41 - Manual Transmission.pdf

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41–1
MANUAL TRANSMISSION/TRANSAXLE
–
MANUAL TRANSAXLE SYSTEM
MANUAL TRANSAXLE SYSTEM
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.
41075–01
Symptom
Suspect Area
See page
Noise
6. Oil (Level low)
7. Oil (Wrong)
8. Gear (Worn or damaged)
41–2
41–2
41–63
41–74
41–63
41–74
9. Bearing (Worn or damaged)
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O–Ring (Worn or damaged)
41–2
41–28
41–3
41–28
1. Control cable (Faulty)
41–9
41–12
41–63
41–74
41–63
41–74
Hard to shift or will not shift
2. Synchronizer ring (Worn or damaged)
3. Shifting key spring (Damaged)
Jumps out of gear
1. Locking ball spring (Damaged)
2. Gear Shift fork (Worn)
3. Gear (Worn or damaged)
41–28
41–28
41–63
41–74
41–63
41–74
4. Bearing (Worn or damaged)
2004 COROLLA (RM1037U)
Author:
Date:
1401
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41–2
MANUAL TRANSMISSION/TRANSAXLE
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MANUAL TRANSAXLE OIL
MANUAL TRANSAXLE OIL
ON–VEHICLE INSPECTION
41076–01
0 – 5 mm
(0 – 0.20 in.)
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:
Excessively large or small amount of oil may cause
troubles.
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
D25304
m (400 kgf
V
cm, 29 ft
V
lbf)
2004 COROLLA (RM1037U)
Author:
Date:
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41–3
MANUAL TRANSMISSION/TRANSAXLE
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FRONT DIFFERENTIAL OIL SEAL
FRONT DIFFERENTIAL OIL SEAL
REPLACEMENT
1.
41077–02
DRAIN MANUAL TRANSAXLE OIL
Torque: 39.2 N
m (400 kgf
V
cm, 29 ft
V
lbf)
2.
REMOVE FRONT WHEELS
3.
REMOVE ENGINE UNDER COVER LH
4.
REMOVE ENGINE UNDER COVER RH
5.
DRAIN TRANSAXLE OIL
6.
REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6 )
SST 09520–01010, 09520–24010 (09520–32040)
7.
REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30–6 )
SST 09520–01010, 09520–24010 (09520–32040)
8. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST, remove the transaxle case oil seal.
SST 09308–00010
SST
C94266
9. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST, remove the transmission case oil seal.
SST 09308–00010
SST
D25305
SST
10. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST and a hammer, install the transaxle case oil
seal.
SST 09554–14010, 09950–70010 (09951–07200)
Drive in depth: 1.9 0.3 mm (0.075 0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
D25722
2004 COROLLA (RM1037U)
Author:
Date:
1403
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41–4
MANUAL TRANSMISSION/TRANSAXLE
–
FRONT DIFFERENTIAL OIL SEAL
SST
11. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST and a hammer, install the transmission case
oil seal.
SST 09554–14010, 09950–70010 (09951–07200)
Drive in depth: 9.9 0.3 mm (0.390 0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
D26133
12. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–6 )
13. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–6 )
14. INSTALL FRONT WHEELS
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
15. ADD MANUAL TRANSAXLE OIL
Oil grade: API GL–4 or GL–5
Viscosity: SAE 75 W–90
Capacity:1.9 liters (2.0 US qts, 1.7 lmp. qts)
Torque: 39.2 N
m (400 kgf
V
cm, 29 ft
V
lbf)
0 – 5 mm
(0 – 0.20 in.)
D25304
16. INSPECT AND ADJUST MANUAL TRANSAXLE OIL (See page 41–2 )
17. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26–5 )
18. CHECK ABS SPEED SENSOR SIGNAL (See page 05–297 )
2004 COROLLA (RM1037U)
Author:
Date:
1404
V
V
V
V
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41–5
MANUAL TRANSMISSION/TRANSAXLE
–
FLOOR SHIFT SHIFT LEVER ASSY
FLOOR SHIFT SHIFT LEVER ASSY
COMPONENTS
4107A–01
17.5 (178, 13)
Floor Shift Lever
Knob Sub–assy
Console Panel Upper
Console Box Carpet
Parking Brake Hole Cover Sub–assy
5.0 (51, 44 in. V lbf)
Clip
Shift Cable Grommet
Retainer No. 1
Console Box Sub–assy Rear
Floor Shift Cable Transmission
Control Shift
12 (122, 9)
Washer
Clamp
Clip
Clip
5.0 (51, 44 in. V lbf)
Clip
12 (122, 9)
Clip
Washer
Floor Shift Cable Transmission
Control Select
Floor Shift Shift Lever Assy
Front Floor Heat Insulator
Clip
5.5 (56, 49 in.
lbf)
N
m (kgf
V
cm, ft
V
lbf)
: Specified torque
B53749
2004 COROLLA (RM1037U)
Author:
Date:
1405
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