Toyota Corolla (2004+). Manual - part 25

 

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Toyota Corolla (2004+). Manual - part 25

 

 

40-1
AUTOMATIC TRANSMISSION / TRANS
- AUTOMATIC TRANSAXLE ASSY (ATM)
AUTOMATIC TRANSAXLE ASSY (ATM)
400LF-01
PRECAUTION
1.
The automatic transaxle is composed of highly precision-finished parts, necessitating careful
inspection before reassembly because even a small nick could cause fluid leakage or affect
the performance. The manuals here are organized so that you work on only one component
group at a time. This will help avoid confusion from similar-looking parts of different sub-as-
semblies being on your workbench at the same time. The component groups are inspected and
repaired from the converter housing side. As much as possible, complete the inspection, repair
and reassembly before proceeding to the next component group. If a defect is
found in a certain
component group during reassembly, inspect and repair this group immediately. If a compo-
nent group cannot be assembled because parts are being ordered, be sure to keep all parts of
the group in a separate container while proceeding with disassembly, inspection, repair and
reassembly of other component groups.
Recommended ATF: T-IV
2.
All disassembled parts should be washed clean and any fluid passages and holes should be
blown through with compressed air.
3.
Dry all parts with compressed air-never use shop rags.
4.
When using compressed air, always aim away from yourself to prevent accidentally spraying
ATF or kerosene on your face.
5.
The recommended automatic transaxle fluid or kerosene should be used for cleaning.
6.
After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs,
and reassembly.
7.
When disassembling a valve body, be sure to match each valve together with the correspond-
ing spring.
8.
New discs for the brakes and clutches that are to be used for replacement must be soaked in
ATF for at least 15 minutes before reassembly.
9.
All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
10.
All gaskets and rubber O-rings should be replaced.
11.
Do not apply adhesive cements to gaskets and similar parts.
12.
Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed
in the groove correctly.
13.
If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be re-
placed.
14.
Check thrust bearings and races for wear or damage. Replace if necessary.
15.
Use petroleum jelly to keep parts in place.
16.
When working with FIPG material, you must observe the following.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the
gasket surface.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) ma-
terial must be removed and reapplied.
40-30
AUTOMATIC TRANSMISSION / TRANS
- SHIFT LOCK SYSTEM (ATM)
SHIFT LOCK SYSTEM (ATM)
400LV-01
ON-VEHICLE INSPECTION
1.
CHECK SHIFT LOCK OPERATION
(a) Shift the shift lever to P position.
(b) Turn the ignition switch to LOCK.
(c)
Check that the shift lever cannot be shifted to any other positions other than P.
(d) Turn the ignition switch to ON, depress the brake pedal and check that the shift lever can be shifted
to any other positions.
2.
CHECK SHIFT LOCK RELEASE BUTTON OPERATION
(a) Using a screwdriver, remove the shift lock release button cover.
(b) When operating the shift lever with the shift lock release button pressed and the ignition key in ACC
or ON, check that the lever can be shifted to any other positions.
3.
CHECK KEY INTERLOCK OPERATION
(a) Turn the ignition switch to ON.
(b) Depress the brake pedal and shift the shift lever to any other positions other than P.
(c)
Check that the ignition key cannot be turned to LOCK.
(d) Shift the shift lever to P position, turn the ignition key to LOCK and check that the ignition key can be
removed.
4.
INSPECT SHIFT LOCK CONTROL ECU
(a) Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the shift lock control ECU connector.
E
IG
STP
C63995
Terminal
Measuring Condition
Voltage (V)
5 (IG) - 1 (E)
Ignition switch ON
10 - 14
5 (IG) - 1 (E)
Ignition switch OFF
0
3 (STP) - 1 (E)
Depress brake pedal
10 - 14
3 (STP) - 1 (E)
Release brake pedal
0
40-31
AUTOMATIC TRANSMISSION / TRANS
- SHIFT LOCK SYSTEM (ATM)
(b) Using an ohmmeter, measure the resistance at terminal
E (1) and body ground.
E
C63995
Terminal
Measuring Condition
Specified Value
1 (E) - Body ground
Always
Continuity
40-22
AUTOMATIC TRANSMISSION / TRANS
- SPEEDOMETER SENSOR (ATM)
SPEEDOMETER SENSOR (ATM)
400LM-01
REPLACEMENT
1.
REMOVE AIR CLEANER CASE
2.
REMOVE AIR CLEANER HOSE NO.1
3.
REMOVE SPEEDOMETER SENSOR
(a) Disconnect the connector.
(b) Remove the bolt and speedometer sensor assembly.
(c)
Remove the clip and driven gear from the speedometer
sensor.
4.
INSTALL SPEEDOMETER SENSOR
Driven Gear
(a) Coat a O-ring with ATF and install it to the speedometer
sensor.
(b) Install the driven gear to the speedometer sensor with the
clip.
O-ring
(c)
Install the speedometer sensor assembly with the bolt.
Clip
C95424
Torque: 11.3 N·m (115 kgf·cm, 9 ftlbf)
(d) Connect the connector.
5.
INSTALL AIR CLEANER HOSE NO.1
6.
INSTALL AIR CLEANER CASE
Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)
40-20
AUTOMATIC TRANSMISSION / TRANS
- TORQUE CONVERTER CLUTCH AND DRIVE
PLATE (ATM)
TORQUE CONVERTER CLUTCH AND DRIVE PLATE (ATM)
400LL-01
INSPECTION
SST
1.
INSPECT TORQUE CONVERTER CLUTCH ASSY
(a) Inspect the one-way clutch.
(1)
Set SST into the inner race of the one-way clutch.
SST
09350-32014 (09351-32010)
(2)
Set SST so that it fits in the notch of the converter
hub and outer race of the one-way clutch.
SST
09350-32014 (09351-32020)
AT0953
(3)
With the torque converter clutch setting up on its
side, check that the one-way clutch locks when it is
Hold
turned counterclockwise, and rotates smoothly
clockwise.
If necessary, clean the torque converter clutch and retest the
Lock
one-way clutch.
Replace the torque converter clutch if the one-way clutch still
Free
Turn
fails the test.
AT3306
(b) Determine the condition of the torque converter clutch
Sample showing minimum amount of
powders in ATF
assy.
(1)
If the inspection result of the torque converter clutch
assy meets the following item, replace the torque
converter clutch.
Malfunction item:
Any metallic sound is heard from the torque convert-
er clutch during stall test or when the shift lever is in
neutral position.
One-way clutch is free or locked in both directions.
Fine powders exceeding the sample limit is identified
in ATF. (See the sample.)
HINT:
The sample shows the auto fluid of approx. 0.25 liters (0.26 US
qts, 0.22 Imp. qts) that is taken out from the removed torque
converter clutch
(c)
Replace the ATF in the torque converter clutch.
Actual Size
(1)
If the ATF is discolored and/or has a foul odor, com-
D25367
pletely stir the ATF in the torque converter clutch
and drain it with the face for installation facing up.
AUTOMATIC TRANSMISSION / TRANS
- TORQUE CONVERTER CLUTCH AND DRIVE
40-21
PLATE (ATM)
(d) Clean and check the oil cooler and oil pipe line.
(1)
If the torque converter clutch is inspected or the ATF
is exchanged, clean the oil cooler and oil pipe line.
HINT:
F
Spray compressed air of 196 kPa (2 kgf/cm2, 28 psi) from
the inlet hose.
F
If plenty of fine powders are identified in the ATF, add new
ATF using a bucket pump and clean it again.
C11090
(2)
If the ATF is cloudy, inspect the oil cooler.
(e) Prevent deformation of the torque converter clutch and
OK
NG
damage to the oil pump gear.
(1)
When any marks due to interference are found on
the end of the bolt for the torque converter clutch
The Bottom is
and on the bottom of the bolt hole, replace the bolt
Damaged
and the torque converter clutch.
(2)
All of the bolts should have the same length.
(3)
No missing spring washer.
D25368
2.
INSPECT DRIVE PLATE & RING GEAR SUB-ASSY
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or ring gear is dam-
aged, replace the drive plate.
C81014
40-23
AUTOMATIC TRANSMISSION / TRANS
- TRANSMISSION VALVE BODY ASSY (ATM)
TRANSMISSION VALVE BODY ASSY (ATM)
400LN-01
REPLACEMENT
1.
REMOVE ENGINE UNDER COVER LH
2.
DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 17.5 Nm (178 kgfcm, 13 ftlbf)
3.
REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all pan bolts,
and carefully remove the oil pan assembly. Discard the
gasket.
(b) Remove the 2 magnets from oil pan.
D09967
(c)
Examine particles in pan.
(1)
Remove the magnets and use them to collect any
steel chips. Look carefully at the chips and particles
in the pan and the magnet to anticipate what type
of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear
AT0103
4.
REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful as some fluid will come out with the oil strainer.
D25128
5.
REMOVE TRANSMISSION VALVE BODY ASSY
(a) Disconnect the 4 solenoid connecters.
D25129
40-24
AUTOMATIC TRANSMISSION / TRANS
- TRANSMISSION VALVE BODY ASSY (ATM)
(b) Remove the bolt and manual detent spring.
F00673
(c)
Remove the 17 bolts.
D25130
(d) While disconnecting the manual valve connecting rod
from the manual valve lever, remove the valve body with
the manual valve together.
D25131
(e) Remove the 2 bolts and 3 solenoid valves.
No.1 Solenoid Assy (S1)
No.2 Solenoid Assy (S2)
(f)
Remove the 3 O-rings from each of the solenoid valves.
Solenoid Assy
(g) Remove the bolt, lock plate and line pressure control
A
No.3 (SL)
valve.
B
Line Pressure
Control Solenoid Assy (SLT)
C
Lock Plate
D25374
40-25
AUTOMATIC TRANSMISSION / TRANS
- TRANSMISSION VALVE BODY ASSY (ATM)
6.
INSTALL TRANSMISSION VALVE BODY ASSY
No.1 Solenoid Assy (S1)
(a)
Coat 3 new O-rings with ATF and install them to each so-
No.2 Solenoid Assy (S2)
Solenoid Assy
lenoid valves.
A
No.3 (SL)
(b)
Install the No.1 and No.2 solenoid valves with the bolt.
B
(c)
Install the No.3 solenoid valve with the bolt.
(d)
Install the line pressure control solenoid valve and lock
plate with the bolt.
Torque:
Bolt A: 11 N·m (110 kgf·cm, 8 ft·lbf)
Bolt B: 11 N·m (110 kgf·cm, 8 ft·lbf)
Bolt C: 6.5 N·m (66 kgf·cm, 58 in.
lbf)
Bolt length:
Bolt A: 25 mm (0.984 in.)
Line Pressure
Bolt B: 60 mm (2.362 in.)
Control Solenoid Assy (SLT)
C
Bolt C: 12 mm (0.472 in.)
Lock Plate
D25374
(e)
While connecting the manual valve connecting rod to the
manual valve lever, install the valve body with the manual
valve together.
D25131
(f)
Install the 17 bolts.
B
B
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 28 mm (1.10 in.)
A
A
Bolt C: 50 mm (1.97 in.)
C
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
A
D25330
(g) Install the manual detent spring and bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
F00673
40-26
AUTOMATIC TRANSMISSION / TRANS
- TRANSMISSION VALVE BODY ASSY (ATM)
(h) Connect the 4 solenoid connectors.
D25129
7.
INSTALL VALVE BODY OIL STRAINER ASSY
A
(a) Install the oil strainer with the 3 bolts.
Bolt length:
A bolt: 12 mm (0.47 in.)
B bolt: 20 mm (0.79 in.)
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
B
D25128
8.
INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Install the 2 magnets to the oil pan.
Magnet
D08582
(b) Install a new gasket to the oil pan and install them to the
transaxle.
(c)
Install the 18 bolts.
Torque: 5.3 N·m (55 kgf·cm, 48 in.lbf)
D09967
9.
INSTALL ENGINE UNDER COVER LH
10. ADD AUTOMATIC TRANSAXLE FLUID
11. INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-2)
40-27
AUTOMATIC TRANSMISSION / TRANS
- TRANSMISSION WIRE (ATM)
TRANSMISSION WIRE (ATM)
400LO-01
REPLACEMENT
1.
REMOVE TRANSMISSION VALVE BODY ASSY (See page 40-23)
2.
REMOVE TRANSMISSION WIRE
(a) Disconnect the transmission wire connector.
(b) Removal the bolt and transmission wire.
D09968
3.
INSTALL TRANSMISSION WIRE
(a) Coat a O-ring with ATF.
(b) Install the transmission wire and bolt.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
(c)
Connect the transmission wire connector.
D09968
4.
INSTALL TRANSMISSION VALVE BODY ASSY (See page
40-23)
41-15
MANUAL TRANSMISSION/TRANSAXLE
- MANUAL TRANSAXLE ASSY
MANUAL TRANSAXLE ASSY
4107C-01
COMPONENTS
Air Cleaner Assy
13 (133, 10)
Hood Sub-assy
5.0 (51, 44 in.lbf)
Battery Clamp
Sub-assy
7.0 (71, 62 in.lbf)
7.0 (71, 62 in.lbf)
3.5 (36, 31 in.lbf)
Clip
13 (133, 10)
Battery
Washer
Battery Tray
Cylinder Head
Clip
Cover No. 2
Clip
Clip
25.5 (260, 19)
Clip
13 (133, 10)
Back-up Lamp Switch
Connector
Battery Carrier
Washer
12.8 (131, 9)
Starter Connector
47 (480, 35)
23 (230, 17)
64 (650, 47)
Floor Shift Transmission
Transverse Engine
Control Cable Assy
52 (530, 38)
Engine Mounting Insulator
37 (378, 27)
12.8 (131, 9)
52 (530, 38)
37 (378, 27)
Filler Plug
F Gasket
39.2 (400, 29)
52 (530, 38)
13 (133, 10)
11.8 (120, 9)
Manual Transaxle Assy
25 (250, 19)
Ground Cable
25 (250, 19)
80 (816, 59)
5.0 (51, 44 in.lbf)
52 (530, 38)
Transverse Engine
N·m (kgf·cm, ft·lbf)
: Specified torque
Engine Mounting Bracket
F Non-reusable part
B53751
41-16
MANUAL TRANSMISSION/TRANSAXLE
- MANUAL TRANSAXLE ASSY
F Snap Ring
Front Drive Shaft Assy LH
F Snap Ring
Front Drive Shaft Assy RH
Transverse Engine
Engine Mounting Bracket
64 (653, 47)
Transverse Engine
Engine Mounting Insulator
Dynamic Damper
87 (887, 64)
Transverse Engine
64 (653, 47)
Engine Mounting Bracket
74 (755, 55)
F Cotter Pin
52 (530, 38)
35.3 (360, 26)
74 (755, 55)
F Cotter Pin
49 (500, 36)
49 (500, 36)
64 (653, 47)
8.0 (82, 71 in.lbf)
29 (296, 21)
89 (908, 66)
52 (530, 38)
39 (400, 29)
89 (908, 66)
52 (530, 38)
F
216 (2,303, 159)
Transverse Engine
157 (600, 116)
Engine Mounting Insulator
113 (1,152, 83)
113 (1,152, 83)
Spring
43 (438, 32)
Spring
Exhaust Pipe
Engine Under
43 (438, 32)
43 (438, 32)
Cover LH
Spring
Brace
Engine Under Cover RH
Spring
43 (438, 32)
N·m (kgf·cm, ft·lbf)
: Specified torque
29.6 (302, 22)
F Non-reusable part
B53752
41-86
MANUAL TRANSMISSION/TRANSAXLE
- DIFFERENTIAL CASE ASSY (C59)
4107L-01
OVERHAUL
1.
REMOVE SPEEDOMETER DRIVE (MTM) GEAR
(a) Remove the speedometer drive (MTM) gear from the front
differential case.
C67982
2.
REMOVE FRONT DIFFERENTIAL RING GEAR
Matchmarks
(a) Place matchmarks on the front differential ring gear and
front differential case.
C94318
(b) Remove the 8 bolts. Using a hammer, remove the front
differential ring gear.
C67984
3.
INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Fixing the front differential pinion from the front differential
case side. Using a dial indicator, measure the backlash of
the front differential side gear.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specification, install the connect
C67989
side gear thrust washers.
41-87
MANUAL TRANSMISSION/TRANSAXLE
- DIFFERENTIAL CASE ASSY (C59)
4.
REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a chisel and a hammer, loosen the staked part of
the front differential case.
C67985
(b) Using a pin punch (f 3 mm) and a hammer, remove the
front differential pinion shaft straight pin from the front dif-
ferential case.
C80412
5.
REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 from the
front differential case.
C80413
6.
REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 front differential
pinion thrust washers, 2 front differential side gear thrust
washers and 2 front differential side gears from the front
differential case.
HINT:
Turning the front differential pinion, remove the 2 pinions and
side gear.
C80414
7.
INSPECT FRONT DIFFERENTIAL PINION THRUST
WASHER
(a) Using a micrometer, measure the thickness of the front
differential pinion thrust washer.
Minimum thickness: 0.92 mm (0.0362 in.)
If the clearance is below the minimum, replace the front differ-
ential pinion thrust washer.
C80415

 

 

 

 

 

 

 

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