Toyota Corolla 2004 Repair Manual - INPUT SHAFT ASSY

OVERHAUL

41–63

–MANUAL TRANSMISSION/TRANSAXLE INPUT SHAFT ASSY (C59)

4107H–01

1. INSPECT 4TH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 4th gear thrust clear-

ance.

4th gear thrust clearance:

Standard clearance: mm (in.) Maximum clearance: mm (in.)

0.10 – 0.55 (0.0039 – 0.0217) 0.55 (0.0217)

C80557

2. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 3rd gear thrust clear-

ance.

3rd gear thrust clearance:

Standard clearance: mm (in.) Maximum clearance: mm (in.)

0.10 – 0.35 (0.0039 – 0.0138) 0.35 (0.0138)

C67816

C80558

3. INSPECT 4TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 4th gear radial clear-

ance.

4th gear radial clearance:

KOYO made

NSK made

Standard clearance:

mm (in.)

0.015 – 0.058

(0.0006 – 0.0023)

0.015 – 0.056

(0.0006 – 0.0022)

Maximum clearance:

mm (in.)

0.058 (0.0023)

0.056 (0.0022)

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

2004 COROLLA (RM1037U)

1463Author: Date:

41–64

C67815

–MANUAL TRANSMISSION/TRANSAXLE INPUT SHAFT ASSY (C59)

4. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 3rd gear radial clear-

ance.

3rd gear radial clearance:

KOYO made

NSK made

Standard clearance:

mm (in.)

0.015 – 0.058

(0.0006 – 0.0023)

0.015 – 0.056

(0.0006 – 0.0022)

Maximum clearance:

mm (in.)

0.058 (0.0023)

0.0056 (0.0022)

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

5. REMOVE 4TH GEAR

(a) Using 2 screwdrivers and a hammer, tap out the snap

ring.
HINT:
Using a waste to prevent the snap ring from being scattered.

SST

C80559

(b) Using SST and a press, remove the input shaft radial ball

bearing rear and 4th gear from the input shaft.

SST 09950–00020

NOTICE:

 Do not tighten SST excessively.
 Support the input shaft assy by hand so that it will not

be dropped off.

Q04983

6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

(a) Remove the 4th gear needle roller bearing and 4th gear

bearing spacer from the input shaft.

C80560

2004 COROLLA (RM1037U)

1464Author: Date:

C80561

41–65

–MANUAL TRANSMISSION/TRANSAXLE INPUT SHAFT ASSY (C59)

7. REMOVE 4TH GEAR SYNCHRONIZER RING

(a) Remove the 4th gear synchronizer ring from the transmis-

sion clutch hub No.2.

8. REMOVE 3RD GEAR

(a) Using 2 screwdrivers and a hammer, tap out the snap

ring.
HINT:
Using a waste to prevent the snap ring from being scattered.

SST

C67821

(b) Using SST and a press, remove the transmission clutch

hub No.2 and 3rd gear from the input shaft.

SST 09950–00020

NOTICE:

 Do not tighten SST excessively.
 Support the input shaft by hand so that it will not be

dropped off.

CM0064

9. REMOVE 3RD GEAR SYNCHRONIZER RING

(a) Remove the 3rd gear synchronizer ring from the 3rd gear.

C68515

2004 COROLLA (RM1037U)

10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

(a) Remove the 3rd gear needle roller bearing from the input

shaft.

C67823

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