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Transaxle Reassembly

  1. Coat all sliding and rotating surfaces with gear oil before assembly. Check differential side bearing preload. See DIFFERENTIAL BEARING PRELOAD  under TRANSAXLE ADJUSTMENTS.
  2. Install No. 3 clutch hub and 3 shifting keys to hub sleeve. Install 2 key springs to hub. Position key springs so that their end gaps are not aligned. Install No. 3 clutch hub into No. 3 hub sleeve. See Figure. Install magnet to transaxle case. Install differential case assembly. See Figure. Install input and output shafts into transaxle case.
  3. Place No. 1 and No. 2 shift forks into groove of No. 1 and No. 2 hub sleeves. Install No. 1 shift fork shaft into No. 1 shift fork hole. Install 2 set bolts of No. 1 and No. 2 shift forks.
  4. Install 2 balls to hole of reverse shift fork. See Figure. Install No. 3 shift fork to reverse shift fork. Using a screwdriver and a hammer, install snap ring. Install No. 3 shift fork shaft with reverse shift fork into transaxle case. See Figure.
  5. Place shift head down, and install No. 2 shift fork shaft. See Figure. To avoid interference of 2 balls, lift up No. 3 shift fork shaft. See Fig 1. Install No. 2 shift fork shaft until it contacts transaxle case. Install No. 2 shift fork and shift head to No. 2 shift fork shaft, and tighten bolts to specification. See TORQUE SPECIFICATIONS .
  6. Using a screwdriver and a hammer, install 2 NEW snap rings to No. 1 and No. 3 shift fork shafts. When installing reverse idler gear, thrust washer and shaft, align alignment mark. See Fig 2. When installing reverse shift arm bracket, set pin on top of reverse shift arm into groove on reverse idler gear. Fit the claw of reverse shift arm bracket with notch of input shaft front bearing. See Figure. Apply FIPG (08826-00090) to transaxle case and install 16 bolts. See Fig 8.
  7. Apply Loctite 242 to lock ball assembly threads. Using hexagon wrench, install lock ball assembly. See Figure. Install 3 balls, springs and seats. Apply sealant to threads, and install 3 straight screw plugs. See Figure.
  8. Install snap ring to No. 2 shift fork shaft. Install reverse idler gear shaft lock bolt. See Figure. Using snap ring expander, install 2 snap rings while pulling up on shafts. See Figure. Install rear bearing retainer. Apply Loctite 242 to retainer bolt threads and install bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
  9. When installing oil receiver pipes, prevent pipes from being deformed. Install oil receiver pipes while placing them against transaxle case. See Fig 3. Using 5th Driven Gear Replacer (09309-12020), install 5th driven gear. See Fig 4. Install spacer, needle roller bearing, 5th gear and synchronizer ring.
  10. Using Upper Ball Joint Dust Cover Replacer (09612-22011) and hammer, drive in No. 3 clutch hub and sleeve assembly with No. 3 shift fork. When installing No. 3 clutch hub assembly, align synchronizer ring slots with No. 3 shifting keys. Ensure 3rd clutch hub assembly is installed in correct direction. See Fig 6. Install bolt to No. 3 shift fork.
  11. Prior to driving in No. 3 hub sleeve and No. 3 hub assembly, place appropriate size wooden block on rear side of input shaft. See Fig 5. When installing components, fix input shaft firmly so that it is not pushed downward. Otherwise, input shaft rear ball bearing will become overloaded, and may be damaged.
  12. Using a dial indicator, check 5th gear thrust clearance. See Figure. Standard thrust clearance should be .0039-.0224" (.100-.570 mm). Service limit thrust clearance is .0224" (.570 mm). Select snap ring that allows minimum axial play. See 5TH GEAR SNAP RING THICKNESS CHART  table. Using a screwdriver and a hammer, install selected snap ring.
  13. Engage gear double meshing. Install NEW lock nut. See Figure. Disengage gear double meshing. Install shift and select lever shaft assembly with NEW gasket. Apply sealant to "A" bolt threads. See Fig 7. Install 4 bolts and lock bolt.
  14. Apply FIPG (08833-00080) to transaxle case cover, and install cover and 9 bolts. See Fig 9. Install control lever housing support bracket and 3 bolts. Install selecting bellcrank assembly and 2 bolts. See Figure.
  15. Install back-up light switch with gasket. Install vehicle speed sensor and bolt. Install release fork assembly and release bearing. Install release fork support and fork boot. See Figure.
Fig 1: Lifting Up No. 3 Gear Shift Fork Shaft
G00204207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Aligning Reverse Idler Gear, Thrust Washer & Shaft
G00204233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Installing Oil Receiver Pipes
G00204182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Installing 5th Driven Gear
G00204208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Positioning Wooden Block On Input Shaft
G00204210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Installing No. 3 Hub Sleeve & No. 3 Clutch Assembly
G00204245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 7: Identifying Shift & Select Lever Shaft Bolt Sealant Locations
G00031313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 8: Identifying Transaxle Case Sealant & Bolt Locations
G00204246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 9: Identifying Transaxle Case Cover Sealant & Bolt Locations
G00031312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5TH GEAR SNAP RING THICKNESS CHART

Identification Mark In. (mm)
A .0886 (2.250)
B .0909 (2.310)
C .0933 (2.370)
D .0957 (2.430)
E .0980 (2.490)
F .1004 (2.550)
G .1028 (2.610)
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