2004款丰田卡罗拉手动变速器系统维修手册(英文版).pdf

41075–01–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM41–11401Author : Date :2004 COROLLA (RM1037U)MANUAL TRANSAXLE SYSTEMPROBLEM SYMPTOMS TABLEUse the table below to help you find the cause of the problem. The numbers indicate the priority of the likelycause of the problem. Check each part in order. If necessary, replace parts.Symptom Suspect Area See pageNoise6. Oil (Level low)7. Oil (Wrong)8. Gear (Worn or damaged)9. Bearing (Worn or damaged)41–241–241–6341–7441–6341–74Oil leakage1. Oil (Level too high)2. Gasket (Damaged)3. Oil seal (Worn or damaged)4. O–Ring (Worn or damaged)41–241–2841–341–28Hard to shift or will not shift1. Control cable (Faulty)2. Synchronizer ring (Worn or damaged)3. Shifting key spring (Damaged)41–941–1241–6341–7441–6341–74Jumps out of gear1. Locking ball spring (Damaged)2. Gear Shift fork (Worn)3. Gear (Worn or damaged)4. Bearing (Worn or damaged)41–2841–2841–6341–7441–6341–7441076–01D253040 – 5 mm(0 – 0.20 in.)41–2–MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE OIL1402Author : Date :2004 COROLLA (RM1037U)MANUAL TRANSAXLE OILON–VEHICLE INSPECTION1. 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 thelowest position of the inner surface of the transmission fill-er plug opening.NOTICE:Excessively large or small amount of oil may causetroubles.After replacing oil, drive the vehicle and check the oillevel.(d) Check for oil leakage when the oil level is low.(e) Install the transmission filler plug and new gasket.Torque: 39.2 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)41077–02C94266SSTD25305SSTD25722SST–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL41–31403Author : Date :2004 COROLLA (RM1037U)FRONT DIFFERENTIAL OIL SEALREPLACEMENT1. DRAIN MANUAL TRANSAXLE OILTorque: 39.2 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)2. REMOVE FRONT WHEELS3. REMOVE ENGINE UNDER COVER LH4. REMOVE ENGINE UNDER COVER RH5. DRAIN TRANSAXLE OIL6. 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 09308–000109. REMOVE TRANSMISSION CASE OIL SEAL(a) Using SST, remove the transmission case oil seal.SST 09308–0001010. 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 oilseal.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.D26133SSTD253040 – 5 mm (0 – 0.20 in.)41–4–MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL1404Author : Date :2004 COROLLA (RM1037U)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 caseoil 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.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 WHEELSTorque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)15. ADD MANUAL TRANSAXLE OILOil grade: API GL–4 or GL–5Viscosity: SAE 75 W–90Capacity:1.9 liters (2.0 US qts, 1.7 lmp. qts)Torque: 39.2 N⋅m (400 kgf⋅cm, 29 ft⋅lbf)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)4107A–01B53749Parking Brake Hole Cover Sub–assyFloor Shift Lever Knob Sub–assyConsole Box CarpetConsole Panel UpperShift Cable GrommetRetainer No. 1Floor Shift Cable TransmissionControl ShiftFloor Shift Cable Transmission Control SelectClipFloor Shift Shift Lever AssyConsole Box Sub–assy RearClip: Specified torqueN⋅m (kgf⋅cm, ft⋅lbf)ClipClampClipClipFront Floor Heat InsulatorWasherClipWasher12 (122, 9)17.5 (178, 13)5.5 (56, 49 in.⋅lbf)12 (122, 9)5.0 (51, 44 in.⋅lbf)5.0 (51, 44 in.⋅lbf)–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY41–51405Author : Date :2004 COROLLA (RM1037U)FLOOR SHIFT SHIFT LEVER ASSYCOMPONENTS4107B–01D26974D26973Cable OuterSpringLockD26976D26975Cable OuterspringLock41–6–MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY1406Author : Date :2004 COROLLA (RM1037U)REPLACEMENTHINT:COMPONENTS: See page 41–51. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB–ASSY2. REMOVE CONSOLE PANEL UPPER (See page 71–10)3. REMOVE PARKING BRAKE HOLE COVER SUB–ASSY (See page 71–10)4. REMOVE CONSOLE BOX SUB–ASSY REAR (See page 71–10)5. SEPARATE FLOOR SHIFT CABLE TRANSMISSIONCONTROL SHIFT(a) Separate the end of the shift cable from the shift leverassy.(b) Using a screwdriver, release the cable outer spring.(c) Turn the lock, separate the shift cable from the shift leverretainer.6. SEPARATE FLOOR SHIFT CABLE TRANSMISSIONCONTROL SELECT(a) Separate the end 。