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Manual Transaxle Unit: Disassembly: Disassembly

  1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
    1. Remove the bolt and hole cover.
    2. Remove the O-ring from the hole cover.
  2. REMOVE SELECTING BELLCRANK ASSEMBLY 
    Fig 1: Identifying Selecting Bellcrank Assembly Bolts
    GTY159061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 bolts and selecting bellcrank from the transaxle case.
    2. Remove the shift and select lever bush from the selecting bellcrank.
  3. REMOVE CONTROL SHIFT LEVER 
    Fig 2: Identifying Control Shift Lever Nut
    GTY163769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the nut and spring washer.
    2. Using a brass bar and hammer, tap out the shift outer lever lock pin.
      Fig 3: Removing Shift Outer Lever Lock Pin
      GTY159063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the control shift lever.
  4. REMOVE CONTROL SHAFT COVER 
    Fig 4: Identifying Control Shaft Cover Bolts
    GTY159064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 4 bolts, control shift cover and gasket from the transaxle case.
  5. FIX MANUAL TRANSAXLE ASSEMBLY 
    Fig 5: Placing Transaxle On Wooden Blocks
    GTY159129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the transaxle on wooden blocks.
  6. REMOVE NO. 1 LOCK BALL ASSEMBLY 
    Fig 6: Identifying Transaxle Case Lock Ball
    GTY159130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the lock ball from the transaxle case.
  7. REMOVE SHIFT GATE PIN 
    Fig 7: Identifying Shift Gate Pin
    GTY158189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the shift gate pin and gasket.
  8. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    Fig 8: Identifying Shift And Select Lever Shaft Assembly
    GTY158705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the shift and select lever shaft from the transaxle case.
  9. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY 
    Fig 9: Identifying Back-Up Light Switch
    GTY159131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the back-up light switch and gasket from the transaxle case.
  10. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    Fig 10: Identifying Transaxle Filler Plug
    GTY159294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the filler plug and gasket from the transaxle case.
  11. REMOVE DRAIN PLUG SUB-ASSEMBLY 
    Fig 11: Identifying Transaxle Drain Plug
    GTY165401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the drain plug and gasket from the transaxle case.
  12. REMOVE MANUAL TRANSAXLE CASE COVER SUB-ASSEMBLY 
    Fig 12: Identifying Transaxle Case Cover Bolts
    GTY158053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 10 bolts and transaxle case cover from the transaxle case.
  13. REMOVE REAR MANUAL TRANSAXLE OUTPUT SHAFT SET NUT 
    Fig 13: Engaging Gears Simultaneously To Lock Transaxle
    GTY159307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Engage the 2 gears simultaneously to lock the transaxle.
    2. Using SST and a hammer, unstake the rear set nut.
      • SST: 09930-00010 
      Fig 14: Unstaking Rear Set Nut Using SST
      GTY166650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the shaft rear set nut from the output shaft.
      • SST: 09229-55010 
      Fig 15: Removing Shaft Rear Set Nut Using SST
      GTY159134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 gears.
  14. INSPECT 5TH GEAR THRUST CLEARANCE 
    Fig 16: Measuring Thrust Clearance
    GTY166684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the thrust clearance.

      Standard clearance

      0.10 to 0.65 mm (0.0039 to 0.0256 in.)

      If the clearance is out of the specification, replace the No. 3 transaxle clutch hub, 5th gear or input shaft rear radial ball bearing.

  15. INSPECT 5TH GEAR RADIAL CLEARANCE 
    Fig 17: Measuring Radial Clearance
    GTY163490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the radial clearance.

      Standard clearance

      0.009 to 0.050 mm (0.0004 to 0.0020 in.)

      If the clearance is out of the specification, replace the 5th gear, 5th gear needle roller bearing or input shaft.

  16. REMOVE NO. 3 TRANSAXLE CLUTCH HUB 
    Fig 18: Removing No 3 Transaxle Clutch Hub Shaft Snap Ring From Input Shaft
    GTY159308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using 2 screwdrivers and a hammer, tap out the No. 3 transaxle clutch hub shaft snap ring from the input shaft.

      HINT: 

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

    2. Remove the shift fork set bolt from the No. 3 gear shift fork.
      Fig 19: Identifying Shift Fork Set Bolt
      GTY159309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the No. 3 transaxle clutch hub, No. 3 transaxle hub sleeve and No. 3 gear shift fork from the input shaft.
      Fig 20: Removing No 3 Transaxle Clutch Hub, Sleeve And Shift Fork Using SST
      GTY159276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-30012 
        • 09951-03010
        • 09953-03010
        • 09954-03010
      • SST: 09950-50013 
        • 09957-04010
      • SST: 09950-60010 
        • 09951-00280
  17. REMOVE 5TH GEAR 
    Fig 21: Identifying 5th Gear
    GTY159310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 5th gear from the input shaft.
  18. REMOVE 5TH GEAR NEEDLE ROLLER BEARING 
    Fig 22: Identifying Needle Roller Bearing
    GTY162551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the needle roller bearing from the input shaft.
  19. REMOVE 5TH DRIVEN GEAR 
    Fig 23: Removing 5th Driven Gear From Output Shaft Using SST
    GTY159312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the 5th driven gear from the output shaft.
      • SST: 09950-30012 
        • 09951-03010
        • 09953-03010
        • 09954-03010
        • 09957-04010
      • SST: 09950-60010 
        • 09951-00180
        • 09955-03011
      • SST: 09950-50013 
  20. REMOVE REAR BEARING RETAINER 
    Fig 24: Identifying Rear Bearing Retainer Screws
    GTY159313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a T45 "TORX" socket, remove the 7 "TORX" screws and bearing retainer from the transaxle case.
  21. REMOVE OUTPUT SHAFT REAR BEARING SHIM 
    Fig 25: Identifying Output Shaft Rear Bearing Shim
    GTY159314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the rear bearing shim from the output shaft.
  22. REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING 
    Fig 26: Removing Input Shaft Snap Ring
    GTY159135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a snap ring expander, remove the shaft snap ring from the input shaft.
  23. REMOVE SHIFT FORK SHAFT SNAP RING 
    Fig 27: Removing No. 1 Gear Shift Fork Shaft Snap Ring
    GTY159136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using 2 screwdrivers and a hammer, tap out the shaft snap ring from the No. 1 gear shift fork shaft.

      HINT: 

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

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

      HINT: 

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

      Fig 28: Removing No. 2 Gear Shift Fork Shaft Snap Ring
      GTY159315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    Fig 29: Identifying Reverse Idler Gear Shaft Bolt
    GTY159190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the reverse idler gear shaft bolt and gasket.
  25. REMOVE CLUTCH TUBE BRACKET 
    1. Remove the bolt and clutch tube bracket.
  26. REMOVE MANUAL TRANSMISSION CASE 
    Fig 30: Identifying Transaxle Case Side Bolts (1 Of 2)
    GTY166890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts from the transaxle case side.
    2. Remove the 14 bolts from the transaxle case side.
      Fig 31: Identifying Transaxle Case Side Bolts (2 Of 2)
      GTY163215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the transaxle case by tapping it using a plastic-faced hammer.
  27. REMOVE NO. 2 OIL RECEIVER PIPE 
    Fig 32: Identifying No. 2 Oil Receiver Pipe Bolt
    GTY164709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and oil receiver pipe from the transaxle case.
      NOTE:

      Do not damage the pipe.

  28. REMOVE NO. 1 OIL RECEIVER PIPE 
    Fig 33: Identifying No. 1 Oil Receiver Pipe Bolt
    GTY164427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and oil receiver pipe from the transaxle case.
      NOTE:

      Do not damage the pipe.

  29. REMOVE REVERSE RESTRICT PIN ASSEMBLY 
    Fig 34: Identifying Reverse Restrict Pin Plug
    GTY159290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 6 mm hexagon wrench, remove the restrict pin plug from the transaxle case.
    2. Using a 5 mm pin punch and hammer, tap out the slotted pin.
      Fig 35: Removing Slotted Pin
      GTY166546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Fig 36: Identifying Reverse Restrict Pin Bolt
      GTY158694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, transmission oil baffle and reverse restrict pin.
  30. REMOVE TRANSAXLE MAGNET 
    Fig 37: Identifying Transaxle Magnet
    GTY165772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the magnet from the transaxle case.
  31. REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY 
    Fig 38: Identifying Reverse Idler Gear Sub-Assembly
    GTY159317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the reverse idler gear with the reverse idler gear shaft from the transaxle case.
    2. Remove the reverse idler gear and reverse idler thrust washer from the gear shaft.
      Fig 39: Exploded View Of Reverse Idler Gear Sub-Assembly
      GTY159287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY 
    Fig 40: Identifying Reverse Shift Arm Bracket Bolts
    GTY166401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 bolts and arm bracket from the transaxle case.
  33. REMOVE NO. 1 GEAR SHIFT FORK SHAFT 
    Fig 41: Identifying No. 1 Gear Shift Fork Set Bolt
    GTY164348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the shift fork set bolt from the No. 1 gear shift fork.
    2. Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shift is pulled up.
      Fig 42: Removing No. 1 Gear Shift Fork Shaft
      GTY163968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring from the No. 1 gear shift fork shaft.

      HINT: 

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

      Fig 43: Removing No. 1 Gear Shift Fork Shaft Snap Ring
      GTY159320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE REVERSE SHIFT FORK ROLLER 
    Fig 44: Removing Reverse Shift Fork Roller
    GTY159101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
  35. REMOVE NO. 2 GEAR SHIFT FORK SHAFT 
    Fig 45: Identifying No. 2 Gear Shift Fork Shaft Bolts
    GTY162909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.
    2. Remove the No. 2 gear shift fork shaft head and No. 1 gear shift head from the transaxle case.
      Fig 46: Identifying No. 2 Shift Fork Shaft And No. 1 Shift Head
      GTY159137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO. 1 GEAR SHIFT FORK 
    Fig 47: Identifying No. 1 Gear Shift Fork
    GTY159138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 1 gear shift fork from the output shaft.
  37. REMOVE NO. 3 GEAR SHIFT FORK SHAFT 
    Fig 48: Identifying No. 3 Shift Fork Shaft
    GTY166081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 3 gear shift fork shaft from the transaxle case.
    2. Using 2 screwdrivers and a hammer, tap out the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.

      HINT: 

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

      Fig 49: Removing No. 3 Gear Shift Fork Shaft Snap Rings
      GTY163681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
  38. REMOVE NO. 2 GEAR SHIFT FORK 
    Fig 50: Identifying No. 2 Shift Fork
    GTY162513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 2 gear shift fork from the input shaft.
  39. REMOVE INPUT SHAFT ASSEMBLY 
    Fig 51: Removing Input Shaft Assembly
    GTY164938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Tilt the output shaft, then remove the input shaft from the transaxle case.
  40. REMOVE OUTPUT SHAFT ASSEMBLY 
    Fig 52: Removing Output Shaft Assembly
    GTY159105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Slightly lift up on the differential case with the output shaft at an angle.
    2. Remove the output shaft from the transaxle case.
  41. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    Fig 53: Identifying Differential Assembly
    GTY165795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the differential case from the transaxle case.
  42. REMOVE MANUAL TRANSAXLE CASE RECEIVER 
    Fig 54: Identifying Transaxle Case Receiver Bolts
    GTY162251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and receiver from the transaxle case.
  43. REMOVE INPUT SHAFT FRONT BEARING 
    Fig 55: Removing Input Shaft Front Bearing Outer Race Using SST
    GTY159139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the input shaft front bearing (outer race) from the transaxle case.
      • SST: 09612-65014 
        • 09612-01040
        • 09612-01050
  44. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    Fig 56: Removing Front Transaxle Case Oil Seal Using SST
    GTY159140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the oil seal from the transaxle case.
      • SST: 09612-65014 
        • 09612-01040
        • 09612-01050
  45. REMOVE OUTPUT SHAFT FRONT BEARING 
    Fig 57: Removing Output Shaft Front Bearing Outer Race Using SST
    GTY166984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the front bearing (outer race) from the transaxle case.
      • SST: 09387-00041 
        • 09387-02020
        • 09387-02010
  46. REMOVE OUTPUT SHAFT COVER 
    Fig 58: Removing Output Shaft Cover
    GTY159318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the output shaft cover from the transaxle case.
  47. REMOVE OUTPUT SHAFT REAR BEARING 
    Fig 59: Removing Output Shaft Rear Bearing Outer Race Using SST
    GTY159141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, tap out the rear bearing from the transaxle case (outer race).
      • SST: 09950-60010 
        • 09951-00680
      • SST: 09950-70010 
        • 09951-07100
  48. REMOVE TRANSMISSION CASE OIL SEAL 
    Fig 60: Removing Transaxle Case Oil Seal Using SST
    GTY159142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, tap out the oil seal from the transaxle case.
      • SST: 09308-00010 
  49. REMOVE TRANSAXLE CASE OIL SEAL 
    Fig 61: Removing Cover Oil Seal
    GTY163676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, pry out the cover oil seal.

      HINT: 

      Tape the screwdriver tip before use to avoid damage.

  50. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    Fig 62: Removing Front Tapered Roller Bearing Outer Race
    GTY159319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a brass bar and hammer, tap out the front tapered roller bearing (outer race) from the transaxle case.
    2. Using SST, remove the case front tapered roller bearing from the front differential case.
      Fig 63: Removing Front Tapered Roller Bearing Using SST
      GTY159292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        • 09957-04010
      • SST: 09950-60010 
        • 09951-00560
  51. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    Fig 64: Removing Rear Tapered Roller Bearing Outer Race Using SST
    GTY159143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, tap out the rear tapered roller bearing (outer race) and rear shim from the transaxle case.
      • SST: 09950-60020 
        • 09951-00790
      • SST: 09950-70010 
        • 09951-07100
    2. Using SST, remove the rear tapered roller bearing (inner race) from the front differential case.
      Fig 65: Removing Rear Tapered Roller Bearing Using SST
      GTY163847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        • 09957-04010
      • SST: 09950-60010 
        • 09951-00490
  52. REMOVE NO. 3 TRANSAXLE HUB SLEEVE 
    Fig 66: Identifying No. 3 Transaxle Hub Sleeve
    GTY162731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 3 transaxle hub sleeve from the No. 3 transaxle clutch hub.
  53. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING 
    Fig 67: Removing No 3 Synchromesh Shifting Key Springs And Synchronizer Ring Set
    GTY159322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 No. 3 synchromesh shifting key springs and synchronizer ring set from the No. 3 transaxle clutch hub while pushing on the No. 3 synchromesh shifting key spring.
  54. REMOVE SYNCHRONIZER PULL RING 
    Fig 68: Removing Synchronizer Pull Ring Snap Ring
    GTY165843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the synchronizer pull ring snap ring.
    2. Remove the synchronizer pull ring, No. 5 synchronizer ring outer, No. 5 synchronizer ring inner and No. 5 synchronizer ring middle.
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