Блок Механической Трансмиссии В Блоке С Главной Передачей Повторная Сборка. Corolla ZZE150

Coat the output shaft cover with MP grease and install it onto the front transaxle case.

ПРИМЕЧАНИЕ:

Insert the output shaft cover projection into the case side hollow.

Coat a new output shaft front bearing with gear oil.

Using SST and a press, install it onto the front transaxle case.

SST

09950-60010(09951-00550)
09950-70010(09951-07150)

ПРИМЕЧАНИЕ:

1. Install the new bearing in the correct direction as shown in the illustration.
   
2. When replacing the output shaft front bearing, replace the output shaft front bearing inner race at the same time.
   

Using SST and a hammer, install a new front transaxle case oil seal onto the front transalxe case.

SST

09950-60010(09951-00370)
09950-70010(09951-07150)

Drive in depth:

15.6 to 16.0 mm (0.6141 to 0.6299 in.)

Coat the lip of the front transaxle case oil seal with MP grease.

Coat a new input shaft front bearing with gear oil, and using SST and a press, install it onto the front transaxle case.

SST

09950-60010(09951-00420)
09950-70010(09951-07150)

Drive in depth:

0 to 0.3 mm (0 to 0.0118 in.)

Using SST and a hammer, install the shift and select lever shaft slide ball bearing onto the transmission case.

SST

09950-60010(09951-00220)
09950-70010(09951-07100)

Drive in depth:

0 to 0.5 mm (0 to 0.020 in.)

Using SST, install the shift and select lever shaft oil seal onto the transmission case.

SST

09950-70010(09951-07150)
09950-60010(09951-00240)

Drive in depth:

9.7 to 10.3 mm (0.382 to 0.406 in.)

Using SST and a press, install the front differential case front tapered roller bearing (inner race) onto the front differential case.

SST

09350-32014(09351-32120)
09950-60010(09951-00530)

Using SST and a press, install the front differential case front tapered roller bearing (outer race) together with the plate washer onto the front transaxle case.

SST

09950-60020(09951-00680)
09950-70010(09951-07150)

Using SST and a press, install the front differential case rear tapered roller bearing (inner race) onto the differential case.

SST

09350-32014(09351-32120)
09950-60010(09951-00530)

Using SST and a press, install the front differential case rear tapered roller bearing (outer race) with the plate washer onto the transmission case.

SST

09309-36010
09950-60020(09951-00710)
09950-70010(09951-07150)

УКАЗАНИЕ:

Use a plate washer of the same thickness as the removed one.

Coat the differential case assembly with gear oil and install it onto the front transaxle case.

Install the manual transmission case with the 16 bolts.

Момент затяжки:

29 Н*м{300 кгс*см, 22 фунт-сила-футов}

Using SST and a torque wrench, turn the differential case assembly to the right and left 2 or 3 times to allow the bearings to settle.

SST

09564-32011

Using SST and a torque wrench, measure the preload.

SST

09564-32011

Preload (at starting):

New bearing:

0.78 to 1.57 N*m (7.95 to 16.0 kgf*cm, 6.9 to 13.89 in.*lbf)

Used bearing:

0.49 to 0.98 N*m (5.0 to 10.0 kgf*cm, 4.34 to 8.67 in.*lbf)

Plate washer thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
AA	2.10 (0.0827)	LL	2.60 (0.1024)
BB	2.15 (0.0846)	MM	2.65 (0.1043)
CC	2.20 (0.0866)	NN	2.70 (0.1063)
DD	2.25 (0.0886)	PP	2.75 (0.1083)
EE	2.30 (0.0906)	QQ	2.80 (0.1102)
FF	2.35 (0.0925)	RR	2.85 (0.1122)
GG	2.40 (0.0945)	SS	2.90 (0.1142)
HH	2.45 (0.0965)	TT	2.95 (0.1161)
JJ	2.50 (0.0984)	UU	3.00 (0.1181)
KK	2.55 (0.1004)	-	-

УКАЗАНИЕ:

The preload changes by approximately 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) per each 0.05 mm (0.0020 in.) change in the plate washer thickness.

Remove the 16 bolts and the manual transmission case.

Remove the differential case assembly from the front transaxle case.

Using SST and a hammer, install a new transmission case oil seal onto the manual transmission case.

SST

09316-60011(09316-00011)

Drive in depth:

9.6 to 10.2 mm (0.378 to 0.402 in.)

Coat the lip of the front transmission case oil seal with MP grease.

Using SST and a hammer, install a new transaxle case oil seal onto the front transaxle case.

SST

09710-20011(09710-06071)
09950-70010(09951-07150)

Drive in depth:

1.6 to 2.2 mm (0.063 to 0.087 in.)

Coat the lip of the transaxle case oil seal with MP grease.

Clean the transmission magnet and install it onto the front transaxle case.

Install the bearing lock plate onto the front transaxle case with the bolt.

Момент затяжки:

11 Н*м{115 кгс*см, 8.3 фунт-сила-футов}

Install the No. 1 oil receiver pipe onto the manual transmission case with the bolt.

Момент затяжки:

17 Н*м{175 кгс*см, 13 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. Do not deform the No. 1 oil receiver pipe.
   
2. Install the No. 1 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.
   

Install the No. 2 oil receiver pipe onto the manual transmission case with the bolt.

Момент затяжки:

17 Н*м{175 кгс*см, 13 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. Do not deform the No. 2 oil receiver pipe.
   
2. Install the No. 2 oil receiver pipe while holding it against the manual transmission case as shown in the illustration.
   

Install the reverse restrict pin assembly onto the manual transmission case.

ПРИМЕЧАНИЕ:

Set the reverse restrict pin assembly in the correct orientation.

Using a pin punch (φ5 mm) and a hammer, install the slotted pin onto the reverse restrict pin assembly.

Drive in depth:

15.5 to 16.5 mm (0.6102 to 0.6496 in.)

Apply sealant to the reverse restrict pin plug.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a hexagon wrench and a torque wrench, install the reverse restrict pin plug onto the manual transmission case.

Момент затяжки:

13 Н*м{130 кгс*см, 9.3 фунт-сила-футов}

Install the manual transaxle case receiver onto the front transaxle case with the bolt.

Момент затяжки:

11 Н*м{115 кгс*см, 8.3 фунт-сила-футов}

Coat the differential case tapered roller bearing with gear oil and install the differential case assembly onto the front transaxle case.

Coat the sliding and rotating surfaces of the input and output shafts with gear oil and install them onto the transaxle case.

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.

УКАЗАНИЕ:

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

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

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

Apply sealant to the shift fork set bolt.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the shift fork set bolt.

Момент затяжки:

16 Н*м{160 кгс*см, 12 фунт-сила-футов}

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

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

Install the reverse shift fork onto the No. 3 gear shift fork shaft.

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

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

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

ПРИМЕЧАНИЕ:

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

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

Момент затяжки:

16 Н*м{160 кгс*см, 12 фунт-сила-футов}

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

Момент затяжки:

17 Н*м{175 кгс*см, 13 фунт-сила-футов}

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

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

ПРИМЕЧАНИЕ:

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

Install the 13 bolts onto the manual transmission side.

Момент затяжки:

29 Н*м{300 кгс*см, 22 фунт-сила-футов}

Coat the 3 bolts with sealant and install it onto the manual transaxle side.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

29 Н*м{300 кгс*см, 22 фунт-сила-футов}

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

Момент затяжки:

29 Н*м{300 кгс*см, 22 фунт-сила-футов}

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

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

29 Н*м{300 кгс*см, 22 фунт-сила-футов}

Install the 2 shift detent balls, 2 shift detent ball springs and 2 No. 1shift detent ball spring seats onto the manual transmission case.

Coat 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

Момент затяжки:

22 Н*м{224 кгс*см, 16 фунт-сила-футов}

Install the shift detent ball, shift detent ball compression spring and shift detent No. 1 ball spring seat onto the front transaxle case.

Coat the shift detent ball plug with sealant and install it using a hexagon wrench.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

22 Н*м{224 кгс*см, 16 фунт-сила-футов}

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

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

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

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

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

27 Н*м{280 кгс*см, 20 фунт-сила-футов}

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

SST

09309-12020

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

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

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

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

ПРИМЕЧАНИЕ:

Do not set the 2 shifting key springs opening in the same position.

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

SST

09636-20010

ПРИМЕЧАНИЕ:

1. Do not install the No. 3 transmission clutch hub in the wrong direction.
   
2. Install the No. 3 transmission clutch hub with the No. 3 synchronizer ring key groove and No. 3 synchromesh shifting key aligned.
   
3. Check that the 5th gear is rotating.
   
4. Place a suitable sized wooden block to support the input shaft.
   

Select a snap ring that will allow minimum axial play.

Clearance:

0.1 mm (0.004 in.) or less

Snap ring thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.25 (0.0886)	E	2.49 (0.0980)
B	2.31 (0.0909)	F	2.55 (0.1004)
C	2.37 (0.0933)	G	2.61 (0.1028)
D	2.43 (0.0957)	-	-

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

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

Standard clearance:

TMC made:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

TMUK, TMMT made:

0.10 to 0.57 mm (0.0039 to 0.0224 in.)

Maximum clearance:

TMC made:

0.55 mm (0.0217 in.)

TMUK, TMMT made:

0.57 mm (0.0224 in.)

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

Standard clearance:

NSK made bearing:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Except NSK made bearing:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)

Maximum clearance:

NSK made bearing:

0.056 mm (0.0022 in.)

Except NSK made bearing:

0.058 mm (0.0023 in.)

Coat the No. 3 transmission clutch hub sleeve with gear oil and install it together with the No. 3 gear shift fork onto the No. 3 transmission clutch hub.

УКАЗАНИЕ:

Set the No. 3 transmission clutch hub in the correct orientation.

Coat the gear shift fork lock bolt with sealant, and install it onto the No. 3 gear shift fork.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

16 Н*м{160 кгс*см, 12 фунт-сила-футов}

Engage the 2 gears simultaneously to lock the transmission.

Install a new manual transmission output shaft rear set nut.

Момент затяжки:

118 Н*м{1200 кгс*см, 87 фунт-сила-футов}

Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.

Disengage the 2 gears.

Apply FIPG to the manual transaxle case cover sub-assembly as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

ПРИМЕЧАНИЕ:

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

Install the manual transmission case cover sub-assembly with the 9 bolts onto the manual transmission case.

Момент затяжки:

18 Н*м{185 кгс*см, 13 фунт-сила-футов}

Coat the shift and select lever shaft assembly with gear oil, and install it onto the transmission case.

Using SST and a hammer, install a new control shaft cover oil seal onto the control shaft cover.

SST

09950-60010(09951-00280)
09950-70010(09951-07150)

Drive in depth:

0.2 to 1.2 mm (0.0079 to 0.0472 in.)

Coat the control shaft cover oil seal with MP grease.

Coat the 4 bolts with sealant. Install a new gasket and the control shaft cover onto the manual transmission case with the 4 bolts.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

20 Н*м{200 кгс*см, 14 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.

Coat the shift guide pin with sealant.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Install the washer and shift guide pin.

Момент затяжки:

11 Н*м{112 кгс*см, 8.1 фунт-сила-футов}

Coat the No. 1 lock ball assembly with sealant and install it onto the manual transmission case.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Момент затяжки:

29 Н*м{300 кгс*см, 22 фунт-сила-футов}

Install the dust boot onto the control shaft cover.

Install the shift lever damper with the lock pin onto the shift and select lever shaft assembly.

Install the washer with the nut.

Момент затяжки:

12 Н*м{120 кгс*см, 8.7 фунт-сила-футов}

Install the dust boot onto the shift and select lever shaft oil seal.

Install the floor shift control shift lever with the lock pin onto the shift and select lever shaft assembly.

Install the washer with the nut.

Момент затяжки:

12 Н*м{120 кгс*см, 8.7 фунт-сила-футов}

Install the selecting bell crank assembly together with the control bell crank dust cover onto the manual transmission case with the 2 bolts and nut.

Момент затяжки:

25 Н*м{250 кгс*см, 18 фунт-сила-футов} for bolt

12 Н*м{120 кгс*см, 8.7 фунт-сила-футов} for nut

ПРИМЕЧАНИЕ:

Apply MP grease to the inside circumferential surface of the control shift lever bush.

Using SST, install the back-up light switch assembly onto the manual transmission case with a new gasket.

SST

09817-16011

Момент затяжки:

40 Н*м{410 кгс*см, 30 фунт-сила-футов}

Install the back-up light switch wire harness into the 2 clamps.

Install a new O-ring onto the speedometer driven hole cover sub-assembly.

Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with the bolt.

Момент затяжки:

11 Н*м{115 кгс*см, 8.3 фунт-сила-футов}

Install the manual transmission filler plug onto the manual transmission case with a new gasket.

Момент затяжки:

39 Н*м{400 кгс*см, 29 фунт-сила-футов}

Install the drain plug onto the manual transmission case with a new gasket.

Момент затяжки:

39 Н*м{400 кгс*см, 29 фунт-сила-футов}