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

Transaxle Assembly

  1. Apply gear oil to output shaft. Slide 2nd gear and No. 1 synchro ring onto output shaft. Install No. 1 clutch hub and shifting keys to hub sleeve. See Fig 1. Install shifting key springs under shifting keys. Ensure key springs are positioned so end gaps are not in line. Using Installer (09515-30010) and press, align synchro ring slots with shifting keys and install clutch hub No. 1.
    Fig 1: View of No. 1 Clutch Hub
    G95B55765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Assemble 1st gear, needle roller bearing and inner race. Apply gear oil to bearing. Install locking ball in shaft. Slide No. 1 synchro ring and 1st gear on shaft. Align synchro ring slots with shifting keys. Turn inner race to align with locking ball. Select and install snap ring from OUTPUT SHAFT SNAP RING SELECTION  table that allows minimum axial play.
    OUTPUT SHAFT SNAP RING SELECTION

    Model Thickness (mm)
    Z54F
      2.15-2.20
      2.20-2.25
      2.25-2.30
      2.30-2.35
      2.35-2.40
      2.40-2.45
      2.45-2.50
      2.50-2.55
      2.55-2.60
  3. Using feeler gauge, measure 2nd gear thrust clearance. Using dial indicator, measure 1st gear thrust clearance.
    1ST & 2ND GEAR THRUST CLEARANCE

    Application In. (mm)
    1st Gear .0059-.0108 (.150-.275)
    2nd Gear .0059-.0098 (.150-.250)
  4. Apply gear oil to output shaft. Slide 3rd gear and No. 2 synchro ring onto shaft. Install key springs and shifting keys to No. 2 clutch hub. See Fig 2. Install clutch hub to hub sleeve. Using Installer (09515-30010) and press, align synchro ring slots with shifting keys and press in clutch hub.
    Fig 2: View of No. 2 Clutch Hub
    G95C55766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Apply gear oil to output shaft. Slide large thrust bearing onto shaft. Slide No. 2 synchro ring, needle roller bearing and 4th gear onto shaft. Align synchro ring slots with shifting keys. Slide thrust washer onto output shaft. Install snap ring.
  6. Stick small 4th gear thrust bearing onto spacer with grease. Using Installer (09612-22011) and press, install spacer. Using installer and press, install output shaft front bearing. Ensure outer race groove is facing toward front. Select and install snap ring from OUTPUT SHAFT FRONT BEARING SNAP RING SELECTION  table that allows minimum axial play.
    OUTPUT SHAFT FRONT BEARING SNAP RING SELECTION

    Model Thickness (mm)
    Z54F
      2.10-2.15
      2.15-2.20
      2.20-2.25
      2.25-2.30
      2.30-2.35
      2.35-2.40
      2.40-2.45
      2.45-2.50
      2.50-2.55
  7. Using feeler gauge, measure 3rd gear thrust clearance. Using dial indicator, measure 4th gear thrust clearance.
    3RD & 4TH GEAR THRUST CLEARANCE

    Application In. (mm)
    3rd Gear .0059-.0098 (.150-.250)
    4th Gear .0008-.0094 (.020-.240)
  8. Using Installer (09612-22011) and press, install 5th gear. Select and install snap ring from 5TH GEAR SNAP RING SELECTION  table that allows minimum axial play.
    5TH GEAR SNAP RING SELECTION

    Model Thickness (mm)
    Z54F
      2.10-2.15
      2.15-2.20
      2.20-2.25
      2.25-2.30
      2.30-2.35
      2.35-2.40
  9. Using press, install sleeve yoke. Mount intermediate plate in vise by securing lower protrusion. Tap in output shaft and countergear together about halfway. Align idler gear with notched portion of reverse idler gear shaft.
  10. Tap in idler gear shaft bearing about halfway. Ensure idler gear and output shaft spacer are not contacting each other. Tap in each gear shaft until the bearing is in as far as possible.
  11. Install 2 snap rings. Install front bearing retainer and release arm plate. Tighten 4 bolts to 108 INCH lbs. (13 N.m). Apply gear oil to countergear shaft. Install locking ball in shaft. Slide thrust washer onto shaft and align groove with steel ball. Install needle roller bearing, counter 5th gear and No. 3 synchro ring.
  12. Install No. 3 clutch hub and shifting keys to hub sleeve. See Fig 3. Install shifting key springs under shifting keys. Ensure key springs are positioned so their end gaps are not in line. Using Installer (09612-22011) and press, install clutch hub. Ensure synchro ring slots are aligned with shifting keys.
    Fig 3: View of No. 3 Clutch Hub
    G95D55767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. Select and install snap ring from NO. 3 CLUTCH HUB SNAP RING SELECTION table that allows minimum axial play. Using feeler gauge, measure 5th countergear thrust clearance.
    NO. 3 CLUTCH HUB SNAP RING SELECTION

    Model Thickness (mm)
    Z54F
      1.80-1.85
      1.85-1.90
      1.90-1.95
      1.95-2.00
      2.00-2.05
      2.05-2.10
      2.10-2.15
    5TH COUNTER GEAR THRUST CLEARANCE

    Model In. (mm)
    Z54F .0059-.0128 (.150-.325)
  14. Align claws of key retainer with key groove of clutch hub. Install shifting key retainer snap ring. Assemble reverse shift arm and shift head with "E" clip. Install No. 3 shift fork guide bushing, compression spring, and spacer. Install snap ring.
  15. Align shift fork No. 1 with hub sleeve No. 1 groove. Align reverse shift fork with reverse gear groove. Install No. 1 shift fork, reverse shift fork, No. 1 shift fork shaft and release head.
  16. Install No. 2 shift fork, shift fork shaft and release head. Align No. 2 shift fork into No. 2 hub sleeve groove.
  17. Using Socket (09313-30021), remove screw plug for interlock pin. Place No. 1 and No. 2 hub sleeve in neutral. Align bolt holes of No. 1 shift fork and shaft and No. 2 shift fork and shaft. Align interlock pin groove of No. 1 shift fork shaft with interlock pin hole of No. 2 shift fork shaft.
  18. Apply grease to the 3 interlock pins and install. Connect reverse shift arm and reverse shift fork. Align shift fork No. 3 with hub sleeve No. 3 groove. Install reverse shift arm, No. 3 shift fork and No. 3 shift fork shaft.
  19. Apply sealer to screw plug and tighten to 16 ft. lbs. (22 N.m). Tap in slotted spring pin for reverse shift head. Tap in slotted spring pins for No. 3 shift fork and release heads. Install shift fork mount bolts and tighten to 13 ft. lbs. (18 N.m). Install detent ball and spring into reverse shift fork hole. Install screw plug and tighten to 16 ft. lbs. (22 N.m).
  20. Remove intermediate plate from vise. Install new gasket on intermediate plate. Install transmission case to intermediate plate. Install snap ring. Install 3 detent balls and locking springs. Apply sealer to screw plugs and tighten to 16 ft. lbs. (22 N.m).
  21. Insert reverse shift arm pivot through reverse shift arm. Tighten pivot bolt to 22 ft. lbs. (29 N.m). Install snap rings on No. 1 and No. 2 shift fork shafts. Install each gear shift head to fork shafts and drive in roll pin.
  22. Install speedometer drive gear locking ball, drive gear, and snap ring. Install extra low gear snap ring. Install locking ball in output shaft. Install and align groove of thrust washer with locking ball. Install needle roller bearings, extra low gear and transfer clutch hub with snap ring. Using a feeler gauge, measure extra low gear thrust clearance.
    EXTRA LOW GEAR THRUST CLEARANCE

    Model In. (mm)
    Z54F .0070-.0169 (.180-.430)
  23. Remove snap ring, transfer clutch hub, extra low gear and needle roller bearing. Install extra low gear and shifting keys to hub sleeve. See Fig 4. Install shifting key springs under shifting keys so end gaps are not in line.
    Fig 4: View of Transfer Clutch Hub
    G95C55774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Install reverse restrict pin to transfer adapter. Align pin holes and tap in roll pin. Apply sealer to screw plug and tighten to 16 ft. lbs. (22 N.m).
  25. Install transfer shift lever shaft and rear drive shift link lever as a unit with plate washer. Align cutouts of lever lock pin and shift lever shaft. Install lever lock pin, spring washer and nut. Tighten nut to 108 INCH lbs. (13 N.m).
  26. Apply gear oil to output shaft. Install 2 needle roller bearings on output shaft. Install new gasket on transmission case. Install No. 4 shift fork to No. 4 hub sleeve. Install extra low gear assembly and No. 4 sleeve in transfer adaptor.
  27. Install select lever on transfer adapter. Install transfer adapter. Turn select lever and insert tip into shift head groove. Tighten 9 bolts to 18 ft. lbs. (25 N.m). Install reverse restrict pin and spring. Tighten plug to 30 ft. lbs. (40 N.m).
  28. Install interlock pin. Install snap ring on No. 4 shift fork shaft and install. Install No. 4 shift head. Align pin holes and tap in roll pin until flush with shift fork. Apply sealer to screw plug and tighten to 18 ft. lbs. (25 N.m). Install gear shift head No. 4 bolt and tighten to 108 INCH lbs. (13 N.m). Stake one lock plate claw flush with flat surface of nut. For claw contacting protruding portion of nut, stake only half on tightening side.
  29. Install detent ball, spring and spring seat. Install transfer case cover with new gasket and tighten 4 bolts to 14 ft. lbs. (19 N.m). Install No. 4 synchro ring and transfer clutch hub by aligning slots with shifter keys. Install snap ring. Temporarily install input shaft. Cover tip of input shaft with shop cloth, secure with pliers and install oil pump drive shaft by turning clockwise. Remove input shaft.
  30. Assemble transfer shift fork and transfer shift fork shaft. Align pin holes and install roll pin. Put transfer shift fork on transfer hub sleeve. Install transfer shift fork assembly and transfer hub sleeve as a unit. Install transfer shift lever shaft into transfer shift fork groove. Install detent ball, spring and spring seat. Apply sealer to screw plug and tighten to 18 ft. lbs. (25 N.m).
  31. Install oil baffle, transfer output shaft, oil pump rotors, and oil pump cover. Tighten bolts to 14 ft. lbs. (19 N.m). Install new gasket on transfer adapter. Install extension housing and shift lever housing as a unit. Tighten bolts to 19 ft. lbs. (26 N.m).
  32. Install shift lever lock plate and set bolt to lever housing. Tighten bolt to 25 ft. lbs. (34 N.m). Stake one lock plate claw flush with flat surface of nut. For claw contacting protruding portion of nut, stake only half on tightening side.
  33. Install new gasket and shift lever retainer. Tighten bolts to 14 ft. lbs. (19 N.m). Install reverse restrict pin and tighten to 30 ft. lbs. (40 N.m). Install back-up light, 4WD indicator, and extra low gear switches. Install speedometer driven gear and mounting insulator.
  34. Install a new "O" ring on transaxle case groove. Install a new gasket on transaxle case. Apply grease to input shaft spline and end. Connect transmission to differential carrier. Ensure splines of sleeve yoke and drive pinion are aligned.
  35. Align splines of input shaft and clutch disc. Insert input shaft into transmission case. Install case cover with new gasket. Apply sealer to input shaft mount bolts. Install and tighten all bolts to 18 ft. lbs. (25 N.m).
TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)
Drain Plug 30 (40)
Drive Pinion Nut 188 (255)
Extension Housing Bolts 18 (25)
Filler Plug 30 (40)
Intermediate Plate Screw Plugs (3) 16 (22)
No. 4 Shift Head Screw Plug 18 (25)
Oil Pump Cover Bolts 14 (19)
Reverse Arm Interlock Pin Screw Plug 16 (22)
Reverse Shift Arm Pivot Bolt 22 (29)
Reverse Shift Fork Screw Plug 16 (22)
Ring Gear Bolts 71 (96)
Side Bearing Cap Bolt 36 (49)
Shift Fork Set Bolts 13 (18)
Shift Lever Housing Bolt 25 (33)
Shift Lever Retainer Restrict Pin 30 (40)
Shift Lever Retainer Bolts 14 (19)
Transmission Case Cover Bolts 18 (25)
Transfer Adapter Bolts 18 (25)
Transfer Adapter Restrict Pin Screw Plug 16 (22)
Transfer Adapter Restrict Pin Plug 30 (40)
Transfer Adapter Shift Shaft Screw Plug 18 (25)
Transfer Case Cover Bolts 14 (19)
INCH Lbs. (N.m) 
Differential Cover Bolt 108 (13)
Front Bearing Retainer Bolt 108 (13)
No. 4 Shift Head Bolt 108 (13)
Oil Pump Drive Shaft 108 (13)
Oil Receiver Bolts 48 (5)
Rear Bearing Retainer Bolts 108 (13)
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