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Toyota Corolla (2004+). Manual - part 32

41-96

MANUAL TRANSMISSION/TRANSAXLE

- SHIFT & SELECT LEVER SHAFT ASSY (C59)

14.

INSTALL SELECT INNER LEVER

(a)

Coat the select spring seat No.1 with MP grease, install

it to the shift & select lever shaft.

(b)

Install the select return spring and select inner lever to the

shift & select lever shaft.

(c)

Using a pin punch (f 5 mm) and a hammer, install the

slotted pin to the select lever inner lever.

Drive in depth: 3.0 - 4.0 mm (0.1181 - 0.1575 in.)

C80581

15.

INSTALL SHIFT LEVER INNER NO.1

(a)

Coat the shift interlock plate and shift lever inner No.1 with

MP grease.

(b)

Install the shift interlock plate with shift lever inner No.1 to

the shift & select lever shaft.

(c)

Using a pin punch (f 5 mm) and a hammer, install the

slotted pin to the shift lever inner No.1.

Drive in depth: 0

0.5 mm (0

0.0197 in.)

C80582

16.

INSTALL SHIFT LEVER INNER NO.2

(a)

Install the shift lever inner No.2 to the shift & select lever

shaft.

(b)

Using a pin punch (f 5 mm) and a hammer, install the

slotted pin to the shift lever inner No.2.

Drive in depth: 0

0.5 mm (0

0.0197 in.)

C80583

17. INSTALL SELECT SPRING SEAT NO.2

(a) Coat the select spring seat No.2 with MP grease, install

it with select return spring to the shift & select lever shaft.

(b) Using a plier, install the E-ring to the shift & select lever

shaft.

C80584

18. INSTALL SELECTING BELLCRANK NO.2 BUSH

(a) Coat the selecting bellcrank No.2 bushes with MP grease,

install them to the selecting bellcrank.

C80571

41-97

MANUAL TRANSMISSION/TRANSAXLE

- SHIFT & SELECT LEVER SHAFT ASSY (C59)

19. INSTALL SELECTING BELLCRANK DUST COVER

NO.2

(a) Coat the selecting bellcrank dust cover No.2 with MP

grease, install it to the selecting bellcrank No.2.

C80763

20. INSTALL SELECTING BELL CRANK NO.2

(a) Install the selecting bellcrank No.2, selecting bellcrank

No.2 plate washer and spring washer with nut.

Torque: 11.8 N m (120 kgf cm, 9 ft lbf)

C80762

21. INSTALL SELECTING BELLCRANK DUST COVER

NO.1

(a) Install the selecting bellcrank dust cover No.1 to the se-

lecting bellcrank assy.

C80761

22. INSTALL CONTROL SHIFT LEVER BUSH

(a) Coat the control shift lever bush with MP grease, install it

to the selecting bellcrank assy.

C80760

41-1

MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE SYSTEM

MANUAL TRANSAXLE SYSTEM

41075-01

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

cause of the problem. Check each part in order. If necessary, replace parts.

Symptom

Suspect Area

See page

6. Oil (Level low)

41-2

7. Oil (Wrong)

41-2

8. Gear (Worn or damaged)

41-63

Noise

41-74

9. Bearing (Worn or damaged)

41-63

41-74

1. Oil (Level too high)

41-2

2. Gasket (Damaged)

41-28

Oil leakage

3. Oil seal (Worn or damaged)

41-3

4. O-Ring (Worn or damaged)

41-28

1. Control cable (Faulty)

41-9

41-12

2. Synchronizer ring (Worn or damaged)

41-63

Hard to shift or will not shift

41-74

3. Shifting key spring (Damaged)

41-63

41-74

1. Locking ball spring (Damaged)

41-28

2. Gear Shift fork (Worn)

41-28

3. Gear (Worn or damaged)

41-63

Jumps out of gear

41-74

4. Bearing (Worn or damaged)

41-63

41-74

42-9

CLUTCH

- CLUTCH MASTER CYLINDER ASSY (MTM)

CLUTCH MASTER CYLINDER ASSY (MTM)

4203O-01

COMPONENTS

Clutch Master Cylinder

Push Rod Clevis w/ Hole Pin

Clutch Reservoir Tube

Clevis

Boot

Clip

Inlet Union

Clip

Stop Plate

FGrommet

Slotted Spring Pin

Lock Nut

24.5 (245, 18)

15.2 (155, 11)

Push Rod

Piston

Snap Ring

Spring

Master Cylinder Body

Clutch Pedal Spring

11.8 (120, 9)

Nm (kgfcm, ftlbf)

: Specified torque

F Non-reusable part

Lithium soap base glycol grease

MP grease

D11544

42-10

CLUTCH

- CLUTCH MASTER CYLINDER ASSY (MTM)

4203P-02

OVERHAUL

DRAIN CLUTCH FLUID

REMOVE BRAKE MASTER CYLINDER SUB-ASSY (See page 32-13)

REMOVE BRAKE BOOSTER ASSY (See page 32-20)

DISCONNECT CLUTCH RESERVOIR TUBE

(a) Loosen the clip and disconnect the clutch reservoir tube

from the clutch master cylinder assy.

HINT:

Use a container to catch the fluid.

D07708

DISCONNECT CLUTCH MASTER CYLINDER TO

FLEXIBLE HOSE TUBE

(a) Using SST, disconnect the flexible hose tube.

SST

09023-00100

HINT:

SST

Use a container to catch the fluid.

D07707

REMOVE CLUTCH PEDAL SPRING

REMOVE CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS W/HOLE PIN

(a) Remove the clip and hole pin.

D26327

REMOVE CLUTCH MASTER CYLINDER ASSY

(a) Remove the 2 nuts and clutch master cylinder assy.

42-11

CLUTCH

- CLUTCH MASTER CYLINDER ASSY (MTM)

REMOVE CLUTCH MASTER CYLINDER KIT

(a) Using a pin punch and a hammer, drive out the slotted

spring pin.

(b) Remove the inlet union and grommet.

(c)

Loosen the lock nut, and remove the clevis.

(d) Remove the lock nut from the push rod.

(e) Remove the boot from the cylinder body.

D07728

(f)

While pushing the push rod, using snap ring pliers, re-

move the snap ring.

(g) Remove the push rod from the cylinder body.

NOTICE:

The piston may pop up out of the cylinder body. Therefore,

slowly remove the push rod from the cylinder body.

(h) Remove the stop plate from the push rod.

(i)

Remove the piston with spring from the cylinder.

CL0533

NOTICE:

Be careful not to damage the inside of the cylinder body.

10. INSTALL CLUTCH MASTER CYLINDER KIT

(a) Coat parts with lithium soap base glycol grease, as shown

in the illustration.

(b) Install the piston with spring into the cylinder.

NOTICE:

Be careful not to damage the inside of the cylinder body.

(c)

Install the stop plate to the push rod.

(d) Install the push rod to the cylinder body.

CL0528

(e) While pushing the push rod, using snap ring pliers, install

the snap ring.

(f)

Install the boot to the cylinder body.

(g) Install the lock nut to the push rod.

(h) Temporarily install the clevis with the lock nut to the push

rod.

(i)

Install the inlet union and a new grommet.

CL0533

42-12

CLUTCH

- CLUTCH MASTER CYLINDER ASSY (MTM)

(j)

Using a pin punch and a hammer, drive in the slotted

Protrusion

spring pin.

1.5 - 3.5 mm

(0.059 - 0.138 in.)

D07719

11. INSTALL CLUTCH MASTER CYLINDER ASSY

(a) Install the clutch master cylinder assy with the 2 nuts.

Torque: 11.8 N m (120 kgf cm, 9 ft lbf)

12. INSTALL CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS W/HOLE PIN

(a) Apply MP grease to the contact surface of the hole pin

and clevis bush.

(b) Connect the clevis to the clutch pedal sub-assy with the

hole pin.

HINT:

Install the hole pin from the right side of the vehicle.

MP Grease

D26306

(c)

Install the clip to the hole pin.

13. INSTALL CLUTCH PEDAL SPRING

14. CONNECT CLUTCH MASTER CYLINDER TO

FLEXIBLE HOSE TUBE

(a) Using SST, connect the flexible hose tube.

SST

09023-00100

Torque: 15.2 N m (155 kgf cm, 11 ft lbf)

SST

D07707

15. CONNECT CLUTCH RESERVOIR TUBE

(a) Connect the clutch reservoir tube with the clip to the clutch

master cylinder assy.

NOTICE:

Facing the white mark upward.

White Mark

D07708

42-13

CLUTCH

CLUTCH MASTER CYLINDER ASSY (MTM)

16. INSTALL BRAKE BOOSTER ASSY (See page

32-20)

17. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (See page

32-13)

18. BLEED BRAKE LINE (See page

32-4)

19. BLEED CLUTCH PIPE LINE

(a) Fill the brake reservoir tank with clutch fluid and bleed clutch system.

Torque: 8.4 N m (85 kgf cm, 73 in. lbf)

20. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page

32-6)

21. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSY (See page

42-2)

22. CHECK BRAKE FLUID LEAKAGE

23. CHECK CLUTCH FLUID LEAKAGE

24. CHECK FLUID LEVEL IN RESERVOIR

42-2

CLUTCH

- CLUTCH PEDAL SUB-ASSY (MTM)

CLUTCH PEDAL SUB-ASSY (MTM)

4203L-01

ADJUSTMENT

INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSY

(a) Turn over the floor carpet.

(b)

Check that the pedal height is correct.

Push Rod Play and

Pedal height from asphalt sheet:

Free Play Adjust Point

135.8 - 145.8 mm (5.346 - 5.740 in.)

(c)

Adjust the pedal height.

(1)

Loosen the lock nut and turn the stopper bolt until

the height is correct. Tighten the lock nut.

Torque: 24.5 N m (245 kgf cm, 18 ft lbf)

(d)

Check that the pedal free play and push rod play are cor-

Pedal Height

rect.

Adjust Point

(1)

Depress the pedal until the clutch resistance begin

to be felt.

Push Rod

Pedal free play: 5.0 - 15.0 mm (0.197 - 0591 in.)

Play

(2)

Gently depress the pedal until the resistance begins

to increase a little.

Push rod play at pedal top:

1.0 - 5.0 mm (0.039 - 0.197 in.)

Pedal Height

D26341

(e)

Adjust the pedal free play and push rod play.

(1)

Loosen the lock nut and turn the push rod until the

free play and push rod play are correct.

(2)

Tighten the lock nut.

(3)

After adjusting the pedal free play, check the pedal

height.

(4)

Connect the air duct and install the lower finish pan-

el.

Pedal Free Play

CL0102

42-3

CLUTCH

- CLUTCH PEDAL SUB-ASSY (MTM)

(f)

Check the clutch release point.

(1)

Pull the parking brake lever and install wheel stop-

per.

25 mm (0.98 in.) or more

(2)

Start the engine and idle the engine.

Release Point

(3)

Without depressing the clutch pedal, slowly shift the

shift lever into reverse position until the gears con-

tact.

Full Stroke

(4)

Gradually depress the clutch pedal and measure

End Position

CL0512

the stroke distance from the point that the gear

noise stops (release point) up to the full stroke end

position.

Standard distance: 25 mm (0.98 in.) or more

(From pedal stroke end position to release point)

If the distance is not as specified, perform the following opera-

tions.

Check pedal height.

Check push rod play and pedal free play.

Bleed the clutch line.

Check the clutch cover assy and disc assy.

42-4

CLUTCH

- CLUTCH PEDAL SUB-ASSY (MTM)

4203M-01

COMPONENTS

Clutch Master Cylinder

19.1 (195, 14)

Push Rod Clevis w/ Hole Pin

Clip

Clutch Pedal Spring

36.8 (375, 27)

Clutch Pedal Support Sub-assy

Clutch Pedal Bush

11.8 (120, 9)

Clutch Pedal No.1 Cushion

Clutch Start

Switch Assy Connector

Clutch Master

Cylinder Push Rod

Clutch Pedal Bush

Clevis Bush

Clutch Pedal

Clutch Pedal Sub-assy

Pad

Nm (kgfcm, ftlbf)

: Specified torque

F Non-reusable part

Clutch Pedal Sub-assy

MP Grease

D26342

42-5

CLUTCH

- CLUTCH PEDAL SUB-ASSY (MTM)

4203N-02

REPLACEMENT

REMOVE INSTRUMENT PANEL SUB-ASSY LOWER (See page 71-10)

REMOVE CLUTCH PEDAL SPRING

REMOVE CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS W/HOLE PIN

(a) Remove the clip and hole pin.

D26327

REMOVE CLUTCH PEDAL SUPPORT SUB-ASSY

(a) w/ Cruise control:

Disconnect the clutch switch assy connector.

(b) Disconnect the clutch start switch assy connector.

(c)

Remove the 2 nuts, bolt and clutch pedal support assy.

D26343

REMOVE CLUTCH PEDAL SUB-ASSY

(a) Remove the bolt and nut.

(b) Remove the clutch pedal sub-assy from the clutch pedal

support.

D26333

REMOVE CLUTCH PEDAL PAD

42-6

CLUTCH

- CLUTCH PEDAL SUB-ASSY (MTM)

REMOVE CLUTCH PEDAL BUSH

(a) Remove the 2 bushes from the clutch pedal.

D26334

REMOVE CLUTCH PEDAL NO.1 CUSHION

(a) Using needle-nose pliers, remove the No.1 cushion from

the clutch pedal.

D26335

REMOVE CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS BUSH

(a) Using a 8 mm hexagon wrench and a hammer, remove

the clevis bush from the clutch pedal sub-assy.

D26336

10. INSTALL CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS BUSH

(a) Apply MP grease to inside of a new clevis bush.

(b) Install the clevis bush to the clutch pedal.

HINT:

Install the clevis bush from the right side of the vehicle.

MP Grease

D26337

11. INSTALL CLUTCH PEDAL NO.1 CUSHION

(a) Using needle-nose pliers, install the No.1 cushion to the

clutch pedal.

D26335

42-7

CLUTCH

- CLUTCH PEDAL SUB-ASSY (MTM)

12. INSTALL CLUTCH PEDAL BUSH

(a) Apply MP grease to both side of 2 new bushes.

(b) Install the 2 bushes to the clutch pedal.

MP Grease

D26334

13. INSTALL CLUTCH PEDAL PAD

14. INSTALL CLUTCH PEDAL SUB-ASSY

(a) Install the clutch pedal sub-assy to the clutch pedal sup-

port with the bolt and nut.

Torque: 36.8 N m (375 kgf cm, 27 ft lbf)

HINT:

Install the bolt from the right side of the vehicle.

D26333

15. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSY

(a) Install the clutch pedal support to the vehicle with the 2

nuts and bolt.

Torque:

Bolt: 19.1 N m (195 kgf cm, 14 ft lbf)

Nut: 11.8 N m (120 kgf cm, 9 ft lbf)

(b) Connect the clutch start switch assy connector.

(c)

w/ Cruise control:

Connect the clutch switch assy connector.

D26343

16. INSTALL CLUTCH MASTER CYLINDER PUSH ROD

CLEVIS W/HOLE PIN

(a) Apply MP grease to the contact surface of the hole pin

and clevis bush.

(b) Connect the clevis to the clutch pedal sub-assy with the

hole pin.

HINT:

Install the hole pin from the right side of the vehicle.

MP Grease

D26306

(c)

Install the clip to the hole pin.

42-8

CLUTCH

- CLUTCH PEDAL SUB-ASSY (MTM)

17. INSTALL CLUTCH PEDAL SPRING

18. INSTALL INSTRUMENT PANEL SUB-ASSY LOWER

19. INSPECT SRS WARNING LIGHT (See page 05-424)

20. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSY (See page

42-2)

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