Installation
RA62 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSMISSION ASSEMBLY: INSTALLATION
1. INSTALL TRANSMISSION UPPER COVER SUB-ASSEMBLY
(a) Install the transmission upper cover sub-assembly with the 2 bolts.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
2. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
(a) Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
3. INSTALL CLUTCH COVER ASSEMBLY Installation
4. INSTALL CLUTCH DISC ASSEMBLY Installation
5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY Installation
6. INSTALL MANUAL TRANSMISSION ASSEMBLY
(a) Make sure that the knock pins are not loose, bent, damaged or scratched and then install the manual transmission onto the engine with the contact surfaces of the engine and manual transmission flat against each other.
(b) Install the manual transmission to the engine with the 9 bolts.
Bolt A - Torque : 72 Nm (730 kgf-cm, 53 ft-lbf)
Bolt B - Torque : 37 Nm (380 kgf-cm, 28 ft-lbf)
NOTICE:
* Temporarily tighten bolt A*1, fully tighten bolt A*2, lift the rear end of the transmission, and fully tighten bolt A*1 and the other bolts. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.
* Do not apply excessive force to the transmission assembly as this will break the input shaft.
* Insert dowel pins into the dowel holes securely so that the end face of the transmission assembly fits close against the engine assembly before tightening the bolts.
7. INSTALL ENGINE REAR MOUNTING MEMBER
(a) Tilt up the manual transmission assembly.
(b) Install the engine rear mounting member with the 4 bolts and 4 nuts.
Nut - Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)
Bolt - Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)
8. INSTALL FLOOR SHIFT LEVER ASSEMBLY
(a) Install the 2 bushings to the shift lever assembly.
(b) Install the washer to the floor shift lever assembly.
(c) Install the shift lever assembly with a new E-ring.
(d) Install the shift and select lever boot.
9. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY
(a) Install the floor shift control shift lever retainer sub-assembly with the 2 nuts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
10. INSTALL CLUTCH COVER ASSEMBLY
(a) Align the matchmarks on the clutch cover assembly and the flywheel sub-assembly.
Text in Illustration
(b) Install the clutch cover to the flywheel sub-assembly with 6 new bolts.
Torque : 19 Nm (195 kgf-cm, 14 ft-lbf)
NOTICE:
Tighten the bolts a little at a time in a diagonal pattern until they are all tightened.
11. INSTALL NO. 1 CLUTCH HOUSING COVER
(a) Install the No. 1 clutch housing cover with the 4 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Bolt length:
20 mm (0.787 in.)
12. INSTALL NO. 2 CLUTCH HOUSING COVER
(a) Install the No. 2 clutch housing cover with the 4 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
Bolt length:
16 mm (0.630 in.)
13. CONNECT WIRE HARNESS
(a) Connect the back-up light switch connector, wire harness clamp and install the wire harness.
14. CONNECT GROUND CABLE
(a) Connect the ground cable with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(a) Install the clutch release cylinder assembly with the 2 bolts.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
16. INSTALL CLUTCH ACCUMULATOR ASSEMBLY
(a) Install the clutch accumulator assembly with the 3 bolts and nut.
Bolt - Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
Nut - Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
17. INSTALL FRONT NO. 6 FLOOR HEAT INSULATOR
(a) Install the front No. 6 floor heat insulator with the 3 nuts.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
18. INSTALL STARTER ASSEMBLY
Installation.
19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
Installation.
20. INSTALL NO. 2 ENGINE UNDER COVER Installation
21. INSTALL NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY LH Installation
22. INSTALL NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY RH Installation
23. INSTALL FRONT FLOOR COVER LH Installation
24. INSTALL FRONT FLOOR COVER RH Installation
25. INSTALL ENGINE UNDER COVER
26. INSTALL SHIFT LEVER CAP
(a) Apply adhesive to 4 bolts.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Temporarily install the shift lever cap with the 4 bolts.
(c) Move the shift lever to the 2nd gear. Adjust the guide plate so that dimension A is as shown in the illustration with the shift lever cap pushed toward neutral (select direction).
Dimension A:
0.3 to 0.6 mm (0.0118 to 0.0236 in.)
(d) Fully tighten the 4 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
27. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT
(a) Install the shift lever boot with the 4 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) Connect the 4 wire harness clips.
28. INSTALL NO. 2 CONSOLE BOX DUCT Installation
29. INSTALL CONSOLE BOX Installation
30. INSTALL CONSOLE BOX REGISTER ASSEMBLY Installation
31. INSTALL FRONT ASH RECEPTACLE ASSEMBLY Installation
32. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY Installation
33. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY Installation
34. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY Installation
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
36. ADD MANUAL TRANSMISSION OIL Replacement
37. INSPECT FOR OIL LEAK
38. INSPECT FOR EXHAUST GAS LEAK