MANUAL TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE

  1. INSTALL MANUAL TRANSAXLE ASSEMBLY

    1. C303177

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

    2. C259604C01
      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. C303171N01

      Install the 5 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 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.

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

    5. Install the 4 bolts.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  2. INSTALL ENGINE MOUNTING BRACKET LH

    1. C303169C01

      *a

      Temporarily Install

      Install the engine mounting bracket LH to the manual transaxle assembly with the 4 bolts in the order shown in the illustration.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

  3. INSTALL ENGINE MOUNTING INSULATOR LH

    1. C303167C01

      *a

      Temporarily Install

      Install the engine mounting insulator LH with the 3 bolts in the order shown in the illustration.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

    2. C303166C01

      *a

      Temporarily Install

      Install the 3 bolts to the engine mounting bracket LH in the order shown in the illustration.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

  4. INSTALL ENGINE MOVING CONTROL ROD BRACKET

    1. Temporarily install the engine moving control rod bracket to the manual transaxle assembly with the 3 bolts.

    2. C303306N01

      Fully tighten the 3 bolts in the order shown in the illustration.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

  5. INSTALL FAN SHROUD ASSEMBLY

    Click here

  6. CONNECT NO. 2 RADIATOR HOSE

    Click here

  7. INSTALL ENGINE MOVING CONTROL ROD

    1. C304362N01

      Install the engine moving control rod to the front suspension crossmember sub-assembly with the 2 bolts.

      Bolt (A)

      110 N*m

      1122 kgf*cm

      81 ft.*lbf

      Bolt (B)

      120 N*m

      1224 kgf*cm

      89 ft.*lbf

  8. INSTALL NO. 1 DRIVE SHAFT HEAT INSULATOR

    Click here

  9. INSTALL WIRE HARNESS CLAMP BRACKET

    1. C303164N01

      Install the 4 wire harness clamp brackets to the manual transaxle assembly with the 4 bolts.

      Bolt (A)

      12.8 N*m

      131 kgf*cm

      9 ft.*lbf

      Bolt (B)

      25.5 N*m

      260 kgf*cm

      19 ft.*lbf

      Bolt (C)

      29 N*m

      296 kgf*cm

      21 ft.*lbf

  10. CONNECT NO. 3 ENGINE WIRE

    1. Connect the No. 3 engine wire to the manual transaxle assembly with the bolt.

      12.8 N*m

      131 kgf*cm

      9 ft.*lbf

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

  11. CONNECT ENGINE WIRE

    1. Engage the 3 clamps to connect the engine wire to the manual transaxle assembly.

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

  12. INSTALL STARTER ASSEMBLY

    Click here

  13. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  14. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  15. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  16. CONNECT CLUTCH RELEASE CABLE ASSEMBLY

    1. C305933

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

    2. C303640C01
      V100135

      Lithium Soap Base Glycol Grease

      Apply lithium soap base glycol grease to the clevis of the clutch release fork lever.

    3. C303642C01

      *1

      Clutch Release Fork Lever

      *a

      Push

      *b

      Turn

      While pushing the clutch release fork lever, adjust the clutch release cable end clamp.

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

    5. Depress the clutch pedal a few times to ensure the clutch release cable assembly works smoothly.

      Note:

      Depress the clutch pedal 50 times or more when replacing the clutch release cable assembly with a new one.

  17. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. C299039N01

      Connect the transmission control select cable to the floor shift control lever housing support bracket with a new clip (B).

    2. Connect the transmission control select cable to the manual transaxle assembly with the clip (A).

    3. C299038N01

      Connect the transmission control shift cable to the floor shift control lever housing support bracket with a new clip (B).

    4. Connect the transmission control shift cable to the manual transaxle assembly with the clip (A).

    5. Engage the clamp to connect the engine wire to the wire harness clamp bracket.

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

    Click here

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

    Click here

  20. INSTALL SHIFT LEVER DAMPER

    1. Install the shift lever damper to the shift and select lever shaft with the 2 nuts.

      15 N*m

      153 kgf*cm

      11 ft.*lbf

  21. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  22. INSTALL BATTERY

    Click here

  23. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  24. ADD MANUAL TRANSAXLE OIL

    Click here

  25. ADD ENGINE COOLANT

    Click here

  26. INSPECT MANUAL TRANSAXLE OIL

    Click here

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click here

  28. INSPECT FOR OIL LEAK

  29. INSPECT FOR EXHAUST GAS LEAK

  30. INSPECT FOR COOLANT LEAK

    Click here

  31. INSTALL FRONT FENDER LINER LH

    1. C302674C01
      V100135

      Bolt
      V100136

      Screw

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