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Disassembly [06/2018 - 03/2019]: Procedure

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  1. SECURE MANUAL TRANSAXLE ASSEMBLY 
    1. Place the manual transaxle assembly on wooden blocks.
      GTY935494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
  2. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the manual transmission filler plug and gasket from the manual transmission case.
      GTY891779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE MANUAL TRANSMISSION DRAIN PLUG 
    1. Remove the manual transmission drain plug and gasket from the manual transmission case.
      GTY891777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY 
    1. Using a 27 mm deep socket wrench, remove the back-up light switch assembly and gasket from the manual transmission case.
      GTY891774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NEUTRAL POSITION SWITCH 
    1. Using SST, remove the neutral position switch and gasket from the manual transmission case.
      GTY881558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09816-30010 
  6. REMOVE TRANSMISSION REVOLUTION SENSOR 
    1. Remove the bolt and transmission revolution sensor from the manual transmission case.
      GTY891785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the transmission revolution sensor.
      GTY846442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP 
    1. Remove the release cylinder bleeder plug cap from the release cylinder bleeder plug.
      GTY891782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE RELEASE CYLINDER BLEEDER PLUG 
    1. Remove the release cylinder bleeder plug from the clutch release bleeder sub-assembly.
      GTY891781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY 

    Refer to PROCEDURE - Step 3 [06/2018 - 01/2019] , or refer to PROCEDURE - Step 3 [01/2019 - 03/2019]

  10. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY TO BLEEDER TUBE 

    Refer to PROCEDURE - Step 4 [06/2018 - 01/2019] , or refer to PROCEDURE - Step 4 [01/2019 - 03/2019]

  11. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5 [06/2018 - 01/2019] , or refer to PROCEDURE - Step 5 [01/2019 - 03/2019]

  12. REMOVE LOCK BALL PIN 
    1. Using a 10 mm hexagon socket wrench, remove the shift and select lever shaft straight screw with head plug from the manual transmission case.
      GTY853621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shift and Select Lever Shaft Straight Screw with Head Plug
      *2 No. 2 Lock Ball Pin Return Spring
      *3 Lock Ball Pin
    2. Using a Magnet Hand, remove the No. 2 lock ball pin return spring and lock ball pin from the manual transmission case.
  13. REMOVE NO. 2 LOCK BALL PIN 
    1. Using a 10 mm hexagon socket wrench, remove the shift and select lever shaft straight screw with head plug from the transaxle (MTM) case sub-assembly.
      GTY858820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shift and Select Lever Shaft Straight Screw with Head Plug
      *2 No. 1 Lock Ball Pin Return Spring
      *3 No. 2 Lock Ball Pin
    2. Using a Magnet Hand, remove the No. 1 lock ball pin return spring and No. 2 lock ball pin from the transaxle (MTM) case sub-assembly.
  14. REMOVE SHIFT DETENT BALL 
    1. Using a 6 mm hexagon socket wrench, remove the shift detent ball plug from the transaxle (MTM) case sub-assembly.
      GTY861944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shift Detent Ball Plug
      *2 No. 2 Shift Detent Ball Compression Spring
      *3 Shift Detent Ball
    2. Using a Magnet Hand, remove the No. 2 shift detent ball compression spring and shift detent ball from the transaxle (MTM) case sub-assembly.
    3. Using a 6 mm hexagon socket wrench, remove the 2 shift detent ball plugs from the manual transmission case.
      GTY867318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Shift Detent Ball Plug
      *2 Shift Detent Ball Compression Spring
      *3 Shift Detent Ball
    4. Using a Magnet Hand, remove the 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.
  15. REMOVE MANUAL TRANSMISSION CASE 
    1. Remove the 18 bolts.
      GTY891791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, separate the manual transmission case from the transaxle (MTM) case sub-assembly.
      GTY937978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the manual transmission case.

    3. While turning the outer No. 1 shift lever counterclockwise, remove the manual transmission case from the transaxle (MTM) case sub-assembly as shown in the illustration.
      GTY881603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Outer No. 1 Shift Lever
      *a Turn Counterclockwise
      NOTE:

      As the outer No. 1 shift lever will turn clockwise strongly under its own weight when the manual transmission case is lifted a certain amount and the inner No. 1 shift lever and inner No. 2 shift lever become disengaged, make sure to hold the outer No. 1 shift lever firmly.

      GTY870792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inner No. 1 Shift Lever
      *2 Inner No. 2 Shift Lever
      *3 Outer No. 1 Shift Lever
      *a Movement Inside Manual Transaxle Assembly
  16. REMOVE INNER SELECT LEVER SET BOLT 
    1. Using a 6 mm hexagon socket wrench, remove the inner select lever set bolt.
      GTY937963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE OUTER SELECT LEVER 
    1. Remove the outer select lever from the transaxle (MTM) case sub-assembly.
      GTY891720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY 
    1. Rotate the shift and select lever shaft assembly counterclockwise to the position shown in the illustration and remove it from the transaxle (MTM) case sub-assembly.
      GTY937962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INNER SELECT LEVER 
    1. Remove the inner select lever from the transaxle (MTM) case sub-assembly.
      GTY891716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE OUTER SELECT LEVER OIL SEAL 
    1. Using a screwdriver with its tip wrapped with protective tape, remove the outer select lever oil seal from the transaxle (MTM) case sub-assembly.
      GTY922863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Do not damage the transaxle (MTM) case sub-assembly.

  21. REMOVE INPUT SHAFT ASSEMBLY 
    1. Remove the input shaft assembly together with the output shaft assembly, No. 1 fork shaft assembly, No. 2 gear shift fork assembly and No. 3 gear shift fork assembly from the transaxle (MTM) case sub-assembly.
      GTY842288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Input Shaft Assembly
      *2 Output Shaft Assembly
      *3 No. 1 Fork Shaft Assembly
      *4 No. 2 Gear Shift Fork Assembly
      *5 No. 3 Gear Shift Fork Assembly
      NOTE:

      To prevent damage to the front output shaft bearing (inner race), slightly raise the differential case assembly.

    2. Remove the No. 1 fork shaft assembly, No. 2 gear shift fork assembly and No. 3 gear shift fork assembly from the input shaft assembly and output shaft assembly.
  22. REMOVE NO. 1 GEAR SHIFT HEAD 
    1. Using a 5 mm pin punch and hammer, remove the shift head set slotted spring pin and No. 1 gear shift head from the No. 1 gear shift fork shaft.
      GTY938025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 1 GEAR SHIFT FORK ASSEMBLY 
    1. Using a 5 mm pin punch and hammer, remove the shift fork slotted pin and No. 1 gear shift fork assembly from the No. 1 gear shift fork shaft.
      GTY938026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE DIFFERENTIAL CASE ASSEMBLY 
    1. Remove the differential case assembly together with the No. 2 output shaft assembly and No. 4 fork shaft assembly from the transaxle (MTM) case sub-assembly.
      GTY848170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Differential Case Assembly
      *2 No. 2 Output Shaft Assembly
      *3 No. 4 Fork Shaft Assembly
    2. Remove the No. 4 fork shaft assembly from the No. 2 output shaft assembly.
  25. REMOVE NO. 4 GEAR SHIFT FORK 
    1. Remove the bolt and No. 4 gear shift fork from the No. 4 gear shift fork shaft.
      GTY892002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case front tapered roller bearing (outer race) from the transaxle (MTM) case sub-assembly.
      GTY851577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Case Front Tapered Roller Bearing (Outer Race)
      *2 Front Differential Oil Baffle
      • SST: 09308-36010 
      NOTE:
      • Make sure that SST is not hooked on the front differential oil baffle.
      • Do not damage the transaxle (MTM) case sub-assembly.
    2. Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.
      GTY856941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-60011 
        1. 09951-00500
  27. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.
      GTY860445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Differential Case Rear Tapered Roller Bearing (Outer Race)
      *2 Front Differential Case Rear Shim
      • SST: 09308-36010 
      NOTE:

      Do not damage the manual transmission case.

    2. Using SST, remove the front differential case rear tapered roller bearing (inner race) from the differential case assembly.
      GTY839477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      • SST: 09950-40011 
        1. 09951-04010
        2. 09952-04010
        3. 09953-04020
        4. 09954-04010
        5. 09955-04061
        6. 09957-04010
        7. 09958-04011
      • SST: 09950-60011 
        1. 09951-00500
  28. REMOVE TRANSMISSION MAGNET 
    1. Remove the transmission magnet from the transaxle (MTM) case sub-assembly.
      GTY891973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE BREATHER PLUG 
    1. Remove the breather plug from the transaxle (MTM) case sub-assembly.
      GTY891978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE) 
    1. Using SST, remove the front output shaft bearing (outer race) from the transaxle (MTM) case sub-assembly.
      GTY855579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09308-00010 
      NOTE:

      Do not damage the transaxle (MTM) case sub-assembly.

  31. REMOVE OUTPUT SHAFT (MTM) COVER 
    1. Remove the output shaft (MTM) cover from the transaxle (MTM) case sub-assembly.
      GTY891971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REVERSE GEAR SHAFT COVER 
    1. Remove the reverse gear shaft cover from the transaxle (MTM) case sub-assembly.
      GTY891969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DIFFERENTIAL OIL BAFFLE 
    1. Remove the front differential oil baffle from the transaxle (MTM) case sub-assembly.
      GTY938019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, remove the front transaxle case oil seal from the transaxle (MTM) case sub-assembly.
      GTY890816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00360
      • SST: 09950-70010 
        1. 09951-07150
  35. REMOVE FRONT DRIVE SHAFT OIL SEAL RH 
    1. Using SST and a hammer, remove the front drive shaft oil seal RH from the transaxle (MTM) case sub-assembly.
      GTY897265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00590
      • SST: 09950-70010 
        1. 09951-07200
  36. REMOVE TRANSAXLE CASE STRAIGHT PIN 
    1. Remove the 3 transaxle case straight pins from the transaxle (MTM) case sub-assembly.
      GTY891986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE REAR REVERSE GEAR SHAFT BEARING SHIM 
    1. Remove the rear reverse gear shaft bearing shim from the manual transmission case.
      GTY891985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE REAR INPUT SHAFT BEARING SHIM 
    1. Remove the rear input shaft bearing shim from the manual transmission case.
      GTY891994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE INPUT SHAFT (MTM) COVER 
    1. Remove the input shaft (MTM) cover from the manual transmission case.
      GTY891993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 1 OIL RECEIVER PIPE (MTM) 
    1. Disengage the 2 guides and remove the No. 1 oil receiver pipe (MTM) from the manual transmission case.
      GTY891997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE OUTER NO. 1 SHIFT LEVER 
    1. Using a 5 mm pin punch and hammer, remove the inner shift lever slotted spring pin from the inner No. 1 shift lever.
      GTY924994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hole
      NOTE:

      Perform this step carefully so that the inner shift lever slotted spring pin does not fly out.

      HINT: 

      When removing the inner shift lever slotted spring pin, align the inner shift lever slotted spring pin with the hole in the neutral position switch.

    2. Remove the outer No. 1 shift lever and inner No. 1 shift lever from the manual transmission case.
      GTY843970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Outer No. 1 Shift Lever
      *2 Inner No. 1 Shift Lever
  42. REMOVE OUTER SHIFT LEVER OIL SEAL 
    1. Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the manual transmission case.
      GTY846981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Do not damage the manual transmission case.

  43. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE) 
    1. Using SST, remove the rear output shaft bearing (outer race) and rear output shaft bearing shim from the manual transmission case.
      GTY932759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Output Shaft Bearing (Outer Race)
      *2 Rear Output Shaft Bearing Shim
      • SST: 09308-00010 
      NOTE:

      Do not damage the manual transmission case.

  44. REMOVE FRONT DRIVE SHAFT OIL SEAL LH 
    1. Using SST and a hammer, remove the front drive shaft oil seal LH from the manual transmission case.
      GTY873942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00620
      • SST: 09950-70010 
        1. 09951-07150
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