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Transaxle Disassembly

NOTE: Refer to Fig 2 , for Disassembly and Reassembly of 6-Speed Transaxle and Components.
  1. Remove speedometer driven gear, reverse shift arm pivot, back-up light and 4WD switches, rear mount stay and restrict pin. Remove transmission case cover. Using magnetic probe, remove spring and ball.
  2. Using remover, remove straight screw plug. Using pin punch and hammer, drive out pin. Remove 6 bolts and shift lever housing, set bolt and lock plate.
  3. Remove extension housing. Using plug remover, remove straight screw plug. Using magnetic probe, remove spring and ball. Remove shift fork shaft with hub, hub sleeve and shift fork.
  4. Temporarily install input shaft. Cover input shaft tip with shop cloth and secure with pliers. Remove oil pump drive shaft. Note that drive shaft has left hand threads.
  5. Remove gear shift No. 4 head set bolt and locked plate. Using snap ring pliers, remove snap ring. Remove No. 4 shift fork with shift fork shaft. Use care that shifting key does not fly out. Using magnetic probe, remove interlock pin.
  6. Remove transfer case adaptor from transmission case. Turn select lever and remove tip from shift head groove. Remove transfer adaptor with select lever and extra low gear from transmission case.
  7. Remove output shaft and oil pump gear from extension housing. Remove speedometer drive gear. Using a pin punch and hammer, drive out slotted spring pins and remove gear shift heads. Remove "C" washer from No. 1 and 2 shift fork shafts.
  8. Using hexagon wrench, remove straight screw plugs. Using magnetic probe, remove springs and balls. Using snap ring pliers, remove bearing snap ring. Remove transmission case cover and input shaft.
  9. Using a plastic hammer, tap on case protrusion to separate case from intermediate plate. Remove case from intermediate plate. Mount intermediate plate in vise by securing protrusion on lower part of plate.
  10. Remove straight screw plug, spring and ball. Using a pin punch, drive out 4 slotted spring pins. Remove gear shift head. Set each fork shaft to neutral position.
  11. Holding shift fork, pull out fork shaft and remove fork. Remove interlock pins from fork shaft and intermediate plate. Using feeler gauge, measure counter 5th gear thrust clearance. See COUNTER 5TH GEAR THRUST CLEARANCE  .
    COUNTER 5TH GEAR THRUST CLEARANCE

    Application In. (mm)
    Standard Clearance .0059-.0128 (.15-.32)
    Maximum Clearance .0157 (.40)
  12. Using screwdriver, remove hole snap ring. Remove shifting key retainer. Using snap ring pliers, remove snap ring. Using hub remover, remove clutch hub No. 3, synchro ring and counter 5th gear together. Remove needle roller bearing.
  13. Remove spacer, steel ball and bearing retainer. Using snap ring pliers, remove 2 snap rings. Using plastic hammer, tap reverse gear shaft, idler gear and output shaft halfway out from intermediate plate. Support gear shaft by hand.
  14. Remove idler gear and reverse gear shaft together. Using plastic hammer, tap out counter gear and output shaft together. Support gear and shaft by hand. Using dial indicator, measure 1st and 4th gear thrust clearance. See GEAR THRUST CLEARANCE  .
    GEAR THRUST CLEARANCE

    Application Specification In. (mm)
    1st Gear .0059-.0108 (.15-.27)
    2nd & 3rd Gear .0059-.0098 (.15-.25)
    4th Gear .0008-.0094 (.02-.24)
    Maximum Clearance .0118 (.30)
  15. Using remover, press out sleeve yoke. Using snap ring pliers, remove snap ring. Using remover, press out 5th gear.
  16. Using snap ring pliers, remove output shaft front bearing snap ring. Using remover, press out output shaft front bearing, spacer and thrust bearing.
  17. Remove 4th gear, synchronizer ring and needle roller bearing. Use care not to drop needle roller bearing when removing gear. Using 2 screwdrivers and a hammer, tap out snap ring, spacer and thrust bearing.
  18. Using remover, press out clutch hub No. 2, synchronizer ring and 3rd gear. Using snap ring pliers, remove 1st gear snap ring. Remove 1st gear, synchronizer, needle roller bearing and inner race.
  19. Remove steel ball. Using remover, press out clutch hub No. 1, synchronizer and 2nd gear.
  20. Remove differential from transaxle. Install differential carrier to work stand with ring gear in horizontal position. Measure and record ring gear backlash. If backlash is not .0039-.0059" (.10-.15 mm), adjust side bearing preload or repair as necessary.
  21. Check ring gear runout. If maximum runout is greater than .0028" (.07 mm), install NEW ring gear. Inspect teeth pattern for proper wear. Using adaptor and torque meter, measure preload. Total preload should be 5.2-8.7 INCH Lbs. (.59-.98 N.m)
  22. Using remover, remove oil seals from differential carrier. Remove side bearing caps. Tag bearing cap, outer race and side washer to show reassembly location. See Fig 1 .
    Fig 1: Exploded View of Toyota Differential
    G00219632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. Using remover, remove side washer on ring gear teeth side. Remove differential case and bearing outer race. Remove side washer and oil reservoir.
  24. Loosen staked part of drive pinion nut. Using remover, loosen nut and turn drive pinion clockwise. Using press, remove drive pinion.
    Fig 2: Exploded View of Toyota 6-Speed Transaxle
    G00219631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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