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Toyota Corolla (2004+). Manual - part 28

41-28

MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

4107F-01

OVERHAUL

REMOVE MANUAL TRANSMISSION FILLER PLUG

(a) Remove the manual transmission filler plug and gasket

from the manual transmission case.

C80549

REMOVE DRAIN (MTM) PLUG SUB-ASSY

(a) Remove the drain (MTM) plug sub-assy and gasket from

the manual transmission case.

C80550

REMOVE SPEEDOMETER SENSOR (W/O ABS)

(a) Remove the bolt and speedometer sensor from the transaxle case.

(b) Remove the O-ring from the speedometer sensor.

REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUB-ASSY (W/O ABS)

(a) Remove the clip and speedometer driven (MTM) gear sub-assy from the speedometer sensor.

REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (W/ ABS)

(a) Remove the bolt and speedometer driven hole cover sub-assy from the transaxle case.

(b) Remove the O-ring from the speedometer driven hole cover.

REMOVE CLUTCH RELEASE FORK SUB-ASSY

(a) Remove the clutch release fork sub-assy with clutch re-

lease bearing assy from the transaxle case.

C67601

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

REMOVE CLUTCH RELEASE BEARING ASSY

(a) Remove the clutch release bearing clip and clutch release

bearing assy from the clutch release fork sub-assy.

C67602

REMOVE RELEASE FORK SUPPORT

(a) Remove the clutch release fork support from the trans-

axle case.

C67604

REMOVE CLUTCH RELEASE FORK BOOT

(a) Remove the clutch release fork boot from the transaxle

case.

C80331

10. REMOVE BACK UP LAMP SWITCH ASSY

(a) Remove the back up lamp switch assy and gasket from

the manual transmission case.

C95184

11. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING

SUPPORT BRACKET

(a) Remove the 3 bolts and floor shift control lever housing

support bracket from the transaxle case.

C80333

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

12. REMOVE SELECTING BELL CRANK ASSY

(a) Remove the 2 bolts and selecting bellcrank assy from the

manual transmission case.

(b) Remove the control shift lever bush.

C95185

13. FIX MANUAL TRANSAXLE ASSY

(a) Using 2 wooden blocks, fix the manual transaxle assy.

C80336

14. REMOVE LOCK BALL ASSY NO.1

(a) Remove the lock ball assy No.1 from the manual trans-

mission case.

C95186

15. REMOVE SHIFT & SELECT LEVER SHAFT ASSY

(a) Remove the 4 bolts, shift & select lever shaft assy and

gasket from the manual transmission case.

C95187

16. REMOVE MANUAL TRANSMISSION CASE COVER

SUB-ASSY

(a) Remove the 9 bolts.

C95188

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Using a plastic hammer, carefully tap the projection of the

manual transmission case cover sub-assy to remove it

from the manual transmission case.

NOTICE:

Do not damage the manual transmission case.

C95189

17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT

REAR SET NUT

(a) Using a chisel and a hammer, loosen the staked part of

the manual transmission output shaft rear set nut.

C80341

(b) Engage the gear to the double meshing.

(c)

Remove the manual transmission output shaft rear set

nut.

(d) Disengage the double mashing of the gear.

Q06512

18. REMOVE GEAR SHIFT FORK NO.3

(a) Remove the gear shift fork lock bolt from the gear shift fork

No.3.

C80342

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Remove the transmission hub sleeve No.3 with gear shift

fork No.3 from the transmission clutch hub No.3.

C80343

19. INSPECT 5TH GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 5th gear thrust clear-

ance.

5th gear thrust clearance:

Standard clearance: mm (in.)

Maximum clearance: mm (in.)

0.10 - 0.57 (0.0039 - 0.0224)

0.57

(0.0224)

C80344

20. INSPECT 5TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 5th gear radial clear-

ance.

5th gear radial clearance: mm (in.)

Standard clearance: mm (in.)

Maximum clearance: mm (in.)

KOYO made:

KOYO made: 0.058 ( 0.0023)

0.015 - 0.058 (0.0006 - 0.0023)

NSK made:

NSK made: 0.056 (0.0022)

0.015 - 0.056 (0.0006 - 0.0022)

C80345

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

21. REMOVE TRANSMISSION CLUTCH HUB NO.3

(a) Using 2 screwdrivers and a hammer, tap out the snap

ring.

HINT:

Using a waste to prevent the snap ring from being scattered.

C80346

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Using SST, remove the transmission clutch hub No.3, 5th

SST

gear and synchronizer ring No.3 from the input shaft.

SST

09950-40011 (09951-04020,

09952-04010,

09953-04030,

09954-04010,

09955-04071,

09957-04010), 09950-60010 (09951-00200)

C80347

(c)

Remove the 3 synchromesh shifting keys and 2 synchro-

mesh shifting key springs from the transmission clutch

hub No.3.

D07737

22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

(a) Remove the 5th gear needle roller bearing and 5th gear

bearing spacer from the input shaft.

C80348

23. REMOVE 5TH DRIVEN GEAR

(a) Using SST, remove the 5th driven gear from the output

shaft.

SST

09950-30012 (09951-03010, 09953-03010,

09954-03010, 09955-03011, 09957-04010),

09950-60010 (09951-00190)

C80349

24. REMOVE BEARING RETAINER REAR (MTM)

(a) Remove the 5 bolts and bearing retainer rear (MTM) from

the manual transmission case.

C80350

41-34

MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

25. REMOVE OUTPUT SHAFT REAR BEARING HOLE

SNAP RING

(a) Using a snap ring expander, remove the output shaft rear

bearing hole snap ring from the output shaft.

C80351

26. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP

RING

(a) Using a snap ring expander, remove the input shaft rear

bearing hole snap ring from the input shaft.

C80352

27. REMOVE REVERSE IDLER GEAR SHAFT BOLT

(a) Remove the reverse idler gear shaft bolt and gasket from

the manual transmission case.

C67639

28. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING

(a) Using 2 screwdrivers and a hammer, tap out the snap ring

from the gear shift fork shaft No.2.

HINT:

Using a waste to prevent the snap ring from being scattered.

C80353

29. REMOVE SHIFT DETENT BALL

(a) Using a hexagon wrench, remove the 2 shift detent ball

plugs from the manual transmission case.

C67634

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Using a magnetic finger, remove the 2 seats, 2 springs

and 2 shift detent balls from the manual transmission

case.

C67635

(c)

Using a hexagon wrench, remove the shift detent ball

plug from the transaxle case.

C80354

(d) Using a magnetic finger, remove the seat, spring and shift

detent ball from the transaxle case.

C80355

30. REMOVE LOCK BALL ASSY NO.1

(a) Using a hexagon wench, remove the lock ball assy No.1

from the manual transmission case.

C80356

31. REMOVE MANUAL TRANSMISSION CASE

(a) Remove the 3 bolts from the transaxle case side.

C80357

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Remove the 13 bolts from the manual transmission case

side.

C80358

(c)

Using a brass bar and a hammer, carefully tap the projec-

tion of the manual transmission case to remove it from the

transaxle case.

NOTICE:

Do not damage the manual transmission case and trans-

axle case.

C67642

32. REMOVE REVERSE IDLER GEAR SUB-ASSY

(a) Remove the reverse idler gear sub-assy, thrust washer

and reverse idler gear shaft from the transaxle case.

C80359

33. REMOVE REVERSE SHIFT ARM BRACKET ASSY

(a) Remove the 2 bolts and reverse shift arm bracket assy

from the transaxle case.

C80360

34. REMOVE GEAR SHIFT FORK SHAFT NO.2

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

shift head No.1.

C80361

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Remove the gear shift fork shaft No.2 and gear shift head

Gear Shift

No.1 from the transaxle case.

Fork Shaft

No.2

Gear Shift

Head No.1

C80362

35. REMOVE GEAR SHIFT FORK SHAFT SUB-ASSY

NO.1

(a) Using 2 screwdrivers and a hammer, tap out the snap

rings.

HINT:

Using a waste to prevent the snap ring from being scattered.

C80363

(b) Remove the gear shift fork lock bolt and gear shift fork

shaft sub-assy No.1 from the gear shift fork No.1.

C80364

(c)

Remove the gear shift fork No.1.

Gear Shift

Fork No.1

C80365

36. REMOVE GEAR SHIFT FORK SHAFT NO.3

(a) Using 2 screwdrivers and a hammer, tap out the snap ring

from the gear shift fork shaft No.3.

HINT:

Using a waste to prevent the snap ring from being scattered.

C80366

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Remove the shift fork shaft No.3 with reverse shift fork

Gear Shift

and gear shift fork No.2 from the transaxle case.

Fork Shaft No.3

Fork No.2

Reverse

Shift Fork

C80367

(c)

Using a magnetic finger, remove the 2 balls from the re-

verse shift fork.

C80368

(d) Using 2 screwdrivers and a hammer, tap out the snap

ring.

HINT:

Using a waste to prevent the snap ring from being scattered.

(e) Remove the reverse shift fork from the gear shift fork shaft

No.3.

C80369

37. REMOVE INPUT SHAFT ASSY

(a) Remove the input and output shaft assy from the trans-

axle case.

C80586

38. REMOVE DIFFERENTIAL CASE ASSY

(a) Remove the differential case assy from the transaxle

case.

C67656

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

39. REMOVE MANUAL TRANSAXLE CASE RECEIVER

(a) Remove the bolt and manual transaxle case receiver from

the transaxle case.

C67657

40. REMOVE REVERSE RESTRICT PIN ASSY

(a) Using a hexagon wrench, remove the reverse restrict pin

plug from the manual transmission case.

C80372

(b) Using a pin punch (f 5 mm) and a hammer, drive out the

slotted spring pin and remove the reverse restrict pin assy

from the manual transmission case.

C80373

41. REMOVE OIL RECEIVER PIPE NO.1 (MTM)

(a) Remove the bolt and oil receiver pipe No.1 (MTM) from

the manual transmission case.

NOTICE:

Be careful not to damage the oil receiver pipe No.1 (MTM).

C67644

42. REMOVE OIL RECEIVER PIPE NO.2 (MTM)

(a) Remove the bolt and oil receiver pipe No.2 (MTM) from

the manual transmission case.

NOTICE:

Be careful not to damage the oil receiver pipe No.2 (MTM).

C80374

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

43. REMOVE BEARING LOCK PLATE

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

case.

C67658

44. REMOVE TRANSMISSION MAGNET

(a) Remove the transmission magnet from the transaxle

case.

C67659

45. REMOVE INPUT SHAFT FRONT BEARING

(a) Using SST, remove the input shaft front bearing from the

transaxle case.

SST

09612-65014 (09612-01050, 09612-01060)

SST

C81783

46. REMOVE FRONT TRANSAXLE CASE OIL SEAL

(a) Using a screwdriver, remove the front transaxle case oil

seal from the transaxle case.

C95411

47. REMOVE OUTPUT SHAFT FRONT BEARING

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

transaxle case.

SST

09308-00010

C82141

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

48. REMOVE OUTPUT SHAFT (MTM) COVER

(a) Remove the output shaft (MTM) cover from the transaxle

case.

C67719

49. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED

ROLLER BEARING

(a) Using SST, remove the FR differential case front tapered

roller bearing (outer race) and shim from the transaxle

case.

SST

09612-65014 (09612-01040, 09612-01050)

SST

C81785

(b) Using SST, remove FR differential case front tapered roll-

er bearing (inner race) from the front differential case.

SST

09950-00020, 09950-00030, 09950-40011

(09957-04010), 09950-60010 (09951-00360)

NOTICE:

Be careful not to damage bearing.

Z16129

50. REMOVE TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, drive out the transaxle case oil

SST

seal from the transaxle case.

SST

09950-60010 (09951-00530), 09950-70010

(09951-07150)

C81789

51. REMOVE FR DIFFERENTIAL CASE REAR TAPERED

ROLLER BEARING

SST

(a) Using SST, remove the FR differential case rear tapered

roller bearing (outer race) and shim from the manual

transmission case.

SST

09612-65014 (09612-01040, 09612-01050)

C81788

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MANUAL TRANSMISSION/TRANSAXLE

- MANUAL TRANSAXLE ASSY (C59)

(b) Using SST and a hammer, remove the FR differential

case rear tapered roller bearing (inner race) from the front

differential case.

SST

09950-40011 (09951-04010,

09952-04010,

09953-04020,

09954-04010,

09955-04061,

09957-04010,

09958-04011),

09950-60010

SST

(09951-00360)

NOTICE:

C95108

Be careful not to damage bearing.

52. REMOVE TRANSMISSION CASE OIL SEAL

(a) Using SST and a hammer, remove the transmission case

oil seal from the manual transmission case.

SST

09950-60010 (09951-00600), 09950-70010

SST

(09951-07100)

C81787

53. INSPECT SYNCHRONIZER RING NO.3

(a) Check for wear or damage.

(b) Check the braking effect of the synchronizer ring. Turn the

synchronizer ring in one direction while pushing it to the

gear cone, check that the ring locks.

If the braking effect is insufficient, apply a small amount of the

fine lapping compound between the synchronizer ring and gear

cone. Lightly rub the synchronizer ring and gear cone together.

C67848

NOTICE:

Ensure the file lapping compound is completely washed off

after rubbing.

(c)

Check again the breaking effect of the synchronizer ring.

(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.

Minimum clearance: 0.75 mm (0.0295 in.)

If the clearance is less than minimum, replace the synchronizer

ring and gear cone by applying a small amount of the fine lap-

ping compound on gear cone.

NOTICE:

Ensure the fine lapping compound is completely washed

C67850

off after rubbing.

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