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Home >> Scion >> 2005 >> tC L4-2.4L (2AZ-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Transmission Replacement

Transmission Replacement









MANUAL TRANSAXLE ASSEMBLY (MTM)
REPLACEMENT





NOTICE: When disconnecting the battery terminal, initialize the system(s) shown after the terminal is reconnected.

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE COLUMN HOLE COVER SILENCER SHEET
3. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2
4. REMOVE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO.1
5. REMOVE FRONT WHEELS
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE ENGINE UNDER COVER RH
8. DRAIN TRANSAXLE OIL
a. Remove the filler plug and gasket.
b. Remove the drain plug and gasket, and drain the oil.
c. Install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
9. REMOVE EXHAUST PIPE ASSEMBLY CENTER
10. REMOVE HOOD SUB-ASSEMBLY
11. REMOVE ENGINE COVER SUB-ASSEMBLY NO.1
12. REMOVE AIR CLEANER ASSEMBLY
13. REMOVE BATTERY CLAMP SUB-ASSEMBLY
14. REMOVE BATTERY
15. REMOVE BATTERY TRAY
16. REMOVE BATTERY CARRIER
a. Remove the 4 bolts and battery carrier.
17. REMOVE STARTER ASSEMBLY





18. SEPARATE WIRE HARNESS
a. Remove the 3 bolts, and separate the 3 wire harnesses.





19. DISCONNECT CONNECTOR
a. Disconnect the backup lamp switch connector.





20. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY
a. Remove the 3 bolts and separate the release cylinder.





21. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
a. Remove the 2 clips and 2 washers, and separate the 2 cables from the transaxle.
b. Remove the 2 clips, and separate the 2 cables from the bracket.
22. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)
23. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
24. DISCONNECT PRESSURE FEED TUBE ASSEMBLY





25. SUSPEND ENGINE ASSEMBLY
a. Install the No.1 and No.2 engine hangers in the correct direction.
Parts No.:
No.1 engine hanger: 12281-28010
No.2 engine hanger: 12282-28010
Bolt: 9151-26102.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
b. Attach the engine chain hoist to the engine hanger.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

26. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
27. SUPPORT MANUAL TRANSAXLE ASSEMBLY
a. Support the manual transaxle with a transmission jack.





28. REMOVE ENGINE MOUNTING INSULATOR LH
a. Remove the 5 bolts, nut and engine mounting insulator LH.





29. REMOVE ENGINE MOUNTING BRACKET LH
a. Remove the 3 bolts and engine mounting bracket LH.





30. REMOVE MANUAL TRANSAXLE ASSEMBLY
a. Remove the 10 bolts.
b. Separate and remove the transaxle from the engine.





31. REMOVE MANUAL TRANSMISSION CASE PROTECTOR
a. Remove the 2 bolts and case protector.





32. REMOVE ENGINE MOUNTING BRACKET FR
a. Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
b. Remove the 2 bolts and engine mounting bracket FR from the transaxle.





33. REMOVE ENGINE MOUNTING BRACKET RR
a. Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR.
b. Remove the 3 bolts and engine mounting bracket RR from the transaxle.





34. INSTALL ENGINE MOUNTING BRACKET RR
a. Install the engine mounting bracket RR and 3 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)





35. INSTALL ENGINE MOUNTING BRACKET FR
a. Install the engine mounting bracket FR and 2 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





36. INSTALL MANUAL TRANSMISSION CASE PROTECTOR
a. Install the case protector with the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





37. INSTALL MANUAL TRANSAXLE ASSEMBLY
a. Align the input shaft with the clutch disc and install the transaxle to the engine.
b. Install the 10 bolts.
Torque:
Bolt A: 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B: 46 Nm (469 kgf-cm, 34 ft. lbs.)
Bolt C: 44 Nm (449 kgf-cm, 32 ft. lbs.)





38. INSTALL ENGINE MOUNTING BRACKET LH
a. Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)





39. INSTALL ENGINE MOUNTING INSULATOR LH
a. Install the engine mounting insulator LH with the 5 bolts and nut.
Torque:
Bolt A: 52 Nm (530 kgf-cm, 38 ft. lbs.)
Bolt B: 87 Nm (887 kgf-cm, 64 ft. lbs.)
40. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
SST 09670-00010
41. CONNECT PRESSURE FEED TUBE ASSEMBLY
SST 09023-12701
42. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
43. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH





44. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
a. Connect the 2 cable ends, and install the 2 washers and 2 clips.
b. Install 2 new clips to the control cable bracket.





45. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
a. Install the release cylinder with the 3 bolts.
Torque:
Bolt A: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
Bolt B: 12 Nm (120 kgf-cm, 9 ft. lbs.)





46. CONNECT CONNECTOR
a. Connect the backup lamp switch connector.





47. CONNECT WIRE HARNESS
a. Install the 3 wire harnesses with the 3 bolts.
Torque:
Bolt A: 26 Nm (260 kgf-cm, 19 ft. lbs.)
Bolt B: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
Bolt C: 13 Nm (133 kgf-cm, 9.6 ft. lbs.)
48. INSTALL STARTER ASSEMBLY
49. INSTALL BATTERY CARRIER
a. Install the battery carrier and 3 bolts.
Torque: 13 Nm (131 kgf-cm, 9 ft. lbs.)
50. INSTALL BATTERY TRAY
51. INSTALL BATTERY
52. INSTALL BATTERY CLAMP ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
53. INSTALL AIR CLEANER ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
54. INSTALL ENGINE COVER SUB-ASSEMBLY NO.1
55. INSTALL HOOD ASSEMBLY
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
56. ADJUST HOOD SUB-ASSEMBLY
57. INSTALL EXHAUST PIPE ASSEMBLY CENTER
58. ADD TRANSAXLE OIL
59. INSPECT TRANSAXLE OIL
60. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
61. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO.1
62. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2
63. INSTALL COLUMN HOLE COVER SILENCER SHEET
64. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
65. INSPECT STEERING WHEEL CENTER POINT
66. ADD POWER STEERING FLUID
67. BLEED POWER STEERING FLUID
68. CHECK POWER STEERING FLUID LEVEL IN RESERVOIR
69. CHECK FOR FLUID LEAKAGE
70. INSPECT FRONT WHEEL ALIGNMENT
71. INSTALL ENGINE UNDER COVER LH
72. INSTALL ENGINE UNDER COVER RH
73. CHECK ABS SPEED SENSOR SIGNAL


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