Manual Transaxle Unit: Disassembly

REMOVE MANUAL TRANSMISSION FILLER PLUG
1. Remove the manual transmission filler plug and gasket from the manual transmission case.
  
  Fig 1: Removing Manual Transmission Filler Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRAIN (MTM) PLUG SUB-ASSEMBLY
1. Remove the drain (MTM) plug sub-assembly and gasket from the manual transmission case.
REMOVE SPEEDOMETER SENSOR (w/o ABS)
1. Remove the bolt and speedometer sensor from the transaxle case.
2. Remove the O-ring from the speedometer sensor.
  
  Fig 2: Removing Drain (MTM) Plug Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (w/ ABS)
1. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle case.
2. Remove the O-ring from the speedometer driven hole cover.
REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
1. Remove the clutch release fork sub-assembly with the clutch release bearing assembly from the transaxle case.
  
  Fig 3: Removing Clutch Release Fork Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE BEARING ASSEMBLY
1. Remove the clutch release bearing clip and clutch release bearing assembly from the clutch release fork sub-assembly.
  
  Fig 4: Removing Clutch Release Bearing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RELEASE FORK SUPPORT
1. Remove the clutch release fork support from the transaxle case.
  
  Fig 5: Removing Release Fork Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH RELEASE FORK BOOT
1. Remove the clutch release fork boot from the transaxle case.
  
  Fig 6: Removing Clutch Release Fork Boot
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK UP LIGHT SWITCH ASSEMBLY
1. Remove the back up light switch assembly and gasket from the manual transmission case.
  
  Fig 7: Removing Back Up Light Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET
1. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.
  
  Fig 8: Removing Floor Shift Control Lever Housing Support Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SELECTING BELL CRANK ASSEMBLY
1. Remove the 2 bolts and selecting bell crank assembly from the manual transmission case.
2. Remove the control shift lever bush.
  
  Fig 9: Removing Selecting Bell Crank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX MANUAL TRANSAXLE ASSEMBLY
1. Place the manual transaxle assembly on wooden blocks.
  
  Fig 10: Placing Manual Transaxle Assembly On Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCK BALL ASSEMBLY NO. 1
1. Remove the lock ball assembly No. 1 from the manual transmission case.
  
  Fig 11: Removing Lock Ball Assembly No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Remove the 4 bolts, shift & select lever shaft assembly and gasket from the manual transmission case.
  
  Fig 12: Removing Shift And Select Lever Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
1. Remove the 9 bolts.
  
  Fig 13: Identifying Manual Transmission Case Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap the projection of the manual transmission case cover subassembly to remove it from the manual transmission case.
  NOTE: Do not damage the manual transmission case.
  
  Fig 14: Removing Manual Transmission Case Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT
1. Using a chisel and a hammer, loosen the staked part of the manual transmission output shaft rear set nut.
  
  Fig 15: Loosening Staked Part Of Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage two gears simultaneously to lock the transmission.
3. Remove the manual transmission output shaft rear set nut.
4. Disengage the two gears.
  
  Fig 16: Removing Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK NO. 3
1. Remove the gear shift fork lock bolt from the gear shift fork No. 3.
  
  Fig 17: Removing Gear Shift Fork Lock Bolt From Gear Shift Fork No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the transmission hub sleeve No. 3 with the gear shift fork No. 3 from the transmission clutch hub No. 3.
INSPECT 5TH GEAR THRUST CLEARANCE (See INSPECTION )
INSPECT 5TH GEAR RADIAL CLEARANCE (See INSPECTION )

Fig 18: Removing Transmission Hub Sleeve No. 3 With Gear Shift Fork No. 3 From Transmission Clutch Hub No. 3
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CLUTCH HUB NO. 3
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a shop rag to keep the snap ring from flying.
  
  Fig 19: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the transmission clutch hub No. 3, 5th gear and synchronizer ring No. 3 from the input shaft.
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010), 09950-60010 (09951-00200)
  
  Fig 20: Removing Transmission Clutch Hub No. 3, 5th Gear And Synchronizer Ring No. 3 From Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from the transmission clutch hub No. 3.
  
  Fig 21: Removing Synchromesh Shifting Keys And Key Springs From Transmission Clutch Hub No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH GEAR NEEDLE ROLLER BEARING
1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
  
  Fig 22: Removing 5th Gear Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 5TH DRIVEN GEAR
1. Using SST, remove the 5th driven gear from the output shaft.
  SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190)
  
  Fig 23: Removing 5th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RETAINER REAR (MTM)
1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.
  
  Fig 24: Removing Bearing Retainer Rear (MTM)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
  
  Fig 25: Removing Output Shaft Rear Bearing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING
1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring from the input shaft.
  
  Fig 26: Removing Input Shaft Rear Bearing Hole Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SHAFT BOLT
1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
  
  Fig 27: Removing Reverse Idler Gear Shaft Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT FORK SHAFT SNAP RING
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 2.
  HINT:
  
  Use a shop rag to keep the snap ring from flying.
  
  Fig 28: Removing Shift Fork Shaft Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT DETENT BALL
1. Using a hexagon wrench, remove the 2 shift detent ball plugs from the manual transmission case.
  
  Fig 29: Removing Shift Detent Ball Plugs From Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the 2 seats, 2 springs and 2 shift detent balls from the manual transmission case.
  
  Fig 30: Removing Seats, Springs And Shift Detent Balls From Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench, remove the shift detent ball plug from the transaxle case.
  
  Fig 31: Removing Shift Detent Ball Plug From Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a magnetic finger, remove the seat, spring and shift detent ball from the transaxle case.
  
  Fig 32: Removing Seat, Spring And Shift Detent Ball From Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCK BALL ASSEMBLY NO. 1
1. Using a hexagon wench, remove the lock ball assembly No. 1 from the manual transmission case.
  
  Fig 33: Removing Lock Ball Assembly No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE
1. Remove the 3 bolts from the transaxle case side.
  
  Fig 34: Removing Bolts From Transaxle Case Side
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the manual transmission case side.
  
  Fig 35: Removing Bolts From Manual Transmission Case Side
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, carefully tap the projection of the manual transmission case to remove it from the transaxle case.
  NOTE: Do not damage the manual transmission case and transaxle case.
  
  Fig 36: Removing Manual Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE IDLER GEAR SUB-ASSEMBLY
1. Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the transaxle case.
  
  Fig 37: Removing Reverse Idler Gear Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
1. Remove the 2 bolts and reverse shift arm bracket assembly from the transaxle case.
  
  Fig 38: Removing Reverse Shift Arm Bracket Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT NO. 2
1. Remove the 2 bolts from the gear shift fork No. 2 and gear shift head No. 1.
  
  Fig 39: Removing Bolts From Gear Shift Fork No. 2 And Gear Shift Head No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork shaft No. 2 and gear shift head No. 1 from the transaxle case.
  
  Fig 40: Removing Gear Shift Fork Shaft No. 2 And Gear Shift Head No. 1 From Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT SUBASSEMBLY NO. 1
1. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a shop rag to keep the snap ring from flying.
  
  Fig 41: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assembly No. 1 from the gear shift fork No. 1.
  
  Fig 42: Removing Gear Shift Fork Lock Bolt And Gear Shift Fork Shaft Sub-Assembly No. 1 From Gear Shift Fork No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the gear shift fork No. 1.
  
  Fig 43: Removing Gear Shift Fork No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT NO. 3
1. Using 2 screwdrivers and a hammer, tap out the snap ring from the gear shift fork shaft No. 3.
  HINT:
  
  Use a shop rag to keep the snap ring from flying.
  
  Fig 44: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift fork shaft No. 3 with the reverse shift fork and gear shift fork No. 2 from the transaxle case.
  
  Fig 45: Removing Shift Fork Shaft No. 3 With Reverse Shift Fork And Gear Shift Fork No. 2 From Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
  
  Fig 46: Removing Balls From Reverse Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using 2 screwdrivers and a hammer, tap out the snap ring.
  HINT:
  
  Use a shop rag to keep the snap ring from flying.
5. Remove the reverse shift fork from the gear shift fork shaft No. 3.
  
  Fig 47: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSEMBLY
1. Remove the input and output shaft assembly from the transaxle case.
  
  Fig 48: Removing Input Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL CASE ASSEMBLY
1. Remove the differential case assembly from the transaxle case.
  
  Fig 49: Removing Differential Case Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSAXLE CASE RECEIVER
1. Remove the bolt and manual transaxle case receiver from the transaxle case.
  
  Fig 50: Removing Manual Transaxle Case Receiver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE RESTRICT PIN ASSEMBLY
1. Using a hexagon wrench, remove the reverse restrict pin plug from the manual transmission case.
  
  Fig 51: Removing Reverse Restrict Pin Plug From Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch ( 5 mm) and a hammer, drive out the slotted pin and remove the reverse restrict pin assembly from the manual transmission case.
  
  Fig 52: Removing Reverse Restrict Pin Assembly From Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER PIPE NO. 1 (MTM)
1. Remove the bolt and oil receiver pipe No. 1 (MTM) from the manual transmission case.
  NOTE: Be careful not to damage the oil receiver pipe No. 1 (MTM).
  
  Fig 53: Removing Oil Receiver Pipe No. 1 (MTM)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER PIPE NO. 2 (MTM)
1. Remove the bolt and oil receiver pipe No. 2 (MTM) from the manual transmission case.
  NOTE: Be careful not to damage the oil receiver pipe No. 2 (MTM).
  
  Fig 54: Removing Oil Receiver Pipe No. 2 (MTM)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING LOCK PLATE
1. Remove the bolt and bearing lock plate from the transaxle case.
  
  Fig 55: Removing Bearing Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the transaxle case.
  
  Fig 56: Removing Transmission Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING
1. Using SST, remove the input shaft front bearing from the transaxle case.
  SST 09612-65014 (09612-01050, 09612-01060)
  
  Fig 57: Removing Input Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT TRANSAXLE CASE OIL SEAL
1. Using a screwdriver, remove the front transaxle case oil seal from the transaxle case.
  
  Fig 58: Removing Front Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the output shaft front bearing from the transaxle case.
  SST 09308-00010
  
  Fig 59: Removing Output Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT (MTM) COVER
1. Remove the output shaft (MTM) cover from the transaxle case.
  
  Fig 60: Removing Output Shaft (MTM) Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the FR differential case front tapered roller bearing (outer race) and shim from the transaxle case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 61: Removing FR Differential Case Front Tapered Roller Bearing (Outer Race) And Shim From Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case.
  SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00360)
  
  NOTE: Be careful not to damage the bearing.
  
  Fig 62: Removing FR Differential Case Front Tapered Roller Bearing (Inner Race) From Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, drive out the transaxle case oil seal from the transaxle case.
  SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
  
  Fig 63: Removing Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the FR differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 64: Removing FR Differential Case Rear Tapered Roller Bearing (Outer Race) And Shim From Manual Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.
  SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
  
  NOTE: Be careful not to damage the bearing.
  
  Fig 65: Removing FR Differential Case Rear Tapered Roller Bearing (Inner Race) From Front Differential Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.
  SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)
INSPECT SYNCHRONIZER RING NO. 3 (See INSPECTION )
INSPECT TRANSMISSION HUB SLEEVE NO. 3 (See INSPECTION )
INSPECT 5TH GEAR (See INSPECTION )
INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY (See INSPECTION )

Fig 66: Removing Transmission Case Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002