LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2007 >> Yaris S, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 17 (Manual Transmission) >> Transaxle Assembly >> Disassembly and Assembly >> Assembly

Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2007 Nissan Versa. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install pinion gear (1) and pinion shaft (2) into clutch housing.
    Fig 1: Identifying Pinion Gear And Pinion Shaft
    G04812768
  2. Install two way connector (1) into clutch housing.
    Fig 2: Identifying Two Way Connector From Clutch Housing
    G04812767
  3. Install bushings (1) until they are flush with end face of clutch housing using a suitable tool (A).
    Fig 3: Installing Bushings
    G04812771
  4. Install oil channel and mainshaft front bearing outer race into clutch housing using Tool (A).

    Tool number A: KV38100200 ( - ) 

    CAUTION: Do not reuse oil channel.
    Fig 4: Identifying Clutch Housing
    G04812772
  5. Install input shaft oil seal (1) into clutch housing using Tool (A).

    Tool number A: ST33220000 ( - ) 

    Fig 5: Identifying Input Shaft Oil Seal Into Clutch Housing
    G04812773
  6. Install snap ring (1) and oil channel (2) onto transaxle case.
    Fig 6: Identifying Snap Ring And Oil Channel Onto Transaxle Case
    G04812774
  7. Install shim and mainshaft rear bearing outer race into transaxle case using Tool (A).

    Tool number A: KV38100200 ( - ) 

    Fig 7: Identifying Shim And Mainshaft Rear Bearing Outer Race Into Transaxle Case
    G04812775
  8. Install bushings (1) into transaxle case using a suitable tool (A).
    Fig 8: Identifying Bushings Into Transaxle Case
    G04812776
  9. Install oil gutter (1) onto transaxle case.
    Fig 9: Identifying Oil Gutter Onto Transaxle Case
    G04812777
  10. Install shift lever oil seal (1) and bushing (2) into transaxle case using a suitable tool (A).
  11. Install control lever oil seal and bushings into transaxle case using a suitable tool.
    Fig 10: Identifying Control Lever Oil Seal And Bushings Into Transaxle Case
    G04812778
  12. Install shift finger (1) into transaxle case.
    Fig 11: Identifying Shift Finger From Transaxle Case
    G04812757
  13. Install control lever (1) and then install retaining pin.
    CAUTION: Do not reuse retaining pin.
    Fig 12: Identifying Control Lever
    G04812756
  14. Install shim and differential side bearing outer race into transaxle case using Tool (A).

    Tool number A: ST33400001 (J-26082) 

    Fig 13: Identifying Shim And Differential Side Bearing
    G04812781
  15. Install differential side bearing outer race into clutch housing using Tool (A).

    Tool number A: KV38100200 ( - ) 

    Fig 14: Identifying Differential Side Bearing Outer Race Into Clutch Housing
    G04812782
  16. Install differential side oil seals (1) into clutch housing and transaxle case using Tool (A).

    Tool number A: KV38100300 (J-25523) 

  17. Install magnet onto clutch housing.
  18. Install final drive assembly into clutch housing.
    Fig 15: Identifying Differential Side Oil Seals Into Clutch Housing
    G04812783
  19. Install input shaft assembly (1), mainshaft assembly (2) and 1st-2nd fork rod assembly (3) into clutch housing.
  20. Install spring washer located under the reverse idler shaft.
    Fig 16: Identifying Input Shaft Assembly, Mainshaft Assembly, And 1st-2nd Fork Rod
    G04812751
  21. Install reverse gear assembly (1) according to the following.
    1. Lift up the input shaft assembly (2) and mainshaft assembly (3).
    2. Install reverse gear assembly (1) and reverse fork rod (4) to clutch housing.
      Fig 17: Removing Spring Washer
      G04812750
  22. While lifting up fork rod (1), install 3rd-4th and 5th-6th fork rod assembly to clutch housing.
    Fig 18: Removing 3rd-4th And 5th-6th Fork Rod Assembly From Clutch Housing
    G04812749
  23. Install retaining pin into 5th-6th shift fork using a suitable tool.
    CAUTION: Do not reuse retaining pin.
    Fig 19: Removing Retaining Pin From 5th-6th Shift Fork
    G04812748
  24. Move 1st-2nd fork rod (1), 3rd-4th and 5th-6th fork rod assembly (2), and reverse fork rod (3) to neutral position.
  25. Install selector (4) into clutch housing.
  26. Install spring of selector into return bushing.
  27. Install bearing Preloading shim onto mainshaft assembly.
  28. Apply recommended sealant onto the mating surface of transaxle case.
    Fig 20: Identifying 1st-2nd Fork Rod, 3Rd-4Th And 5th-6th Fork Rod Assembly
    G04812788
    CAUTION:
    • Remove old sealant adhering to the mating surfaces.

      Also remove any moisture, oil, or foreign material adhering to both mating surfaces.

    • Check for damage on the mating surface.
    • Apply a continuous bead of liquid gasket to the mating surface.
  29. Engage shift finger and selector by moving control lever (1). Install transaxle case to clutch housing.
    Fig 21: Installing Transaxle Case To Clutch Housing
    G04812789
  30. Install seal washer and reverse idler shaft bolt (< =), and then tighten bolt to specification. Refer to "GEAR COMPONENTS ".
    CAUTION: Do not reuse seal washer.
    Fig 22: Locating Reverse Idler Shaft Bolt
    G04812744
  31. Tighten bolts to specification. Refer to "CASE AND HOUSING COMPONENTS ".
    Fig 23: Locating Transaxle Bolts
    G04812743
  32. Apply sealant to the threads of position switch (1). Then install it into transaxle case and tighten to specification. Refer to "CASE AND HOUSING COMPONENTS ".
  33. Install bracket (2), and tighten bolt to specification. Refer to "CASE AND HOUSING COMPONENTS ".
  34. Install shift lever (3), and then install retaining pin using a suitable tool.
    CAUTION: Do not reuse retaining pin.
    Fig 24: Identifying Shift Lever, Bracket And Switch
    G04812792
  35. Install CSC onto clutch housing. Refer to "CASE AND HOUSING COMPONENTS ".
  36. Install a new gasket onto drain plug, and then install it into clutch housing. Tighten drain plug to specification. Refer to "CASE AND HOUSING COMPONENTS ".
  37. Install a new gasket onto filler plug, and then install it into transaxle case. Tighten filler plug to specification. Refer to "CASE AND HOUSING COMPONENTS ".
    CAUTION:
scientia non olet · About LEMON Manuals