Part 2

C59 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE UNIT: REASSEMBLY; 2013 MY Corolla [07/2012 -]





20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY

(a) Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.





HINT
Align the mark on the reverse idler gear shaft with the bolt hole as shown in the illustration.

21. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

(a) Coat the No. 1 gear shift fork and No. 2 gear shift fork with gear oil and install them.





(b) Coat the No. 1 gear shift fork shaft with gear oil and install it.





(c) Apply sealant to the shift fork set bolt.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(d) Install the shift fork set bolt.

Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)

(e) Using a brass bar and a hammer, install a new shaft snap ring onto the No. 1 gear shift fork shaft.





22. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

(a) Coat the 2 shift fork balls with MP grease and install them onto the reverse shift fork.





(b) Install the reverse shift fork onto the No. 3 gear shift fork shaft.

(c) Using a brass bar and a hammer, install 2 new shift fork shaft snap rings onto the No. 3 shift fork shaft.





(d) Coat the No. 3 gear shift fork shaft with gear oil and install it.





23. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

(a) Coat the No. 1 gear shift head and No. 2 gear shift fork shaft with gear oil and install them.





NOTICE:
To avoid interference from the 2 shift fork balls, lift up the No. 3 gear shift fork shaft to the position shown in the illustration.

(b) Coat the 2 shift lock bolts with sealant and install them onto the No. 2 gear shift fork and No. 1 shift head.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)

24. INSTALL REVERSE SHIFT ARM BRACKET ASSEMBLY

(a) Install the reverse shift arm bracket assembly onto the front transaxle case with the 2 bolts.





Torque : 17 Nm (175 kgf-cm, 13 ft-lbf)

25. INSTALL MANUAL TRANSMISSION CASE

(a) Apply FIPG to the manual transmission case as shown in the illustration.





FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

(b) Install the 13 bolts onto the manual transmission side.





Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

(c) Coat the 3 bolts with sealant and install them onto the manual transaxle side.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

26. INSTALL REVERSE IDLER GEAR SHAFT BOLT

(a) Coat the reverse idler gear shaft bolt with sealant and install it with a new gasket.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

27. INSTALL NO. 2 LOCK BALL ASSEMBLY

(a) Coat the No. 2 lock ball assembly with sealant and install it using a hexagon wrench.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)

28. INSTALL SHIFT DETENT BALL

(a) Install the 2 shift detent balls, 2 shift detent ball springs, and 2 shift spring seats onto the manual transmission case.





(b) Coat the threads of the 2 shift detent ball plugs with sealant and install them using a hexagon wrench.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(c) Install the shift detent ball, shift detent ball compression spring, and spring seat onto the transaxle case.





(d) Coat the threads of the shift detent ball plug with sealant and install it using a hexagon wrench.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

29. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING

(a) Using a snap ring expander, install a new input shaft rear bearing hole snap ring onto the input shaft.





30. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING

(a) Using a snap ring expander, install a new output shaft rear bearing hole snap ring onto the output shaft.





31. INSTALL SHIFT FORK SHAFT SNAP RING

(a) Using a brass bar and a hammer, install a new shift fork shaft snap ring onto the No. 2 shift fork shaft.





32. INSTALL REAR BEARING RETAINER

(a) Coat the 5 bolts with sealant and install the rear bearing retainer onto the manual transmission case with the 5 bolts.





Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque : 27 Nm (280 kgf-cm, 20 ft-lbf)

33. INSTALL 5TH DRIVEN GEAR

(a) Using SST, install the 5th driven gear onto the output shaft.





SST : 09309-12020

34. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

(a) Coat the 5th gear needle roller bearing and 5th gear bearing spacer with gear oil, and install them onto the input shaft.





35. INSTALL 5TH GEAR

(a) Coat the 5th gear with gear oil and install it onto the input shaft.





36. INSTALL NO. 3 SYNCHRONIZER RING

(a) Coat the No. 3 synchronizer ring with gear oil and install it onto the 5th gear.





37. INSTALL NO. 3 TRANSMISSION CLUTCH HUB

(a) Install the 3 synchromesh shifting keys and 2 synchromesh shifting key springs onto the No. 3 transmission clutch hub as shown in the illustration.





NOTICE:
Do not set the 2 shifting key spring openings in the same position.

(b) Using SST and a hammer, install the No. 3 transmission clutch hub onto the input shaft.

SST : 09636-20010





NOTICE:
* Do not install the No. 3 transmission clutch hub in the wrong direction.
* Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and the No. 3 synchromesh shifting key aligned.
* Check that the 5th gear can rotate smoothly.
* Place a suitable sized wooden block to support the input shaft.

(c) Select a snap ring that will allow minimum axial play.

Clearance:

0.1 mm (0.00394 in.) or less

Snap Ring Thickness:





(d) Using a brass bar and a hammer, install a new snap ring onto the input shaft.





38. INSPECT 5TH GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 5th gear thrust clearance.





Standard clearance:

0.10 to 0.55 mm (0.00394 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft rear radial ball bearing.

39. INSPECT 5TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 5th gear radial clearance.





Standard clearance:

NSK made bearing
0.015 to 0.056 mm (0.000591 to 0.00220 in.)

JTEKT made bearing
0.015 to 0.058 mm (0.000591 to 0.00228 in.)

Maximum clearance:

NSK made bearing
0.056 mm (0.00220 in.)

JTEKT made bearing
0.058 mm (0.00228 in.)

If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft.