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Home >> Toyota >> 1985 >> Tercel Base >> Repair and Diagnosis >> Transmission >> Manual Trans >> Overhaul - Z54F 4WD 6-Speed >> Transaxle Disassembly

Transaxle Disassembly

  1. Remove mounting insulator, speedometer driven gear, and reverse restrict pin. Remove back-up light, extra low gear, and 4WD indicator switches. Remove 6 bolts, shift lever retainer, and gasket. Unstake shift lever housing mount bolt lock washer and remove bolt.
  2. Remove 9 extension housing bolts, extension housing, shift lever housing and gasket. Remove 3 oil pump cover bolts and oil pump cover. Remove oil pump rotors, transfer output shaft and oil baffle.
  3. Using Socket (09313-30021), remove screw plug. Using magnet, remove spring seat, spring and ball. Remove shift fork, shift shaft and hub sleeve as a unit. Cover input shaft tip with shop cloth and secure with pliers. Remove oil pump drive shaft by turning clockwise. Remove snap ring, transfer clutch hub and No. 4 synchro ring.
  4. Remove 4 transfer case cover bolts, transfer case cover, and gasket. Remove spring seat and spring. Remove detent ball. Unstake No. 4 shift head mount bolt lock plate and remove bolt. Using Socket (09313-30021), remove screw plug. Tap out roll pin. Remove No. 4 shift fork with shift fork shaft. Remove interlock pin.
  5. Remove transfer adapter plug, spring, and reverse restrict pin. Remove 9 bolts attaching transfer adapter to case. Using plastic hammer, tap transfer adapter. Turn select lever and remove tip from shift head groove. Remove transfer adapter with select lever and extra low gear from transmission case.
  6. Install needle roller bearing, extra low gear, and transfer clutch hub with snap ring. Using feeler gauge, measure and record extra low gear thrust clearance. See Fig 1. Remove snap ring, transfer clutch hub, extra low gear and needle roller bearing.
    EXTRA LOW GEAR THRUST CLEARANCE

    Application In. (mm)
    Standard .0070-.0169 (.180-.430)
    Maximum .020 (.50)
    Fig 1: Measuring Extra Low Gear Thrust Clearance
    G95F55769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Remove extra low gear thrust washer. Remove locking ball. Remove speedometer drive gear snap ring. Remove drive gear and locking ball. Drive out roll pins and remove gear shift heads. Remove snap ring from No. 1 and No. 2 shift fork shafts.
  8. Remove 2 input shaft bolts, transmission case cover, and input shaft. Remove reverse shift arm pivot. Using Socket (09313-30021), remove 3 screw plugs. Remove 3 springs and balls. Remove bearing snap ring.
  9. Using plastic hammer, tap case protrusion and separate case from intermediate plate. Mount intermediate plate in vise by securing protrusion on lower part of plate.
  10. Remove screw plug, spring and ball. Remove shift fork mount bolts. Drive out 4 roll pins. Remove gear shift heads. Set each fork shaft to neutral position.
  11. Holding shift fork, pull out fork shaft and remove fork. Remove 3 interlock pins from No. 2 shift fork shaft and intermediate plate. Remove No. 3 shifting fork snap ring. Remove spacer and compression spring. Remove shift fork guide bushing and compression spring. Using feeler gauge, measure counter 5th gear thrust clearance. See Fig 2.
    COUNTER 5TH GEAR THRUST CLEARANCE

    Application In. (mm)
    Standard .0059-.0128 (.150-.325)
    Maximum .016 (.40)
    Fig 2: Measuring Counter 5th Gear Thrust Clearance
    G95B55757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Pry out No. 3 clutch hub snap ring. Remove shifting key retainer. Remove snap ring. Using Puller (09950-20016), remove clutch hub No. 3, synchro ring and counter 5th gear as a unit. Carefully remove needle roller bearing. Remove thrust washer and locking ball.
  13. Remove front bearing retainer and release arm plate. Remove 2 snap rings. Tap idler gear and output shaft halfway from intermediate plate while supporting gear shaft by hand.
  14. Remove idler gear, reverse idler gear and reverse idler gear shaft together. Tap out countergear and output shaft together while supporting gear and shaft by hand. Using dial indicator, measure and record 1st and 4th gear thrust clearance. See Fig 3. Using feeler gauge, measure and record 2nd and 3rd gear thrust clearance. See Fig 4.
    GEAR THRUST CLEARANCES

    Application In. (mm)
    Standard Clearance
    1st Gear .0059-.0108 (.150-.275)
    2nd & 3rd Gear .0059-.0098 (.150-.250)
    4th Gear .0008-.0094 (.020-.240)
    Maximum Clearance .012 (.30)
    Fig 3: Measuring 1st & 4th Gear Thrust Clearances
    G95C55758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Measuring 2nd & 3rd Gear Thrust Clearances
    G95D55759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Using Remover (09950-00020), press out sleeve yoke, remove snap ring, and press out 5th gear. Remove output shaft front bearing snap ring. Using same tool, press out output shaft front bearing, spacer and 4th gear thrust bearing.
  16. Remove 4th gear, synchro ring, and needle roller bearings. Remove snap ring. Remove thrust washer and thrust bearing. Using remover, press out clutch hub No. 2, synchro ring and 3rd gear. 17 Remove 1st gear snap ring. Remove 1st gear, synchro ring, needle roller bearing and inner race. Remove locking ball. Using remover, press out clutch hub No. 1, synchro ring and 2nd gear.
  17. Remove 10 bolts and 2 nuts from transmission case. From transaxle side, install 4 bolts an equal distance apart. Separate transaxle from differential by turning 4 bolts a little at a time on transmission case side. See Fig 5.
    Fig 5: Position of Bolts to Separate Housings
    G95G55760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Install differential carrier to work stand with ring gear in horizontal position. Measure and record ring gear backlash. If backlash is not .004-.006" (.10-.15 mm), adjust side bearing preload or repair as necessary.
  19. Check ring gear runout. If maximum runout is greater than .003" (.07 mm), install new ring gear. Inspect teeth pattern for proper wear. Using Adapter (09556-16010) and torque wrench, measure preload. Total preload should be 5.2-8.7 INCH lbs. (.6-1.0 N.m).
  20. Using Remover (09308-00010), remove oil seals from differential carrier. Remove side bearing caps. Using Remover (09504-22010), remove side bearing thrust washer on ring gear teeth side. Remove differential case, bearing outer races and thrust washer. Tag bearing caps, outer races and thrust washers to show reassembly location.
  21. Remove oil reservoir. Loosen staked part of drive pinion nut. Using Remover (09556-16010), loosen nut and turn drive pinion clockwise. Using Puller (09556-12010), remove rear bearing from drive pinion. Remove drive pinion and spacer.
Fig 6: Exploded View of Toyota Z54F 6-Speed Transaxle
G95I55770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 7: Exploded View of Shifting Components
G95J55771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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