Contents: Removal ↓ Installation ↓
Removal
Turn off the ignition and disconnect the ground wire from the battery.
Remove the air filter housing.
Remove the expansion tank of the cooling system.
With the vehicle standing on its wheels, loosen the nuts securing the drive shafts to the hubs.
Remove the clutch slave cylinder together with the fluid supply pipe.
Caution! Do not press the clutch pedal when the clutch slave cylinder is removed.
Disconnect the electrical connectors from the reverse light switch and vehicle speed sensor.
Remove the bolt and disconnect the ground wire from the gearbox.
Disconnect the control cables from the transmission.
Release the clips securing the wiring harnesses to the engine and gearbox and move the wires to the side.
Remove the starter.
Secure the gearbox to the engine by hooking one hook of the chain through the eye on the end of the gearbox and the other hook through the hole in the end of the cylinder head.
Figure 9.4. Location of the upper transmission-to-engine mounting bolts (A) on pre-2001 models
Figure 9.5. Location of the upper transmission-to-engine mounting bolts (A and B) on 2001-onward models
[The text is taken from the specified website www.ToyotaMan.ru]
Remove the upper gearbox-to-engine mounting bolts (figure 9.4, 9.5). Mark the location of the brackets that are secured with these bolts.
Remove the bolt securing the left support of the power unit to the gearbox.
Raise the car on a lift. Remove the front wheels and the lower engine compartment guard.
Drain the oil from the gearbox.
Remove the drive shafts.
Remove the exhaust pipe.
If equipped, disconnect the oil cooler hoses from the transmission. Close the ends of the hoses with plastic plugs.
Remove the bolt securing the steering gear to the lower cross member. Use soft wire to secure the steering gear to the beam mounted across the engine compartment.
Remove the lower cross and longitudinal beams.
On pre-2001 models, remove the stiffener plate and the plate from the rear end of the engine.
Support the transmission with a transmission jack.
Remove the left gearbox support and its bracket.
Figure 9.6. Location of lower bolts (C, D, E, F, G) gearbox to engine mounts on single-axle vehicles manufactured before 2001
Figure 9.7. Location of the lower bolts (A and B) for fastening the gearbox to the engine on single-drive axle vehicles produced since 2001
Remove the lower gearbox-to-engine mounting bolts (figure 9.6, 9.7).
Make sure all hoses and wires are disconnected from the transmission.
Lower the left side of the engine with the gearbox, then move the gearbox away from the engine and, after the input shaft has cleared the clutch disc hub, lower and remove the gearbox.
Check the condition of the clutch parts, replace worn parts. It is recommended to replace the clutch disc every time the gearbox is removed.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
Clean the splined portion of the gearbox input shaft and lubricate with a thin layer of high-temperature grease. The lubricant layer must be thin and uniform, otherwise, when the clutch is operating, excess lubricant will be thrown onto the working surfaces of the clutch, which may impair its operation.
Move the gearbox towards the engine so that the gearbox input shaft fits into the splines of the clutch driven disc. To align the splines of the transmission input shaft with the splines of the clutch driven disc, it may be necessary to turn the engine crankshaft slightly. When installing the gearbox, do not allow the gearbox input shaft to rest on the clutch disc.
With the gearbox moved forward, install the clutch housing onto the cylinder block guide bushings.
Tighten the gearbox mounting bolts to the specified torque.
Fill the gearbox with oil.