Manual Transaxle Unit: Disassembly

1. Remove the clutch release fork sub-assembly together with the clutch release bearing assembly from the manual transaxle case.
Fig 1: Installing Clutch Release Fork Sub - Assembly To Input Shaft
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1. Remove the clutch release bearing assembly and release bearing hub clip from the clutch release fork sub-assembly.

1. Remove the release fork support from the manual transaxle case.
Fig 2: Installing Clutch Release Bearing Assembly
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1. Remove the clutch release fork boot from the manual transaxle case.

1. Remove the bolt and speedometer driven hole cover sub-assembly.
2. Remove the O-ring.

1. Remove the 2 bolts and selecting bellcrank assembly from the manual transmission case.
   Fig 3: Removing Selecting Bellcrank Assembly

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1. Remove the nut and spring washer.
   Fig 4: Removing Nut And Spring Washer

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2. Using a brass bar and hammer, remove the shift outer lever lock pin.
3. Remove the control shift lever.
   Fig 5: Removing Control Shift Lever

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1. Remove the 4 bolts and control shaft cover from the manual transmission case.
   Fig 6: Install Gasket And Control Shaft Cover With Bolts

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1. Remove the bolt and No. 2 clutch tube bracket.
   Fig 7: Identifying No. 2 Clutch Tube Bracket

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1. Place the manual transaxle assembly on wooden blocks.
   Fig 8: Placing Manual Transaxle Assembly On Wooden Blocks

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1. Remove the No. 1 lock ball assembly from the manual transmission case.
   Fig 9: Locating No. 1 Lock Ball Assembly

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1. Remove the shift gate pin from the manual transmission case.
   Fig 10: Locating Shift Gate Pin

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1. Remove the manual transmission breather plug.
   Fig 11: Locating Manual Transmission Breather Plug

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1. Remove the shift and select lever shaft assembly from the manual transmission case.
   Fig 12: Removing Shift And Select Lever Shaft Assembly

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1. Remove the back-up light switch assembly and gasket from the manual transmission case.
   Fig 13: Installing Back Up Light Switch Assembly To Manual Transmission Case

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1. Remove the manual transmission filler plug and gasket from the manual transmission case.
   Fig 14: Removing Manual Transmission Filler Plug And Gasket From Manual Transmission Case

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1. Remove the drain plug sub-assembly and gasket from the manual transmission case.
   Fig 15: Installing Drain Plug Sub-Assembly With New Gasket To Manual Transmission Case

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1. Remove the 10 bolts and manual transmission case cover from the manual transmission case.
   Fig 16: Removing Manual Transmission Case Cover Sub-Assembly

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1. Engage the 1st and 2nd gears simultaneously.
   Fig 17: Removing Manual Transmission Output Shaft Rear Set Nut

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2. Using SST and a hammer, unstake the manual transmission output shaft rear set nut.

   SST 09930-00010 

   Fig 18: Unstaking Manual Transmission Output Shaft Rear Set Nut

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3. Using SST, remove the manual transmission output shaft rear set nut from the output shaft.

   SST 09229-55010 

   Fig 19: Removing Manual Transmission Output Shaft Rear Set Nut From Output Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disengage the gears.

1. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No. 3 shaft snap ring from the input shaft.

   HINT:

   Use a shop rag or a piece of cloth to keep the snap ring from flying.

   Fig 20: Removing Transmission Clutch Hub No. 3 Shaft Snap Ring From Input Shaft

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2. Remove the shift fork set bolt from the No. 3 gear shift fork.
   Fig 21: Removing Shift Fork Set Bolt From Gear Shift Fork No. 3

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3. Using SST, remove the No. 3 transmission clutch hub and No. 3 gear shift fork from the input shaft.

   SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010), 09950-50013 (09957-04010), 09950-60010 (09951 -00280) 

   Fig 22: Removing No 3 Transmission Clutch Hub, No 3 Transmission Hub Sleeve

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1. Remove the 5th gear from the input shaft.
   Fig 23: Removing 5Th Gear From Input Shaft

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1. Remove the 5th gear needle roller bearing from the input shaft.
   Fig 24: Removing 5Th Gear Needle Roller Bearing From Input Shaft

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1. Using SST, remove the 5th driven gear from the output shaft.

SST 09950-30012 (09951 -03010, 09953-03010, 09954-03010, 09957-04010), 09950-60010 (09951-00180, 09955-03011), 09950-50013 

Fig 25: Removing 5Th Driven Gear From Output Shaft

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1. Using a "TORX" socket wrench (T45), remove the 7 "TORX" screws and rear bearing retainer from the manual transmission case.
   Fig 26: Removing "Torx" Screws And Bearing Retainer Rear (MTM) From Manual Transmission Case

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1. Remove the output shaft rear bearing shim from the output shaft.
   Fig 27: Removing Output Shaft Rear Bearing Shim From Output Shaft

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1. Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
   Fig 28: Removing Input Shaft Rear Bearing Shaft Snap Ring From Input Shaft

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1. Using 2 screwdrivers and a hammer, remove the shift fork shaft, shaft snap ring from the No. 1 gear shift fork shaft.

   HINT:

   Use a shop rag or a piece of cloth to keep the snap ring from flying.

   Fig 29: Removing Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 1

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2. Using 2 screwdrivers and a hammer, remove the shift fork shaft, shaft snap ring from the No. 2 gear shift fork shaft.

   HINT:

   Use a shop rag or a piece of cloth to keep the snap ring from flying.

   Fig 30: Removing Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 2

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1. Remove the reverse idler gear shaft bolt and gasket.

1. Remove the 3 bolts from the manual transaxle case.
   Fig 31: Removing Bolts From Manual Transaxle Case

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2. Remove the 14 bolts from the manual transmission case.
   Fig 32: Removing Bolts From Manual Transmission Case

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3. Tapping with a plastic hammer, remove the manual transmission case.

1. Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.
   Fig 33: Removing Reverse Restrict Pin Assembly

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2. Using a pin punch (ø 5 mm) and hammer, remove the slotted pin.
   Fig 34: Removing Slotted Pin

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3. Remove the bolt, transmission oil baffle and reverse restrict pin assembly.
   Fig 35: Removing Bolt, Transmission Oil Baffle And Reverse Restrict Pin Assembly

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1. Remove the bolt and No. 2 oil receiver pipe from the manual transmission case.

NOTE: Do not damage the pipe.

Fig 36: Removing No. 2 Oil Receiver Pipe

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1. Remove the bolt and No. 1 oil receiver pipe from the manual transmission case.

NOTE: Do not damage the pipe.

Fig 37: Removing No. 1 Oil Receiver Pipe

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1. Remove the transmission magnet from the manual transaxle case.
   Fig 38: Removing Transmission Magnet From Manual Transaxle Case

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1. Remove the reverse idler gear sub-assembly from the manual transaxle case.
   Fig 39: Removing Reverse Idler Gear Sub-Assembly

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2. Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.
   Fig 40: Removing Reverse Gear And Reverse Idler Thrust Washer From Reverse Idler Gear Shaft

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1. Remove the 2 bolts and reverse shift arm bracket assembly from the manual transaxle case.
   Fig 41: Removing Reverse Shift Arm Bracket Assembly

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1. Remove the shift fork set bolt from the No. 1 gear shift fork.
   Fig 42: Removing Shift Fork Set Bolt From No. 1 Gear Shift Fork

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2. Pull out the No. 1 gear shift fork shaft while the No. 3 gear shift fork shaft is pulled up.
   Fig 43: Pulling Out Gear Shift Fork Shaft No. 1

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3. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the No. 1 gear shift fork shaft.

   HINT:

   Use a shop rag or a piece of cloth to keep the snap ring from flying.

   Fig 44: Removing Shift Fork Shaft Snap Ring From Gear Shift Fork Shaft No. 1

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1. Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
   Fig 45: Removing Reverse Shift Fork Roller

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1. Remove the shift fork set bolt and shift head set bolt from the No. 2 gear shift fork and No. 1 gear shift head.
   Fig 46: Removing Shift Fork Set Bolt And Shift Head Set Bolt From Gear Shift Fork No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the No. 2 gear shift fork shaft and No. 1 gear shift head from the manual transaxle case.
   Fig 47: Removing No. 2 Gear Shift Fork Shaft And No. 1 Gear Shift Head From Manual Transaxle Case

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1. Remove the No. 1 gear shift fork.
   Fig 48: Removing No. 1 Gear Shift Fork

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1. Remove the No. 3 gear shift fork shaft from the manual transaxle case.
   Fig 49: Removing No. 3 Gear Shift Fork Shaft From Manual Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using 2 screwdrivers and a hammer, remove the 2 shift fork shaft snap rings from the No. 3 gear shift fork shaft.
3. Remove the reverse shift fork from the No. 3 gear shift fork shaft.
   Fig 50: Removing Reverse Shift Fork From Gear Shift Fork Shaft No. 3

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1. Remove the No. 2 gear shift fork from the input shaft assembly.
   Fig 51: Removing No. 2 Gear Shift Fork From Input Shaft Assembly

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1. Tilt the output shaft, then remove the input shaft from the manual transaxle case.
   Fig 52: Removing Input Shaft From Manual Transaxle Case

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1. Lift the differential case assembly with the output shaft assembly leaned.
   Fig 53: Lifting Differential Case Assembly Up With Output Shaft Assembly Leaned

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2. Remove the output shaft assembly from the manual transaxle case.

1. Remove the differential case assembly from the manual transaxle case.
   Fig 54: Removing Differential Case Assembly From Manual Transaxle Case

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1. Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.
   Fig 55: Removing Bolts And Manual Transaxle Case Receiver From Manual Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case.

SST 09612-65014 (09612-01040, 09612-01050) 

Fig 56: Removing Input Shaft Front Bearing (Outer Race) From Manual Transaxle Case

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1. Using SST, remove the manual transaxle case oil seal from the manual transaxle case.

   SST 09612-65014 (09612-01040, 09612-01050) 

   Fig 57: Removing Manual Transaxle Case Oil Seal From Manual Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case.

   SST 09387-00041 (09387-02020, 09387-02010) 

   Fig 58: Removing Output Shaft Front Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the output shaft cover from the manual transaxle case.
   Fig 59: Removing Output Shaft Cover From Manual Transaxle Case

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1. Using SST and a hammer, remove the output shaft rear bearing from the manual transmission case (outer race).

   SST 09950-60010 (09951 -00680), 09950-70010 (09951-07100) 

   Fig 60: Removing Output Shaft Rear Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the transmission case oil seal from the manual transmission case.

   SST 09308-00010 

   Fig 61: Removing Transmission Case Oil Seal From Manual Transmission Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the front transaxle case cover oil seal.

   HINT:

   Tape the screwdriver tip before use to avoid damage.

   Fig 62: Removing Front Transaxle Case Cover Oil Seal

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1. Using a brass bar and a hammer, remove the front differential case front tapered roller bearing (outer race) from the manual transaxle case.
   Fig 63: Removing Differential Case Rear Tapered Roller Bearing (Outer Race) From Manual Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case front tapered roller bearing from the front differential case.

   SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00560) 

   Fig 64: Removing Front Differential Case Front Tapered Roller Bearing From Front Differential Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.

   SST 09950-60020 (09951 -00790), 09950-70010 (09951-07100) 

   Fig 65: Removing Front Differential Case Rear Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.

   SST 09950-60020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00490) 

   Fig 66: Removing Front Differential Case Rear Tapered Roller Bearing From Front Differential Case

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1. Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.
   Fig 67: Removing No. 3 Transmission Hub Sleeve

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1. Remove the 2 No. 3 synchromesh shifting key springs from the No. 3 transmission clutch hub while pushing on the No. 3 synchromesh shifting key spring.
   Fig 68: Removing Synchromesh Shifting Key Spring No. 3

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1. Using a screwdriver, remove the synchronizer pull ring snap ring.
2. Remove the synchronizer pull ring, No. 5 synchronizer outer ring, No. 5 synchronizer inner ring, and No. 5 synchronizer ring middle from the No. 5 synchronizer ring inner.
   Fig 69: Removing Synchronizer Pull Ring Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002