MANUAL TRANSAXLE ASSY (From July, 2003): Replacement

COMPONENTS: Partial engine assy (See COMPONENTS )

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See  REPLACEMENT  ) 
2. REMOVE FRONT DRIVE SHAFT ASSY RH (SEE  REMOVAL  ) 
3. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE  REMOVAL  ) 
4. REMOVE CLUTCH ACCUMULATOR ASSY (SEE  REPLACEMENT  ) 
5. REMOVE CLUTCH RELEASE CYLINDER ASSY (SEE  OVERHAUL  ) 
6. DISCONNECT WIRE HARNESS 
   1. Disconnect the wire harness clamp.
   2. Disconnect the back-up lamp switch connector, speedometer sensor connector and starter connector.
7. REMOVE ENGINE WIRE NO. 3 
   1. Remove the bolt and disconnect the engine wire No. 3.
      Fig 1: Removing Bolt & Disconnect Engine Wire No. 3

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE WIRE HARNESS CLAMP 
   1. Remove the 2 bolts and 2 wire harness clamps.
      Fig 2: Removing Bolts & 2 Wire Harness Clamps

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE STARTER ASSY 
   1. Remove the 2 bolts and starter assy.
      Fig 3: Removing Bolts & Starter Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE ENGINE MOUNTING BRACKET FR 
    1. Remove the 3 bolts and engine mounting bracket FR.
       Fig 4: Removing Bolts & Engine Mounting Bracket FR

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE MANUAL TRANSMISSION CASE PROTECTOR 
    1. Remove the 2 bolts and manual transmission case protector.
       Fig 5: Removing Bolts & Manual Transmission Case Protector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1 
    1. Remove the 2 bolts and exhaust pipe support bracket No. 1.
       Fig 6: Removing Bolts & Exhaust Pipe Support Bracket No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the 4 bolts and engine mounting insulator LH.
       Fig 7: Removing Bolts & Engine Mounting Insulator LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE MANUAL TRANSAXLE ASSY 
    1. Remove the 10 bolts.
    2. Separate and remove the transaxle from the engine.
    Fig 8: Removing Transaxle To Engine Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. INSTALL MANUAL TRANSAXLE ASSY 
    1. Align the input shaft with the clutch disc and install the transaxle to the engine.
    2. Install the 10 bolts.

       Torque: 

       Bolt A: 64 N.m (653 kgf.cm, 47 ft.lbf) 

       Bolt B: 46 N.m (470 kgf.cm, 34 ft.lbf) 

       Bolt C: 44 N.m (449 kgf.cm, 32 ft.lbf) 

       Fig 9: Installing Transaxle To Engine Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator LH with the 4 bolts.

       Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

    HINT:

    Tighten them in order: A, B, C and D.

    Fig 10: Installing Engine Mounting Insulator LH

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1 
    1. Install the exhaust pipe support bracket No. 1 with the 2 bolts.

       Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

       Fig 11: Installing Exhaust Pipe Support Bracket No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. INSTALL MANUAL TRANSMISSION CASE PROTECTOR 
    1. Install the manual transmission case protector with the 2 bolts.

       Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

       Fig 12: Installing Manual Transmission Case Protector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. INSTALL ENGINE MOUNTING BRACKET FR 
    1. Install the engine mounting bracket FR with the 3 bolts.

       Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

       Fig 13: Installing Engine Mounting Bracket FR

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. INSTALL STARTER ASSY 
    1. Install the starter assy with the 2 bolts.

       Torque: 39 N.m (398 kgf.cm, 29 ft.lbf) 

       Fig 14: Installing Starter Assy With Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. INSTALL WIRE HARNESS CLAMP 
    1. Install the 2 wire harness clamps with the 2 bolts.

       Torque: 8.4 N.m (86 kgf.cm, 74 in.lbf) 

       Fig 15: Installing Wire Harness Clamps

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL ENGINE WIRE NO. 3 
    1. Connect the engine wire No. 3 with the bolt.

       Torque: 9.6 N.m (98 kgf.cm, 85 in.lbf) 

       Fig 16: Connecting Ground Wire No. 3

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. CONNECT WIRE HARNESS 
    1. Install the wire harness clamp.
    2. Connect the back-up lamp switch connector, speedometer sensor connector and starter connector.
24. INSTALL CLUTCH RELEASE CYLINDER ASSY (SEE  OVERHAUL  ) 
25. INSTALL CLUTCH ACCUMULATOR ASSY (SEE  REPLACEMENT  ) 
26. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE  INSTALLATION  ) 
27. INSTALL FRONT DRIVE SHAFT ASSY RH (SEE  INSTALLATION  ) 
28. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See  REPLACEMENT  )