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Manual Transaxle Assembly: Removal

  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  2. SEPARATE STEERING INTERMEDIATE SHAFT (See  REMOVAL  ) 
  3. REMOVE FRONT WHEELS 
  4. REMOVE ENGINE UNDER COVER LH 
  5. REMOVE ENGINE UNDER COVER RH 
  6. REMOVE EXHAUST PIPE ASSEMBLY 

    HINT:

    (See REMOVAL )

  7. DRAIN TRANSAXLE OIL 
  8. REMOVE HOOD SUB-ASSEMBLY 
  9. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 2 nuts caps, clips and No. 2 cylinder head cover.
  10. REMOVE AIR CLEANER ASSEMBLY 
  11. REMOVE BATTERY CLAMP SUB-ASSEMBLY 
  12. REMOVE BATTERY 
  13. REMOVE BATTERY TRAY 
  14. REMOVE BATTERY CARRIER 
    1. Remove the 4 bolts and battery carrier.
      Fig 1: Locating Battery Carrier
      G05194247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT WIRE HARNESS 
    1. Disconnect the wire harness clamp
    2. Remove the 2 bolts and disconnect the 2 wire harness brackets.
      Fig 2: Locating Wire Harness Brackets
      G05234593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and 2 ground cables.
      Fig 3: Locating Bolts And Ground Cables
      G05234594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT CONNECTOR 
    1. Disconnect the back-up light switch connector.
      Fig 4: Locating Back-Up Light Switch Connector
      G05234595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o ABS:

      Disconnect the speed sensor connector.

      Fig 5: Locating Speed Sensor Connector (W/O ABS)
      G05194251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY 
    1. Remove the 5 bolts, separate the release cylinder assembly with clutch piping from the transaxle.
      Fig 6: Locating Clutch Piping With Bolts
      G05234597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the 2 clip, 2 washer and disconnect the cable end of the control cable assembly from the transaxle.
    2. Remove the 2 clip and disconnect the control cable assembly from the bracket.
      Fig 7: Locating Shift Cable End Of Shift Cable
      G05194231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE STARTER ASSEMBLY 
    1. Remove the nut and disconnect the starter wire.
    2. Disconnect the connector.
    3. Remove the 2 bolts and starter assembly.
      Fig 8: Locating Starter Assembly
      G05194255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (See  REMOVAL  ) 
  21. DISCONNECT TIE ROD END SUB-ASSEMBLY RH (See  REMOVAL  ) 
  22. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (See  REMOVAL  ) 
  23. DISCONNECT RETURN TUBE SUB-ASSEMBLY (See  REMOVAL  ) 
  24. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See  REMOVAL  ) 
  25. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See  REMOVAL  ) 
  26. SUSPEND ENGINE ASSEMBLY 
    1. Remove the 2 PCV hoses.
    2. Install the No. 1 and No. 2 engine hangers in the correct direction.

      Parts No.: 

      No. 1 engine hanger: 12281-22021 

      No. 2 engine hanger: 12281-15040 

      Bolt: 91512-B1016 

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

    3. Attach the engine chain hoist to the hangers.
      CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
      Fig 9: Identifying Engine Hangers Installation Position
      G05194256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
  28. SUPPORT MANUAL TRANSAXLE ASSEMBLY 
    1. Support the transaxle with a transmission jack.
  29. REMOVE TRANSVERSE ENGINE, ENGINE MOUNTING INSULATOR 
    1. Remove the 5 bolts, nut and engine mounting insulator LH from the body.
      Fig 10: Locating Engine Mounting Insulator LH And Bolts
      G05234601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE TRANSVERSE ENGINE, ENGINE MOUNTING BRACKET 
    1. Remove the 3 bolts and engine mounting bracket LH from the transaxle.
      Fig 11: Locating Transverse Engine Mounting Bracket And Bolts
      G05194258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE MANUAL TRANSAXLE ASSEMBLY 
    1. Remove the 6 bolts and transaxle from the engine.
      Fig 12: Locating Manual Transaxle Assembly
      G05194259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TRANSVERSE ENGINE, ENGINE MOUNTING BRACKET 
    1. Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
    2. Remove the 2 bolts and engine mounting bracket FR from the transaxle.
      Fig 13: Locating Transverse Engine Mounting Bracket
      G05234604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE TRANSVERSE ENGINE, ENGINE MOUNTING BRACKET 
    1. Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR.
    2. Remove the 3 bolts engine mounting bracket RR from the transaxle.
      Fig 14: Locating Transverse Engine Mounting Bracket
      G05234605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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