Toyota Yaris: Manual Transaxle Unit / Disassembly

(a) Remove the No. 1 clutch housing cover from the front transaxle case.

(a) Remove the release cylinder bleeder plug cap from the release cylinder bleeder plug.

(a) Remove the release cylinder bleeder plug from the clutch release bleeder sub-assembly.

(a) Remove the 3 bolts and control cable bracket from the manual transmission case.

(a) Remove the 2 bolts and selecting bell crank assembly from the manual transmission case.

(a) Using SST, remove the back-up light switch assembly and gasket from the manual transmission case.

SST: 09816-30010

(a) Using SST, remove the neutral position switch and gasket from the manual transmission case.

SST: 09816-30010

(a) Remove the No. 1 lock ball assembly from the manual transmission case.

(a) Remove the No. 2 lock ball assembly from the manual transmission case.

(a) Remove the shift gate pin from the manual transmission case.

(a) Remove the 4 bolts and shift and select lever assembly from the manual transmission case.

(a) While pressing in the shift and select lever shaft straight pin as far as it will go, pull out the shift and select lever shaft straight pin to remove it.

(a) Remove the O-ring from the shift and select lever shaft straight pin.

(a) Remove the manual transmission filler plug and gasket from the manual transmission case.

(a) Remove the manual transmission drain plug and gasket from the manual transmission case.

(a) Place the manual transaxle assembly on wooden blocks.

(a) Using a 6 mm hexagon wrench, remove the 4 detent ball plugs from the front transaxle case.

(a) Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.

(a) Using SST and 27 mm straight hexagon, remove the manual transmission case plugs from the manual transmission case.

SST: 09816-30010

(a) Remove the 8 bolts from the front transaxle case side.

(b) Remove the 10 bolts from the manual transmission case side.

(c) Using snap ring pliers, keep the snap ring stretched and remove the manual transmission case.

(a) Remove the bolt and No. 1 receiver pipe from the manual transmission case.

NOTICE:

Do not damage the No. 1 oil receiver pipe.

(a) Remove the 2 bolts and transmission oil separator from the manual transmission case.

(a) Remove the 2 bolts and transmission oil separator from the front transaxle case.

(a) Using a 5 mm pin punch and a hammer, tap out the slotted spring pin until the 3rd and 4th shift fork shaft becomes free.

*1

No. 2 Gear Shift Head

Protective Tape

(d) Remove the 3rd and 4th shift fork shaft and No. 2 gear shift head from the No. 2 gear shift fork and front transaxle case.

(a) Using a screwdriver, remove the E-ring from the shift arm pivot.

(b) Remove the shift arm pivot from the shift arm.

(c) Remove the No. 5 gear shift fork shaft from the front transaxle case.

(d) Using a 5 mm pin punch and a hammer, remove the slotted spring pin from the No. 3 gear shift head.

(a) Remove the shift arm from the front transaxle case.

(a) Remove the bolt from the reverse shift fork shaft.

(b) Remove the reverse shift fork shaft from the front transaxle case.

(a) Remove the reverse idler gear shaft by sliding and lifting it.

(b) Remove the reverse idler gear, needle roller bearing and reverse idler thrust washer from the reverse idler gear shaft.

(a) Bend left and right sides of SST in opposite directions.

SST: 09312-52010

NOTICE:

Do not bend SST more than necessary.

(b) Install SST to the top and bottom of the No. 3 transmission hub sleeve.

SST: 09312-52010

NOTICE:

Make sure that SST does not easily come loose.

HINT:

Install SST in a tensioned state so that the No. 3 transmission hub sleeve does not shift out of position.

(c) Remove the 3 shafts at the same time.

(a) Remove the differential gear assembly from the front transaxle case.

(a) Remove the transmission magnet from the front transaxle case.

(a) Remove the No. 1 gear shift fork from the No. 1 output shaft assembly.

(a) Remove the No. 2 gear shift fork from the No. 1 gear shift fork.

(a) Remove the No. 3 gear shift fork from the No. 2 output shaft assembly.

(a) Remove the reverse shift fork from the No. 3 gear shift fork.

(a) Using SST, remove the output shaft rear bearing outer race from the manual transmission case.

SST: 09387-00041

SST: 09387-02020

(a) Remove the output shaft rear bearing shim from the manual transmission case.

(a) Using SST, remove the No. 2 output shaft rear bearing outer race from the manual transmission case.

SST: 09387-00041

SST: 09387-02020

(a) Remove the output shaft rear bearing shim from the manual transmission case.

(a) Remove the output shaft cover from the manual transmission case.

(a) Using SST, remove the 4 shift fork shaft bearings from the manual transmission case.

SST: 09387-00041

09387-01021

SST: 09527-20011

SST: 09612-65014

(a) Using SST, remove the shift and select lever shaft needle roller bearing from the manual transmission case.

SST: 09387-00041

09387-01021

SST: 09612-65014

(a) Using snap ring pliers, remove the input shaft rear bearing shaft snap ring from the manual transmission case.

(a) Remove the bolt and bearing lock plate from the front transaxle case.

(b) Using SST, remove the input shaft front bearing from the front transaxle case.

SST: 09612-30012

(a) Using a screwdriver with its tip wrapped with protective tape, remove the front transaxle case oil seal from the front transaxle case.

(a) Using SST, remove the output shaft front bearing from the front transaxle case.

SST: 09387-00041

SST: 09387-02020

SST: 09527-17011

(a) Remove the output shaft cover from the front transaxle case.

(a) Using SST, remove the No. 2 output shaft front bearing outer race from the front transaxle case.

SST: 09387-00041

SST: 09387-02020

SST: 09527-17011

(a) Remove the output shaft cover from the front transaxle case.

(a) Remove the 3 manual transmission case straight pins from the front transaxle case.

(a) Using SST, remove the 4 shift fork shaft bearings from the front transaxle case.

SST: 09387-00041

09387-01021

SST: 09612-65014

(a) Using a brass bar and a hammer, remove the front differential case rear tapered roller bearing outer race and front differential case rear shim from the manual transmission case.

(b) Using SST, remove the front differential case rear tapered roller bearing from the front No. 1 differential case sub-assembly.

SST: 09950-00020

SST: 09950-00030

SST: 09950-40011

09957-04010

SST: 09950-60011

09951-00540

(a) Using SST, remove the front drive shaft oil seal RH from the transmission sleeve yoke.

SST: 09308-00010

NOTICE:

Be careful not to damage the transmission sleeve yoke.

(a) Using SST, remove the front differential case front tapered roller bearing outer race from the front transaxle case.

SST: 09387-00041

SST: 09387-02020

SST: 09527-17011

(b) Using SST, remove the front differential case front tapered roller bearing and transmission sleeve yoke from the front No. 1 differential case sub-assembly.

SST: 09950-00020

SST: 09950-00030

SST: 09950-40011

09957-04010

SST: 09950-60011

09951-00410