Manual Transaxle Unit: Disassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE MANUAL TRANSMISSION FILLER PLUG
1. Remove the manual transmission filler plug and gasket from the manual transmission case.
  
  Fig 1: Identifying Manual Transmission Filler Plug & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRAIN PLUG SUB-ASSEMBLY
1. Remove the drain plug sub-assembly and gasket from the manual transmission case.
REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
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 sub-assembly.
  
  Fig 2: Identifying Speedometer Driven Hole Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPEEDOMETER SENSOR (w/o ABS)
1. Remove the bolt and speedometer sensor from the transaxle case.
REMOVE BACK-UP LIGHT SWITCH ASSEMBLY
1. Separate the back-up light switch wire harness from the 2 clamps.
2. Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.
  SST 09817-16011
  
  Fig 3: Identifying SST, Back-Up Light Switch Assembly & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SELECTING BELL CRANK ASSEMBLY
1. Remove the 2 bolts and nut and remove the selecting bell crank assembly from the manual transmission case.
2. Remove the control shift lever bush.
  
  Fig 4: Locating Selecting Bell Crank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SHIFT CONTROL SHIFT LEVER
1. Remove the nut and spring washer.
  
  Fig 5: Locating Nut & Spring Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, remove the lock pin.
3. Remove the floor shift control shift lever.
  
  Fig 6: Identifying Brass Bar, Hammer & Lock Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT LEVER DAMPER
1. Remove the nut and spring washer.
  
  Fig 7: Locating Nut & Spring Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a brass bar and a hammer, remove the lock pin.
3. Remove the shift lever damper.
  
  Fig 8: Identifying Brass Bar, Hammer & Lock Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX MANUAL TRANSAXLE ASSEMBLY
1. Place the manual transaxle assembly on wooden blocks.
  
  Fig 9: Placing Manual Transaxle Assembly On Wooden Blocks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCK BALL ASSEMBLY NO.1
1. Remove lock ball assembly No. 1 from the manual transmission case.
  
  Fig 10: Identifying Lock Ball Assembly No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT GATE PIN
1. Remove the shift gate pin and washer from the transmission case.
  
  Fig 11: Locating Shift Gate Pin & Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL SHAFT COVER
1. Remove the 4 bolts, control shaft cover and gasket from the manual transmission case.
  
  Fig 12: Identifying Bolts, Control Shaft Cover & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL SHAFT COVER OIL SEAL
1. Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.
  
  Fig 13: Identifying Screwdriver & Control Shaft Cover Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY
1. Remove the shift and select lever shaft assembly from the transmission case.
  
  Fig 14: Identifying Shift & Select Lever Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
1. Remove the 9 bolts.
  
  Fig 15: 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 sub-assembly to remove the manual transmission case cover from the manual transmission case.
  NOTE: Do not damage the manual transmission case.
  
  Fig 16: Using Plastic Hammer, Carefully Tap Projection Of 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 17: Identifying Chisel, Hammer & Manual Transmission Output Shaft Rear Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 2 gears simultaneously to lock the transmission.
3. Remove the manual transmission output shaft rear set nut.
4. Disengage the 2 gears.
  
  Fig 18: Identifying 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 gear shift fork No. 3.
  
  Fig 19: Locating Gear Shift Fork No. 3 With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove transmission hub sleeve No. 3 with gear shift fork No. 3 from transmission clutch hub No. 3.
  
  Fig 20: Identifying Transmission Hub Sleeve No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR THRUST CLEARANCE
1. Using a dial indicator, measure the 5th gear thrust clearance.
  Standard clearance:
  
  0.10 to 0.55 mm (0.0039 to 0.0217 in.)
  
  Maximum clearance:
  
  0.55 mm (0.0217 in.)
  
  If the clearance exceeds the maximum, replace transmission clutch hub No. 3, the 5th gear or input shaft rear radial ball bearing.
  
  Fig 21: Measuring 5th Gear Thrust Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 5TH GEAR RADIAL CLEARANCE
1. Using a dial indicator, measure the 5th gear radial clearance.
  Standard clearance:
  
  KOYO made:
  
  0.015 to 0.058 mm (0.0006 to 0.0023 in.)
  
  NSK made:
  
  0.015 to 0.056 mm (0.0006 to 0.0022 in.)
  
  Maximum clearance:
  
  KOYO made:
  
  0.058 mm (0.0023 in.)
  
  NSK made:
  
  0.056 mm (0.0022 in.)
  
  Fig 22: Measuring 5th Gear Radial Clearance Using Dial Indicator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.
REMOVE 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 off.
  
  Fig 23: Identifying Screwdrivers, Hammer & Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove transmission clutch hub No. 3, the 5th gear and synchronizer ring No. 3 from the input shaft.
  SST 09950-40011 (09951-04020,09952-04010, 09953-04030, 09954-04010, 09955-04011), 09950-60010 (09951-00180)
  
  Fig 24: Identifying SST & Transmission Clutch Hub No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 3 synchromesh shifting keys and 2 synchromesh shifting key springs from transmission clutch hub No. 3.
  
  Fig 25: Identifying Synchromesh Shifting Keys & Springs
  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 26: Identifying 5th Gear Needle Roller Bearing & Bearing Spacer
  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, 09955-03021), 09950-60010 (09951-00180)
  
  Fig 27: Identifying SST & 5th Driven Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING RETAINER REAR
1. Remove the 5 bolts and bearing retainer rear from the manual transmission case.
  
  Fig 28: Identifying Bearing Retainer Rear Bolts
  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 29: Identifying Snap Ring Expander & 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 30: Identifying Snap Ring Expander & 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 reverse idler gear shaft gasket from the manual transmission case.
  
  Fig 31: Identifying 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 gear shift fork shaft No. 2.
  HINT:
  
  Use a shop rag or piece of cloth to keep the snap ring from flying off.
  
  Fig 32: Identifying Screwdrivers, Hammer & 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 33: Identifying Hexagon Wrench & Shift Detent Ball Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a magnetic finger, remove the 2 shift detent ball spring seats No. 1, 2 shift detent ball springs and 2 shift detent balls from the manual transmission case.
  
  Fig 34: Identifying Shift Detent Ball Spring Seats No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hexagon wrench, remove the shift detent ball plug from the front transaxle case.
  
  Fig 35: Identifying Hexagon Wrench & Shift Detent Ball Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a magnetic finger, remove the seat, spring and ball from the front transaxle case.
  
  Fig 36: Identifying Seat, Spring & Ball
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOCK BALL ASSEMBLY NO.2
1. Using a hexagon wrench, remove lock ball assembly No. 2 from the manual transmission case.
  
  Fig 37: Identifying Hexagon Wrench & Lock Ball Assembly No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL TRANSMISSION CASE
1. Remove the 3 bolts from the front transaxle case.
  
  Fig 38: Identifying Front Transaxle Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 13 bolts from the manual transmission case.
  
  Fig 39: Identifying Manual Transmission Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, carefully tap the projections of the manual transmission case to remove the transmission case from the transaxle case.
  NOTE: Do not damage the manual transmission case and transaxle case.
  
  Fig 40: Tapping Projections Of Manual Transmission Case Using Brass Bar & Hammer
  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 front transaxle case.
  
  Fig 41: Identifying Reverse Idler Gear Sub-Assembly, Thrust Washer & Reverse Idler Gear Shaft
  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 front transaxle case.
  
  Fig 42: Identifying Reverse Shift Arm Bracket Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT NO.2
1. Remove the 2 bolts from gear shift fork No. 2 and gear shift head No. 1.
  
  Fig 43: Identifying Gear Shift Fork No. 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove gear shift fork shaft No. 2 and gear shift head No. 1 from the front transaxle case.
  
  Fig 44: Identifying Gear Shift Fork Shaft No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GEAR SHIFT FORK SHAFT NO.1
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 off.
  
  Fig 45: Identifying Screwdrivers, Hammer & Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the shift fork set bolt and gear shift fork shaft No. 1 from gear shift fork No. 1.
  
  Fig 46: Identifying Bolt & Gear Shift Fork Shaft No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove gear shift fork No. 1.
  
  Fig 47: Identifying 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 gear shift fork shaft No. 3.
  HINT:
  
  Use a shop rag or piece of cloth to keep the snap ring from flying off.
  
  Fig 48: Identifying Screwdrivers, Hammer & Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove shift fork shaft No. 3 together with the reverse shift fork and gear shift fork No. 2 from the manual transaxle case.
  
  Fig 49: Identifying Shift Fork Shaft No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a magnetic finger, remove the 2 reverse shift fork balls from the reverse shift fork.
  
  Fig 50: Identifying Reverse Shift Fork
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using 2 screwdrivers and a hammer, tap the snap ring out of shift fork shaft No. 3.
  HINT:
  
  Use a shop rag or piece of cloth to keep the snap ring from flying off.
5. Remove the reverse shift fork from gear shift fork shaft No. 3.
  
  Fig 51: Identifying Snap Ring Out Of Shift Fork Shaft No. 3
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT ASSEMBLY
1. Remove the input shaft assembly and output shaft assembly from the front transaxle case.
  
  Fig 52: Identifying Input Shaft Assembly & Output Shaft Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DIFFERENTIAL CASE ASSEMBLY
1. Remove the differential case assembly from the front transaxle case.
  
  Fig 53: Identifying 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 front transaxle case.
  
  Fig 54: Identifying Manual Transaxle Case Receiver & Bolts
  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 55: Identifying Hexagon Wrench & Reverse Restrict Pin Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch (ø5 mm) and a hammer, drive out the slotted spring pin and remove the reverse restrict pin assembly from the manual transmission case.
  
  Fig 56: Identifying Pin Punch, Hammer & Reverse Restrict Pin Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER PIPE NO. 1
1. Remove the bolt and oil receiver pipe No. 1 from the manual transmission case.
  NOTE: Do not damage oil receiver pipe No. 1.
  
  Fig 57: Identifying Oil Receiver Pipe No. 1 & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL RECEIVER PIPE NO. 2
1. Remove the bolt and oil receiver pipe No. 2 from the manual transmission case.
  NOTE: Do not damage oil receiver pipe No. 2.
  
  Fig 58: Identifying Oil Receiver Pipe No. 2 & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING LOCK PLATE
1. Remove the bolt and bearing lock plate from the front transaxle case.
  
  Fig 59: Identifying Bearing Lock Plate & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION MAGNET
1. Remove the transmission magnet from the front transaxle case.
  
  Fig 60: Identifying Transmission Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT SHAFT FRONT BEARING
1. Using SST, remove the input shaft front bearing from the front transaxle case.
  SST 09612-65014 (09612-01050, 09612-01060)
  
  Fig 61: Identifying SST & 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 62: Removing Front Transaxle Case Oil Seal Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT FRONT BEARING
1. Using SST, remove the output shaft front bearing from the front transaxle case.
  SST 09308-00010
  
  NOTE: Do not apply excessive force to the front transaxle case when installing it.
  
  Fig 63: Identifying SST & Output Shaft Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTPUT SHAFT COVER
1. Remove the output shaft cover from the front transaxle case.
  
  Fig 64: Identifying Output Shaft Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
1. Using SST, remove the front differential case front tapered roller bearing (outer race) and plate washer from the front transaxle case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 65: Identifying SST & Front Differential Case Front Tapered Roller Bearing (Outer Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.
  SST 09950-00020, 09950-00030, 09950-40011
  
  (09957-04010), 09950-60010 (09951-00360)
  
  NOTE: Do not damage the bearing.
  
  Fig 66: Identifying SST & Front Differential Case Front Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSAXLE CASE OIL SEAL
1. Using SST and a hammer, remove the transaxle case oil seal from the front transaxle case.
  SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
  
  Fig 67: Identifying SST, Hammer & Transaxle Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING
1. Using SST, remove the front differential case rear tapered roller bearing (outer race) and plate washer from the transmission case.
  SST 09612-65014 (09612-01040, 09612-01050)
  
  Fig 68: Identifying SST & Front Differential Case Rear Tapered Roller Bearing (Outer Race)
  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 09950-40011 (09951-04010,09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
  
  NOTE: Do not damage the bearing.
  
  Fig 69: Identifying SST & Front Differential Case Rear Tapered Roller Bearing (Inner Race)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CASE OIL SEAL
1. Using SST and a hammer, drive out the transmission case oil seal from the manual transmission case.
  SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)
  
  Fig 70: Identifying SST, Hammer & Transmission Case Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT OIL SEAL
1. Using a screwdriver and hammer, remove the shift and select lever shaft oil seal.
  
  Fig 71: Identifying Screwdriver, Hammer, Shift & Select Lever Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT AND SELECT LEVER SHAFT SLIDE BALL BEARING
1. Using SST and a hammer, remove the shift and select lever shaft slide ball bearing.
  SST 09950-60010 (09951-00220), 09950-70010 (09951-07200)
  
  Fig 72: Identifying SST, Hammer, Shift & Select Lever Shaft Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002