip:

      Use a piece of cloth to keep the snap ring from flying off.

    4. G020860C03

      *1

      No. 3 Gear Shift Fork Shaft

      *2

      Compression Spring

      *3

      No. 3 Gear Shift Head

      *4

      No. 3 Gear Shift Fork

      Remove the No. 3 gear shift fork shaft, compression spring, No. 3 gear shift head and No. 3 gear shift fork from the front transaxle case.

    5. G020861

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 3 gear shift fork shaft.

      Tip:

      Use a piece of cloth to keep the snap ring from flying off.

  21. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

    1. C112778

      Using a Magnet Hand, remove the straight pin from the reverse shift fork.

    2. G020862

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 2 gear shift fork shaft.

      Tip:

      Use a piece of cloth to keep the snap ring from flying off.

    3. G020913

      Remove the bolt from the No. 2 gear shift fork.

    4. G020914

      Shift the No. 2 transmission hub sleeve to the 4th gear position.

    5. C303232C01

      *1

      No. 2 Gear Shift Fork Shaft

      *2

      No. 2 Gear Shift Fork

      *3

      Reverse Shift Fork

      Remove the No. 2 gear shift fork shaft, No. 2 gear shift fork and reverse shift fork from the front transaxle case.

    6. G020915

      Using 2 screwdrivers and a hammer, remove the snap ring from the No. 2 gear shift fork shaft.

      Tip:

      Use a piece of cloth to keep the snap ring from flying off.

  22. REMOVE INPUT SHAFT ASSEMBLY

    1. G020916

      Remove the input shaft assembly from the front transaxle case.

  23. REMOVE OUTPUT SHAFT ASSEMBLY

    1. Remove the output shaft assembly from the front transaxle case.

  24. REMOVE FRONT DIFFERENTIAL CASE

    1. G021163

      Remove the front differential case from the front transaxle case.

  25. REMOVE TRANSMISSION MAGNET

    1. G021178

      Remove the transmission magnet from the front transaxle case.

  26. REMOVE FRONT TRANSAXLE CASE OIL SEAL

    1. G020921C03

      *a

      Protective Tape

      Using a screwdriver, remove the front transaxle case oil seal from the front transaxle case.

      Note:

      Be careful not to damage the installation surfaces of the front transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  27. REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE)

    1. G020922N02

      Using SST, remove the front output shaft bearing (outer race) from the front transaxle case.

      09308-00010

      Note:

      Do not damage or deform the front output shaft bearing (outer race) (when reusing the front output shaft bearing (outer race)).

  28. REMOVE OUTPUT SHAFT (MTM) COVER

    1. G020987

      Remove the output shaft (MTM) cover from the front transaxle case.

  29. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)

    1. C230554N04

      Using SST, remove the front differential case front tapered roller bearing (outer race) from the front transaxle case.

      09308-00010

      Note:

      Do not damage or deform the front differential case front tapered roller bearing (outer race) (when reusing the front differential case front tapered roller bearing (outer race)).

  30. REMOVE FRONT DRIVE SHAFT OIL SEAL RH

    1. C230553N02

      Using SST, remove the front drive shaft oil seal RH from the front transaxle case.

      09308-00010

      Note:

      Be careful not to damage the installation surface of the front drive shaft oil seal RH on the front transaxle case.

  31. REMOVE NO. 2 OIL RECEIVER PIPE (MTM)

    1. C230550

      Remove the No. 2 oil receiver pipe (MTM) from the manual transmission case.

      Note:

      Do not damage the No. 2 oil receiver pipe (MTM).

  32. REMOVE REAR INPUT SHAFT BEARING SHIM

    1. G020992

      Remove the rear input shaft bearing shim from the manual transmission case.

  33. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)

    1. C303210C02

      *a

      Turn

      *b

      Hold

      Using SST, remove the rear output shaft bearing (outer race) from the manual transmission case.

      09527-30010

      09612-65014

      09612-01030

      09612-01050

      Note:

      Do not damage or deform the rear output shaft bearing (outer race) (when reusing the rear output shaft bearing (outer race)).

  34. REMOVE REAR OUTPUT SHAFT BEARING SHIM

    1. G020994

      Remove the rear output shaft bearing shim from the manual transmission case.

  35. REMOVE FRONT DRIVE SHAFT OIL SEAL LH

    1. C230551N03

      Using SST, remove the front drive shaft oil seal LH from the manual transmission case.

      09308-00010

      Note:

      Be careful not to damage the installation surface of the front drive shaft oil seal LH on the manual transmission case.

  36. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)

    1. G020989N02

      Using SST, remove the front differential case rear tapered roller bearing (outer race) and differential case shim from the manual transmission case.

      09950-60010

      09951-00620

      09950-70010

      09951-07200

      Note:

      Do not damage or deform the front differential case rear tapered roller bearing (outer race) (when reusing the front differential case rear tapered roller bearing (outer race)).