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Manual Transaxle Unit: Removal

  1. REMOVE ENGINE HOOD 

    Remove the 4 bolts and engine hood.

    1. Torque: 20 Nm (204 kgf.cm, 15 ft.lbf) 

    HINT:

    At the time of installation, please refer to the following item. Adjust the hood (See HOOD ).

  2. REMOVE SUSPENSION UPPER BRACE 

    Remove the 2 bolts, 2 nuts and suspension upper brace.

    1. Torque: 
    2. 74 Nm (755 kgf.cm, 55 ft.lbf) for bolt 
    3. 80 Nm (816 kgf.cm, 59 ft.lbf) for nut 
  3. REMOVE AIR CLEANER CAP AND AIR HOSE ASSEMBLY, AIR FILTER AND AIR CLEANER CASE (See  REMOVAL  ) 
  4. REMOVE BATTERY BRACKET 
    1. Loosen the clamp nut, and remove the clamp, battery and tray.
    2. Remove the 3 bolts and battery bracket.

      Torque: 24 Nm (245 kgf.cm, 18 ft.lbf) 

  5. DISCONNECT ENGINE WIRE FROM TRANSAXLE 

    Torque: 8 N.m (82 kgf.cm, 71 in.lbf) 

  6. DISCONNECT BACK-UP LIGHT SWITCH CONNECTOR 
    Fig 1: Identifying Clips, Washers And Control Cables
    G02631333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT CONTROL CABLES FROM TRANSAXLE 
    1. Remove the 2 clips and 2 washers.
    2. Remove the 2 clips and disconnect the 2 control cables.

    HINT:

    Remove the select cable from the bracket by pressing the projection of the clip.

  8. REMOVE CONTROL CABLE BRACKET 

    Remove the 2 bolts and control cable bracket.

    1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
  9. DISCONNECT GROUND CABLE FROM TRANSAXLE 

    Remove the bolt and disconnect the ground cable.

    1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 
    Fig 2: Identifying Ground Cable Bolt
    G02631334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE 2 MOUNTING BOLTS OF TRANSAXLE UPPER SIDE 

    Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 

    Fig 3: Identifying Transaxle Upper Side Mounting Bolts
    G02631335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. ATTACH ENGINE SUPPORT FIXTURE 
    1. Install the No. 1 engine hanger with the bolt in the correct direction.

      Parts No.:

      NO. 1 ENGINE HANGER - SPECIFICATION TABLE

      No. 1 engine hanger 12281-15040
      Bolt 91642-81025

      Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 

    2. Attach the engine support fixture to the engine hangers.
    Fig 4: Attaching Engine Support Fixture To Engine Hangers
    G02631336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE LEFT ENGINE MOUNTING BRACKET 
    1. Remove the through bolt and nut.

      Torque: 87 N.m (887 kgf.cm, 64 ft.lbf) 

    2. Remove the 3 bolts and mounting bracket.

      Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

  13. REMOVE FRONT AND REAR ENGINE UNDER COVERS 
  14. DRAIN TRANSAXLE OIL (See  MANUAL TRANSAXLE UNIT  ) 
  15. JACK UP TRANSAXLE SLIGHTLY 

    Using a transmission jack, support the transaxle.

  16. REMOVE REAR DRIVE SHAFTS (See  REMOVAL  ) 
    Fig 5: Identifying Bolt, Nuts And Mounting Bracket
    G02631337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT CLUTCH RELEASE CYLINDER AND FRONT ENGINE MOUNTING BRACKET ASSEMBLY 
    1. Remove the 2 bolts.

      Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

      Fig 6: Identifying Clutch Release Cylinder Bolts
      G02631338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the through bolt and nut.

      Torque: 93 N.m (949 kgf.cm, 69 ft.lbf) 

    3. Remove the 2 bolts and disconnect the release cylinder and bracket assembly from the transaxle.

      Torque: 78 N.m (796 kgf.cm, 56 ft.lbf) 

    4. Suspend the release cylinder and bracket assembly securely.
    Fig 7: Identifying Release Cylinder Bracket Assembly, Bolts And Nuts
    G02631339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    Remove the 3 bolts and mounting insulator.

    1. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 
    Fig 8: Identifying Mounting Insulator Bolts
    G02631340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE STARTER 
    1. Disconnect the starter connector.
    2. Remove the nut and disconnect the starter cable.
    3. Remove the 2 bolts and starter.

      Torque: 37 N.m (378 kgf.cm, 28 ft.lbf) 

    Fig 9: Removing Bolts And Starter
    G02631341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE REAR ENGINE MOUNTING INSULATOR 
    1. Remove the through bolt and nut.

      Torque: 93 N.m (949 kgf.cm, 69 ft.lbf) 

    2. Remove the 4 bolts and mounting insulator.

      Torque: 89 N.m (908 kgf.cm, 66 ft.lbf) 

    NOTE: Be sure to tighten the bolt at the upper end of the slot.
    Fig 10: Identifying Bolts And Mounting Insulator
    G02631342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR ENGINE MOUNTING BRACKET 

    Remove the 3 bolts and mounting bracket.

    1. Torque: 78 N.m (796 kgf.cm, 58 ft.lbf) 
    Fig 11: Identifying Mounting Bracket Bolts
    G02631343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE 4 MOUNTING BOLTS OF TRANSAXLE LOWER SIDE 

    Torque: 

    47 N.m (480 kgf.cm, 35 ft.lbf) for bolt A 

    23 N.m (230 kgf.cm, 17 ft.lbf) for bolt B 

  23. REMOVE TRANSAXLE 

    Lower the engine left side, then slowly and carefully remove the transaxle from the engine.

    HINT:

    At the time of installation, please refer to the following items.

    • Align the input shaft with the clutch disc and install the transaxle to the engine.
    • Temporarily tighten the transaxle mounting bolts.
    Fig 12: Identifying Transaxle Lower Side Mounting Bolts
    G02631344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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