Manual Transaxle Unit: Disassembly

1. Remove the manual transmission filler plug and gasket from the manual transmission case.

Fig 1: Identifying Manual Transmission Filler Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the drain (MTM) plug sub-assembly and gasket from the manual transmission case.

1. Remove the bolt and speedometer sensor from the transaxle case.
2. Remove the O-ring from the speedometer sensor.

1. Remove the clip and speedometer driven (MTM) gear sub-assembly from the speedometer sensor.

Fig 2: Identifying Drain (MTM) Plug Sub-Assembly And Gasket

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

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

1. Remove the clutch release bearing clip and clutch release bearing assembly from the clutch release fork sub-assembly.

Fig 4: Identifying Clutch Release Bearing Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release fork support from the transaxle case.

Fig 5: Identifying Release Fork Support

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the clutch release fork boot from the transaxle case.

Fig 6: Identifying Clutch Release Fork Boot

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the back up light switch assembly and gasket from the manual transmission case.

Fig 7: Locating Back Up Light Switch Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.

Fig 8: Locating Floor Shift Control Lever Housing Support Bracket Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and selecting bell crank assembly from the manual transmission case.
2. Remove the control shift lever bush.

Fig 9: Locating Selecting Bell Crank Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place the manual transaxle assembly on wooden blocks.

Fig 10: Placing Manual Transaxle Assembly On Wooden Blocks

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the lock ball assembly No. 1 from the manual transmission case.

Fig 11: Locating Lock Ball Assembly No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts, shift and select lever shaft assembly and gasket from the manual transmission case.

Fig 12: Identifying Shift And Select Lever Shaft Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 9 bolts.
   Fig 13: Identifying Manual Transmission Case Cover Sub-Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer, carefully tap the projection of the manual transmission case cover sub-assembly to remove it from the manual transmission case.
   NOTE: Do not damage the manual transmission case.
   Fig 14: Tapping Projection Of Manual Transmission Case Cover Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Disengaging Gears

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the gear shift fork lock bolt from the gear shift fork No. 3.
   Fig 17: Locating 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.

1. Using 2 screwdrivers and a hammer, tap out the snap ring.

   HINT:

   Use a shop rag or piece of cloth 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

   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: Identifying Synchromesh Shifting Keys

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.

Fig 22: Identifying 5Th Gear Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.

Fig 24: Locating Bearing Retainer Rear Bolts (MTM)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.

Fig 27: Locating Reverse Idler Gear Shaft Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Fig 28: Tapping Out Snap Ring From Gear Shift Fork Shaft No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Identifying Shift Detent Ball Plug

   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/Installing Seat, Spring And Ball

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Remove the 3 bolts from the transaxle case side.
   Fig 34: Locating Transaxle Case Side Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the manual transmission case side.
   Fig 35: Locating Manual Transmission Side Bolts

   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.

Fig 36: Identifying Manual Transaxle Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft from the transaxle case.

Fig 37: Identifying Reverse Idler Gear Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and reverse shift arm bracket assembly from the transaxle case.

Fig 38: Locating Reverse Shift Arm Bracket Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts from the gear shift fork No. 2 and gear shift head No. 1.
   Fig 39: Locating Shift Lock Bolts

   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: Identifying Gear Shift Fork Shaft No. 2 And Gear Shift Head No. 1 From Transaxle Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using 2 screwdrivers and a hammer, tap out the snap ring.

   HINT:

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

   Fig 41: Tapping Out 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: Locating Gear Shift Fork Lock Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the gear shift fork No. 1.

Fig 43: Identifying Gear Shift Fork No. 1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 or piece of cloth to keep the snap ring from flying.

   Fig 44: Tapping Out Snap Ring From Gear Shift Fork Shaft No. 3

   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: Identifying Shift Fork Shaft No. 3 With Reverse Shift Fork And Gear Shift Fork No. 2

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 balls from the reverse shift fork.
   Fig 46: Identifying 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 or piece of cloth to keep the snap ring from flying.

5. Remove the reverse shift fork from the gear shift fork shaft No. 3.

Fig 47: Tapping Out Snap Ring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the input and output shaft assembly from the transaxle case.

Fig 48: Identifying Input And Output Shaft Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the differential case assembly from the transaxle case.

Fig 49: Identifying Differential Case Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and manual transaxle case receiver from the transaxle case.

Fig 50: Locating Manual Transaxle Case Receiver Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 (ø5 mm) and a hammer, drive out the slotted pin and remove the reverse restrict pin assembly from the manual transmission case.

Fig 52: Driving Out Slotted Pin

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 53: Locating Oil Receiver Pipe No. 1 Bolt (MTM)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 54: Locating Oil Receiver Pipe No. 2 Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and bearing lock plate from the transaxle case.

Fig 55: Locating Bearing Lock Plate Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the transmission magnet from the transaxle case.

Fig 56: Locating Transmission Magnet

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

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

1. Remove the output shaft (MTM) cover from the transaxle case.

Fig 60: Identifying Output Shaft (MTM) Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   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) 

Fig 62: Removing FR Differential Case Front Tapered Roller Bearing (Inner Race) From Front Differential Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Driving Out Transaxle Case Oil Seal From Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   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

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)