Toyota Corolla (2004+). Manual — part 30
41-58
MANUAL TRANSMISSION/TRANSAXLE
- MANUAL TRANSAXLE ASSY (C59)
(c)
Using a chisel and a hammer, stake the manual transmis-
sion output shaft rear set nut.
(d) Disengage the gear double meshing.
C80404
96. INSTALL MANUAL TRANSMISSION CASE COVER
FIPG
SUB-ASSY
(a) Apply FIPG to the manual transmission case cover sub-
assy as shown in the illustration.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
NOTICE:
C95194
Parts must be assembled within 10 minutes of application.
Otherwise, the packing (FIPG) material must be removed
and reapplied.
(b) Install the manual transmission case cover sub-assy with
the 9 bolts to the manual transmission case.
Torque: 18.1 N m (185 kgf cm, 14 ft lbf)
C95310
97. INSTALL SHIFT & SELECT LEVER SHAFT ASSY
(a) Coat the 4 bolts with sealant, install them, new gasket and
shift & select lever shaft assy to the manual transmission
case.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 19.6 N m (200 kgf cm, 14 ft lbf)
C95187
NOTICE:
Set the claws of the shift interlock plate into the shift head
part of the gear shift fork shaft securely.
41-59
MANUAL TRANSMISSION/TRANSAXLE
- MANUAL TRANSAXLE ASSY (C59)
98. INSTALL LOCK BALL ASSY NO.1
(a) Coat the lock ball assy No.1 with sealant, install it to the
manual transmission case.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29.4 N m (300 kgf cm, 22 ft lbf)
C95186
99. INSTALL SELECTING BELL CRANK ASSY
(a) Install the selecting bellcrank assy with control shift lever
bush with the 2 bolts to the manual transmission case.
(A)
Torque: 24.5 N m (250 kgf cm, 18 ft lbf)
NOTICE:
Apply MP grease to the inside circumferential surface of
the control shift lever bush (A).
C95185
100. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING
SUPPORT BRACKET
(a) Install the floor shift control lever housing support bracket
with the 3 bolts to the transaxle case.
Torque: 11.3 N m (115 kgf cm, 8 ft lbf)
C80333
101. INSTALL BACK UP LAMP SWITCH ASSY
SST
(a) Using SST, install the backup lamp switch assy with a new
gasket to the manual transmission case.
Torque: 40.2 N m (410 kgf cm, 30 ft lbf)
SST
09817-16011
C80406
102. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (W/ ABS)
(a) Install a new O-ring to the speedometer driver hole cover sub-assy.
(b) Install the speedometer driver hole cover sub-assy with the bolt.
Torque: 11.3 N m (115 kgf cm, 8 ft lbf)
103. INSTALL SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY (W/O ABS)
(a) Install the speedometer driven (MTM) gear sub-assy with clip to the speedometer sensor.
104. INSTALL SPEEDOMETER SENSOR (W/O ABS)
(a) Install a new O-ring to the speedometer sensor.
(b) Install the speedometer sensor with the bolt.
Torque: 11.3 N m (115 kgf cm, 8 ft lbf)
41-60
MANUAL TRANSMISSION/TRANSAXLE
- MANUAL TRANSAXLE ASSY (C59)
105. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the transaxle case.
Torque: 36.8 N m (375 kgf cm, 25 ft lbf)
C67604
106. INSTALL CLUTCH RELEASE FORK BOOT
(a) Install the clutch release fork boot to the transaxle case.
C80331
107. INSTALL CLUTCH RELEASE BEARING ASSY
(a) Coat the clutch release bearing assy with the release hub
grease, install it to the clutch release fork sub-assy.
Sealant:
Part No. 08887-01806, RELEASE HUB GREASE or
equivalent
C67602
108. INSTALL CLUTCH RELEASE FORK SUB-ASSY
(a) Install the clutch release fork sub-assy to the input shaft.
(b) Apply clutch spline grease to spline of the input shaft.
Sealant:
Part No. 08887-01806, CLUTCH SPLINE GREASE or
equivalent
C68381
109. INSTALL DRAIN (MTM) PLUG SUB-ASSY
(a) Install a new gasket with the drain (MTM) plug sub-assy.
Torque: 39.2 N m (400 kgf cm, 29 ft lbf)
C80550
41-61
MANUAL TRANSMISSION/TRANSAXLE
- MANUAL TRANSAXLE ASSY (C59)
110. INSTALL MANUAL TRANSMISSION FILLER PLUG
(a) Install a new gasket with the manual transmission filler
plug.
Torque: 39.2 N m (400 kgf cm, 29 ft lbf)
C80549
41-2
MANUAL TRANSMISSION/TRANSAXLE
- MANUAL TRANSAXLE OIL
MANUAL TRANSAXLE OIL
41076-01
ON-VEHICLE INSPECTION
1.
INSPECT TRANSAXLE OIL
(a) Stop the vehicle on the level place.
(b) Remove the transmission filler plug and gasket.
(c)
Check that the oil surface is within 5 mm (0.20 in.) from the
lowest position of the inner surface of the transmission fill-
er plug opening.
NOTICE:
0 - 5 mm
F
Excessively large or small amount of oil may cause
(0 - 0.20 in.)
D25304
troubles.
F
After replacing oil, drive the vehicle and
check the oil
level.
(d) Check for oil leakage when the oil level is low.
(e) Install the transmission filler plug and new gasket.
Torque: 39.2 N m (400 kgf cm, 29 ft lbf)
41-73
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
OUTPUT SHAFT ASSY (C59)
4107I-01
COMPONENTS
Snap Ring
1st Gear Thrust Washer Pin or Ball
1st Gear Needle Roller Bearing
1st Gear
F Output Shaft Front Bearing
Synchronizer Ring No.1
Output Shaft
Reverse Gear
1st Gear Thrust Washer
2nd Gear Needle Roller Bearing
2nd Gear Bearing Spacer
Synchromesh Shifting Key Spring
Synchromesh Shifting Key
Transmission Clutch Hub No.1
Snap Ring
Synchronizer Ring Set No.2
2nd Gear
3rd Driven Gear
Output Gear Spacer
4th Driven Gear
Output Shaft Rear Bearing
F Non-reusable part
D07721
41-74
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
4107J-01
OVERHAUL
1.
INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 1st gear thrust clear-
ance.
Standard clearance:
0.10 - 0.40 mm (0.0039 - 0.0157 in.)
C68252
2.
INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clear-
ance.
Standard clearance:
0.10 - 0.45 mm (0.0039 - 0.0177 in.)
C68312
3.
INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clear-
ance.
Standard clearance:
Bearing
Clearance: mm (in.)
KOYO made
0.015 - 0.058 (0.0006 - 0.0023)
NSK made
0.015 - 0.056 (0.0006 - 0.0022)
If the clearance is out of specification, replace the 1st gear
C68309
needle roller bearing.
4.
INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clear-
ance.
Standard clearance:
Bearing
Clearance: mm (in.)
KOYO made
0.015 - 0.058 (0.0006 - 0.0023)
NSK made
0.015 - 0.056 (0.0006 - 0.0022)
If the clearance is out of specification, replace the 2nd gear
C68254
needle roller bearing.
41-75
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
5.
REMOVE 4TH DRIVEN GEAR
(a) Using SST and a press, remove the output shaft rear
SST
bearing with 4th driven gear from the output shaft.
SST
09950-00020
C80539
6.
REMOVE OUTPUT GEAR SPACER
(a) Remove the output gear spacer from the output shaft.
C68005
7.
REMOVE 2ND GEAR
(a) Using SST and a press, remove the 3rd driven gear with
SST
2nd gear from the output shaft.
SST
09950-00020
C80540
8.
REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing from the out-
put shaft.
C68008
9.
REMOVE SYNCHRONIZER RING SET NO.2
(a) Remove the synchronizer ring set No.2 from the output
shaft.
C68010
41-76
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
10. REMOVE 1ST GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Using a waste to prevent the snap ring from being scattered.
C68011
(b) Using SST and a press, remove the transmission clutch
SST
hub No.1 with 1st gear from the output shaft.
SST
09950-00020
NOTICE:
F
Do not tighten SST excessively.
F
Support the input shaft by hand so that it will not be
dropped off.
C94308
11. REMOVE SYNCHRONIZER RING NO.1
(a) Remove the synchronizer ring No.1 from the 1st gear.
C68516
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
C68012
13. REMOVE 1ST GEAR THRUST WASHER
(a) Remove the 1st gear thrust washer from the output shaft.
C68013
41-77
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
(a) Remove the 1st gear thrust washer pin or ball from the
output shaft.
C68014
15. REMOVE REVERSE GEAR
(a) Remove the 3 synchromesh shifting keys, 3 synchro-
mesh shifting key springs and reverse gear.
NOTICE:
Using a waste to prevent the synchromesh shifting key and
spring from being scattered.
C68015
16. INSPECT OUTPUT SHAFT
(a) Using a dial indicator and 2 V-blocks, measure the shaft
runout.
Maximum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the output shaft.
V-block
C80545
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Outer diameter:
Part A: 31.985 mm (1.2592 in.)
Part B: 37.985 mm (1.4955 in)
Part C: 32.985 mm (1.2986 in)
If the outer diameter is below the minimum, replace the output
shaft.
A
B
C
C80439
41-78
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
17. INSPECT 2ND GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 2nd gear.
Inside diameter:
New gear: mm (in.)
Maximum inside diameter: mm (in.)
38.015 - 38.031 (1.4967 - 1.4973)
38.031
(1.4973)
If the inside diameter exceeds the maximum, replace the 2nd
gear.
C68018
18. INSPECT 1ST GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 1st gear.
Inside diameter:
New gear: mm (in.)
Maximum inside diameter: mm (in.)
44.015 - 44.031 (1.7329 - 1.7335)
44.031
(1.7335)
If the inside diameter exceeds the maximum, replace the 1st
gear.
C68017
19. INSPECT 1ST GEAR THRUST WASHER
(a) Using a micrometer, measure the thickness of 1st gear
thrust washer.
Thickness:
New thrust washer: mm (in.)
Minimum thickness: mm (in.)
5.975 - 6.025 (0.2352 - 0.2372)
5.9755
(0.2352)
If the thickness is below the minimum, replace the 1st gear
thrust washer.
C68514
20. INSPECT SYNCHRONIZER RING SET NO.2
(a) Coat the 2nd gear cone with gear oil.
Check the braking effect of the synchronizer ring set No.2.
C68023
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance: 0.7 - 1.3 mm (0.0276 -
0.0512 in.)
If the clearance is out of specification, replace the synchronizer
ring set No.2.
C68239
41-79
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
21. INSPECT SYNCHRONIZER RING NO.1
(a) Coat the 1st gear cone with gear oil.
Check the braking effect of the synchronizer ring No.1.
C68021
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.75 - 1.65 mm (0.0295 - 0.065 in.)
If the clearance is out of specification, replace the synchronizer
ring No.1.
C68022
22. INSPECT REVERSE GEAR
(a) Using a vernier caliper gauge, measure the clearance be-
tween reverse gear and shift fork.
Standard clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in.)
A
If the clearance is out of specification, replace the reverse gear
and reverse shift fork.
B
Clearance = (A - B)
C68409
23. INSPECT TRANSMISSION CLUTCH HUB NO.1
(a) Check that the transmission clutch hub No.1 and reverse
gear sub-assy slides smoothly.
(b) Check that the spline gear’s edges of the reverse gear
sub-assy is not worn down.
C68240
41-80
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
24. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil, install it to the trans-
mission clutch hub No.1.
NOTICE:
Be sure to set the reverse gear and transmission clutch
hub No.1 in incorrect orientation.
(b) Using a screwdriver, install the 3 synchromesh shifting
key springs and 3 synchromesh shifting keys.
C68241
25. INSTALL OUTPUT SHAFT FRONT BEARING
SST
(a) Using SST and a press, install the output shaft front bear-
ing (inner race) to the output shaft.
SST
09223-50010
D08263
(b) Select a snap ring from the table below that will make the
thrust clearance of the output shaft front bearing (inner
race) below 0.1 mm (0.0039 in.).
Snap ring thickness:
Part No.
Thickness: mm (in.)
Mark
1.85
- 1.90
90520 - 30032
7
(0.0728
- 0.0748)
1.90
- 1.95
90520 - 30033
8
(0.0748
- 0.0768)
C95325
1.95
- 2.00
90520 - 30002
1
(0.0768
- 0.0787)
2.00
- 2.05
90520 - 30003
2
(0.0787
- 0.0807)
2.05
- 2.10
90520 - 30004
3
(0.0807
- 0.0827)
2.10
- 2.15
90520 - 30005
4
(0.0827
- 0.0846)
2.15
- 2.20
90520 - 30006
5
(0.0846
- 0.0866)
2.20
- 2.25
90520 - 30007
6
(0.0866
- 0.0886)
(c)
Using a brass bar and a hammer, tap in the snap ring.
NOTICE:
Take care not to damage the journal surface of the output
shaft.
41-81
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
26. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
(a) Coat the 1st gear thrust washer pin or ball with MP
grease, install it to the output shaft.
C68014
27. INSTALL 1ST GEAR THRUST WASHER
(a) Coat the 1st gear thrust washer with gear oil, install it to
the output shaft.
C68013
28. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil, install
it to the output shaft.
C68012
29. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil, install it to the output shaft.
C68310
30. INSTALL SYNCHRONIZER RING NO.1
(a) Coat the synchronizer ring No.1 with gear oil, install it to
the 1st gear.
C68311
41-82
MANUAL TRANSMISSION/TRANSAXLE
- OUTPUT SHAFT ASSY (C59)
31. INSTALL TRANSMISSION CLUTCH HUB NO.1
SST
(a) Using SST and a press, install the transmission clutch
hub No.1 to the output shaft.
SST
09316-60011 (09316-00031)
NOTICE:
The 1st gear can be turned.
C94309
(b) Select a snap ring from the table below that will make the
thrust clearance of the transmission clutch hub No.1 be-
low 0.1 mm (0.0039 in.).
Snap ring thickness:
Part No.
Thickness: mm (in.)
Mark
90520 - 29018
2.50
(0.0984)
A
90520 - 29019
2.56
(0.1008)
B
90520 - 29020
2.62
(0.1031)
C
90520 - 29021
2.68
(0.1055)
D
C68244
90520 - 29022
2.74
(0.1079)
E
90520 - 29023
2.80
(0.1102)
F
(c)
Using a brass bar and a hammer, install the snap ring to
the output shaft.
NOTICE:
Take care not to damage the journal surface of the output
shaft.
32. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing with gear oil,
install it to the output shaft.
C68246
33. INSTALL SYNCHRONIZER RING SET NO.2
(a) Coat the synchronizer ring set No.2 with gear oil, install
it to the 2nd gear.
C68247
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