Блок Механической Трансмиссии 'Multimode' Повторная Сборка. Corolla ZZE150

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

ПРИМЕЧАНИЕ:

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

Coat a new output shaft front bearing with gear oil and install it using SST and a press.

SST

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

ПРИМЕЧАНИЕ:

Be sure to install a new bearing in the correct direction, as shown in the illustration.

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

SST

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

Drive in depth:

15.6 to 16.0 mm (0.6142 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.

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 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) 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 front 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 manual transmission case.

SST

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

УКАЗАНИЕ:

Use a front differential case rear plate washer of the same thickness as the removed one.

Install the 4 manual transmission case straight pins into the front transaxle case.

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, 6.90 to 13.90 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)

Select another plate washer.

УКАЗАНИЕ:

Select a thicker plate washer to increase the preload or a thinner plate washer to decrease the preload.

Remove the 16 bolts and manual transmission case from the transaxle 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

09726-36010
09950-70010(09951-07150)

Drive in depth:

9.6 to 10.2 mm (0.3780 to 0.4016 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 (0.0630 to 0.0866 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 with the bolt.

Момент затяжки:

11 Н*м{115 кгс*см, 8 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. Be careful not to damage the No. 1 oil receiver pipe.
   
2. Prevent the No. 1 oil receiver pipe from being deformed.
   
3. Install the No. 1 oil receiver pipe while placing 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. Be careful not to damage the No. 2 oil receiver pipe.
   
2. Prevent the No. 2 oil receiver pipe from being deformed.
   
3. Install the No. 2 oil receiver pipe while placing it against the manual transmission case as shown in the illustration.
   

Install the reverse restrict pin into the manual transmission case.

УКАЗАНИЕ:

Orient the reverse restrict pin correctly.

Using a pin punch (φ 5 mm) and a hammer, install the slotted pin into the reverse restrict pin.

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 into the manual transmission case.

Момент затяжки:

13 Н*м{129 кгс*см, 9 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 фунт-сила-футов}

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

Coat the reverse idler gear, thrust washer and reverse idler gear shaft with gear oil, and install them.

УКАЗАНИЕ:

Align the mark on the reverse idler gear shaft with the bolt hole as 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 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 gear shift fork set bolt.

Момент затяжки:

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

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

Coat the 2 shift fork balls with MP grease and install them into 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 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 from the 2 shift fork balls, lift up the No. 3 gear shift fork shaft as shown in the illustration.

Coat the 2 shift fork set 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 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:

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

Coat the 13 bolts with sealant and install the manual transmission case with the 13 bolts.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

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

Coat the 3 bolts with sealant and install the front transaxle case with the 3 bolts.

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 a new gasket with the bolt.

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 with sealant and install it using a hexagon wrench.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Момент затяжки:

29 Н*м{296 кгс*см, 21 фунт-сила-футов}

Coat the shift detente 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 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{279 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 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.

ПРИМЕЧАНИЕ:

Do not align the openings of the shifting key springs.

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

SST

09636-20010

ПРИМЕЧАНИЕ:

1. Do not install the No. 3 transmission clutch hub with it facing the wrong direction.
   
2. Install the No. 3 transmission clutch hub while checking the positions of the No. 3 synchronizer ring key groove and No. 3 synchromesh shifting key.
   
3. Check that the 5th gear rotates.
   
4. Place the suitable sized wooden block to support the input shaft.
   

Select a No. 3 clutch hub shaft snap ring that will allow minimum axial play.

Clearance:

0.1 mm (0.0039 in.) or less

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:

0.10 to 0.57 mm (0.0039 to 0.0224 in.)

Maximum clearance:

0.57 mm (0.0224 in.)

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

Standard clearance:

KOYO made:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

KOYO made:

0.058 mm (0.0023 in.)

NSK made:

0.056 mm (0.0022 in.)

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

УКАЗАНИЕ:

Orient the No. 3 transmission clutch hub correctly.

Coat the gear shift fork set 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{1199 кгс*см, 87 фунт-сила-футов}

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

Disengage the gears.

Apply FIPG to the transaxle case cover as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

ПРИМЕЧАНИЕ:

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

Install the manual transmission case cover and 2 wire harness clamps onto the manual transmission case with the 9 bolts.

Момент затяжки:

14 Н*м{143 кгс*см, 10 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:

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

Install the shift and select actuator onto the manual transmission case with the wire harness clamp bracket and new 6 bolts.

Момент затяжки:

18 Н*м{184 кгс*см, 13 фунт-сила-футов}

Install the plug and a new gasket onto the manual transmission case.

Момент затяжки:

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

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

Момент затяжки:

37 Н*м{375 кгс*см, 27 фунт-сила-футов}

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using SST, install the neutral position switch with a new gasket onto the manual transmission case.

SST

09817-16011

Момент затяжки:

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

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

SST

09817-16011

Момент затяжки:

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

Install a new O-ring onto the transmission revolution sensor.

Install the transmission revolution sensor and clamp wire harness with the 2 wire harness clamps.

Install the transmission case protector with the 2 bolts.

Момент затяжки:

8.0 Н*м{82 кгс*см, 71 фунт-сила-дюймов}

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

Install the speedometer driven hole cover onto the front transaxle case with the bolt.

Момент затяжки:

11 Н*м{115 кгс*см, 8 фунт-сила-футов}

Install the release fork support onto the front transaxle case.

Момент затяжки:

37 Н*м{375 кгс*см, 27 фунт-сила-футов}

Install the clutch release fork support boot to the release fork support as shown in the illustration.

Install the clutch release fork boot onto the front transaxle case.

Apply release hub grease to the contact surfaces of the release fork and release bearing, release fork and pull rod, and release fork and fork support.

Sealant:

Multemp 8158 Grease or equivalent

Install the release fork onto the release bearing with the clip.

Install the clutch release bearing with release fork onto the front transaxle case.

Apply clutch spline grease to the input shaft spline.

Sealant:

Toyota Genuine Clutch Spline Grease or equivalent

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

Момент затяжки:

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

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

Момент затяжки:

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