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Transaxle Disassembly

  1. Remove release fork and bearing. Remove vehicle speed sensor. Remove back-up light switch. Remove release bearing retainer. Remove engine mount bracket and selecting bellcrank. Remove transmission case cover. Remove lock ball assembly. Remove shift and select lever assembly. See Fig 1.
  2. Lock transmission in 2 gears. Using a hammer and chisel, lift staked section of output shaft lock nut. Remove lock nut. Lock nut has left-hand threads. Unlock transmission gears. Remove No. 3 shift fork set bolt, No. 3 hub sleeve and No. 3 shift fork. Remove 5th driven gear. Measure 5th gear clearance. See Fig 3. Using a dial indicator, measure and record thrust clearance. Standard clearance is .008-.016" (.20-.40 mm). Service limit is .018" (.45 mm). Measure radial clearance (oil clearance) of 5th gear. Standard clearance is .0004-.0020" (.009-.050 mm). Service limit is .0028" (.070 mm). If clearance exceeds maximum, replace gear, roller bearing or input shaft.
  3. Remove snap ring from output shaft. Using a puller, remove No. 3 clutch hub with synchronizer ring. Remove 5th gear. Remove needle roller bearing. Remove rear bearing retainer. Remove 2 bearing snap rings. Pull up on both shafts to assist removing snap rings.
  4. Remove reverse idler gear shaft lock bolt and gasket. Remove differential side bearing retainer, "O" ring and shim. Remove transmission case. Remove reverse idler gear and shaft. Position No. 1 shift fork shaft in Reverse, remove bolts and pull off reverse shift arm. Shift fork shaft into Neutral. Remove screw plug and spring pin. Remove No. 2 shift fork shaft. Remove No. 1 shift fork shaft interlock pin. Remove No. 1 shift fork shaft, No. 1 shift head, No. 1 and No. 2 shift forks, reverse shift fork and input and output shaft assembly. See Fig 2.
  5. Mount shift rod and forks assembly in a vise. Using a pin punch and hammer, drive out 2 slotted spring pins from No. 1 shift fork shaft. Separate No. 1 shift fork shaft, No. 1 shift head, No. 1 and 2 shift forks and reverse shift fork. Remove differential assembly. Remove magnet from transaxle case. Remove No. 5 synchronizer ring with key spring from No. 3 clutch hub. Remove snap ring. Remove synchronizer rings.
  6. Remove transaxle case receiver. See Fig 2. Using Oil Seal Puller (09308-00010), remove input shaft front bearing. Using a press and Bearing Replacer (09310-35010), install a NEW input shaft front bearing. Install transaxle case receiver and tighten bolts to 65 INCH lbs. (7.3 N.m). Remove output shaft front bearing lock plate. Using Oil Seal Puller (09308-00010), remove output shaft front bearing. Remove bolt and bearing lock plate. See Fig 2. Using oil seal puller, remove output shaft front bearing. Using a press and bearing replacer, install NEW bearing. Install bearing lock plate and tighten bolt to 13 ft. lbs. (18 N.m). Replace input shaft seal.
  7. If necessary, replace reverse restrict pin. Remove straight screw plug. Using a pin punch and hammer, remove spring roll pin. Replace reverse restrict pin. Drive spring pin to a depth of .531" (13.5 mm). Apply sealant to plug threads, install and tighten to 9 ft. lbs. (12 N.m).
Fig 1: Exploded View Of Transmission Assembly
G96I01292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Identifying Transmission Components
G96C01294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Measuring 5th Gear Clearances
G99J04352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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