Manual Transaxle Unit: Disassembly

REMOVE MANUAL TRANSMISSION FILLER PLUG
1. Remove the transmission filler plug and gasket from the transmission case.
  
  Fig 1: Removing Transmission Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRAIN PLUG SUB-ASSEMBLY
1. Remove the drain plug and gasket from the transmission case.
  
  Fig 2: Removing Drain Plug And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY
1. Remove the 2 bolts and clutch release cylinder.
REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
1. Remove the bolt and driven hole cover from the transaxle case.
2. Remove the O-ring from the driven hole cover.
  
  Fig 3: Removing Clutch Release Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
1. Remove the clutch release fork with clutch release bearing from the front transaxle case.
  
  Fig 4: Removing Clutch Release Fork With Clutch Release Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE BEARING ASSEMBLY
1. Remove the clutch release fork bearing hub clip and clutch release bearing from the clutch release fork.
  
  Fig 5: Removing Clutch Release Fork Bearing Hub Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RELEASE FORK SUPPORT
1. Remove the clutch release fork support from the front transaxle case.
  
  Fig 6: Removing Clutch Release Fork Support From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE FORK BOOT
1. Remove the clutch release fork boot from the front transaxle case.
  
  Fig 7: Removing Clutch Release Fork Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Using SST, remove the back-up light switch and gasket from the transmission case.
  SST 09817-16011
  
  Fig 8: Removing Back-Up Light Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
1. Remove the 3 bolts and floor shift control lever housing support bracket from the front transaxle case.
  
  Fig 9: Removing Floor Shift Control Lever Housing Support Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SELECTING BELLCRANK ASSEMBLY
1. Remove the 2 bolts and selecting bellcrank from the transmission case.
2. Remove the control shift lever bush.
  
  Fig 10: Removing Control Shift Lever Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX MANUAL TRANSAXLE ASSEMBLY
1. Place the transaxle on wooden blocks.
  
  Fig 11: Placing Transaxle On Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 LOCK BALL ASSEMBLY
1. Remove the lock ball from the transmission case.
  
  Fig 12: Removing Lock Ball From Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Remove the 4 bolts, lever shaft and gasket from the transmission case.
  
  Fig 13: Removing Lever Shaft And Gasket From Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
1. Remove the 9 bolts.
  
  Fig 14: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic-faced hammer, carefully tap the projection of the manual transmission case cover to remove it from the transmission case.
  NOTE: Do not damage the transmission case.
  
  Fig 15: Removing Manual Transmission Case Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION REAR OUTPUT SHAFT SET NUT
1. Using a chisel and hammer, loosen the staked part of the set nut.
  
  Fig 16: Loosening Staked Part Of Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 2 gears simultaneously to lock the transmission.
3. Remove the transmission output shaft rear set nut.
4. Disengage the 2 gears.
  
  Fig 17: Removing Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 GEAR SHIFT FORK
1. Remove the gear shift fork lock bolt from the No. 3 gear shift fork.
  
  Fig 18: Removing Gear Shift Fork Lock Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 3 transmission hub sleeve with No. 3 gear shift fork from the No. 3 transmission clutch hub.
  
  Fig 19: Removing No. 3 Transmission Hub Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 20: Measuring Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the thrust clearance.
  Standard clearance: 0.10 to 0.57 mm (0.0039 to 0.02244 in.)
  
  Maximum clearance: 0.57 mm (0.02244 in.)
  
  If the clearance is greater than the maximum, replace the 5th gear needle roller bearing or input shaft.
  
  Fig 21: Measuring 5th Gear Radial Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT 5TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the 5th gear radial clearance.

Standard clearance

STANDARD CLEARANCE

Item	Specified Condition
KOYO made	0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made	0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance

MAXIMUM CLEARANCE

Item	Specified Condition
KOYO made	0.058 mm (0.0023 in.)
NSK made	0.056 mm (0.0022 in.)

If the clearance is greater than the maximum, replace the gear, needle roller bearing or shaft.

REMOVE NO. 3 TRANSMISSION CLUTCH HUB
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  NOTE: Use a cloth to keep the snap ring from springing away.
  
  Fig 22: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the No. 3 transmission clutch hub, 5th gear and No. 3 synchronizer ring from the input shaft.
  SST 09950-40011 (09951-04020, 09952-04010,
  
  09953-04030, 09954-04010, 09955-04071,
  
  09957-04010), 09950-60010 (09951-00200)
  
  Fig 23: Removing No. 3 Transmission Clutch Hub, 5th Gear And No. 3 Synchronizer Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the No. 3 transmission clutch hub.
  
  Fig 24: Removing Synchromesh Shifting Keys
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH GEAR NEEDLE ROLLER BEARING
1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
  
  Fig 25: Removing 5th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH DRIVEN GEAR
1. Using SST, remove the 5th driven gear from the output shaft.
  SST 09950-30012 (09951-03010, 09953-03010,
  
  09954-03010, 09955-03011, 09957-04010),
  
  09950-60010 (09951-00190)
  
  Fig 26: Removing 5th Driven Gear From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR BEARING RETAINER
1. Remove the 5 bolts and bearing retainer from the manual transmission case.
  
  Fig 27: Removing Bearing Retainer From Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, remove the hole snap ring from the output shaft.
  
  Fig 28: Removing Snap Ring From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING
1. Using a snap ring expander, remove the hole snap ring from the input shaft.
  
  Fig 29: Removing Snap Ring From Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the shaft bolt and gasket from the transmission case.
  
  Fig 30: Removing Reverse Idler Gear Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 2 gear shift fork shaft.
  NOTE: Use a cloth to keep the snap ring from springing away.
  
  Fig 31: Tapping Out Snap Ring From No. 2 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT DETENT BALL
1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the transmission case.
  
  Fig 32: Removing Shift Detent Ball Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the 2 No. 1 shift detent ball spring seats, 2 shift detent ball springs and 2 shift detent balls from the transmission case.
  
  Fig 33: Removing No. 1 Shift Detent Ball Spring Seats
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.
  
  Fig 34: Removing Shift Detent Ball Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.
  
  Fig 35: Removing Seat, Spring And Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 LOCK BALL ASSEMBLY
1. Using a hexagon wrench, remove the No. 2 lock ball from the transmission case.
  
  Fig 36: Removing No. 2 Lock Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE
1. Remove the 3 bolts from the front transaxle case.
  
  Fig 37: Removing Bolts From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the transmission case.
  
  Fig 38: Removing Bolts From Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and hammer, carefully tap the projection of the transmission case to remove it from the transaxle case.
  NOTE: Do not damage the transmission case and transaxle case.
  
  Fig 39: Removing Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
1. Remove the reverse idler gear, thrust washer and reverse idler gear shaft from the front transaxle case.
  
  Fig 40: Removing Reverse Idler Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Remove the 2 bolts and reverse shift arm bracket from the front transaxle case.
  
  Fig 41: Removing Reverse Shift Arm Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 GEAR SHIFT FORK SHAFT
1. Remove the 2 bolts from the No. 2 gear shift fork and No. 1 gear shift head.
  
  Fig 42: Removing 2 Bolts From No. 2 Gear Shift Fork And No. 1 Gear Shift Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the front transaxle case.
  
  Fig 43: Removing No. 2 Gear Shift Fork Shaft And No. 1 Gear Shift Head
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 GEAR SHIFT FORK SHAFT
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  NOTE: Use a cloth to keep the snap ring from springing away.
  
  Fig 44: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift fork set bolt and No. 1 gear shift fork shaft from the No. 1 gear shift fork.
  
  Fig 45: Removing Shift Fork Set Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 1 gear shift fork.
  
  Fig 46: Removing No. 1 Gear Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 GEAR SHIFT FORK SHAFT
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 gear shift fork shaft.
  NOTE: Use a cloth to keep the snap ring from springing away.
  
  Fig 47: Removing Snap Ring From No. 3 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 3 gear shift fork shaft with reverse shift fork and No. 2 gear shift fork from the transaxle case.
  
  Fig 48: Removing No. 3 Gear Shift Fork Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.
  
  Fig 49: Removing Reverse Shift Fork Balls
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using 2 screwdrivers and a hammer, tap out the snap ring from the No. 3 shift fork shaft.
  NOTE: Use a cloth to keep the snap ring from springing away.
5. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
  
  Fig 50: Removing Reverse Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSEMBLY
1. Remove the input shaft and output shaft from the front transaxle case.
  
  Fig 51: Removing Input Shaft And Output Shaft From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL CASE ASSEMBLY
1. Remove the differential case from the front transaxle case.
  
  Fig 52: Removing Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSAXLE CASE RECEIVER
1. Remove the bolt and transaxle case receiver from the front transaxle case.
  
  Fig 53: Removing Bolt And Transaxle Case Receiver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE RESTRICT PIN ASSEMBLY
1. Using a hexagon wrench, remove the reverse restrict pin plug from the transmission case.
  
  Fig 54: Removing Reverse Restrict Pin Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 5 mm pin punch and hammer, tap out the slotted spring pin and remove the reverse restrict pin from the transmission case.
  
  Fig 55: Removing Reverse Restrict Pin From Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 OIL RECEIVER PIPE
1. Remove the bolt and No. 1 oil receiver pipe from the transmission case.
  NOTE: Be careful not to damage the No. 1 oil receiver pipe.
  
  Fig 56: Removing No. 1 Oil Receiver Pipe From Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 OIL RECEIVER PIPE
1. Remove the bolt and No. 2 oil receiver pipe from the transmission case.
  NOTE: Be careful not to damage the No. 2 oil receiver pipe.
  
  Fig 57: Removing Bolt And No. 2 Oil Receiver Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING LOCK PLATE
1. Remove the bolt and bearing lock plate from the front transaxle case.
  
  Fig 58: Removing Bearing Lock Plate From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the front transaxle case.
  
  Fig 59: Removing Transmission Magnet From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING
1. Using SST, remove the front bearing from the front transaxle case.
  SST 09612-65014 (09612-01050, 09612-01060)
  
  Fig 60: Removing Front Bearing From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, pry out the front transaxle case oil seal from the transaxle case.
  
  Fig 61: Prying Out Front Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the front bearing from the front transaxle case.
  SST 09308-00010
  
  NOTE: Do not apply excessive force to the front transaxle case when installing it.
  
  Fig 62: Removing Front Bearing From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT COVER
1. Remove the output shaft cover from the front transaxle case.
  
  Fig 63: Removing Output Shaft Cover From Front Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing (outer race) and plate washer from the front transaxle case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 64: Removing Front Differential Case Front Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.
  SST 09950-00020, 09950-00030, 09950-40011
  
  (09957-04010), 09950-60010 (09951-00360)
  
  NOTE: Be careful not to damage the bearing.
  
  Fig 65: Removing Front Differential Case Front Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, tap out the transaxle case oil seal from the front transaxle case.
  SST 09950-60010 (09951-00530), 09950-70010
  
  (09951-07150)
  
  Fig 66: Tapping Out Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the rear tapered roller bearing (outer race) and plate washer from the transmission case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 67: Removing Rear Tapered Roller Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rear tapered roller bearing (inner race) from the front differential case.
  SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
  
  NOTE: Be careful not to damage the bearing.
  
  Fig 68: Removing Rear Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, tap out the transmission case oil seal from the transmission case.
  SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
  
  Fig 69: Tapping Out Transmission Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT BIMETAL FORMED BUSH
1. Using SST, remove the bush.
  SST 09319-60020
  
  Fig 70: Removing Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002