Toyota Corolla 2004 Repair Manual - OUTPUT SHAFT ASSY
41–74
OVERHAUL
–MANUAL TRANSMISSION/TRANSAXLE OUTPUT SHAFT ASSY (C59)
4107J–01
1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 1st gear thrust clear-
ance.
Standard clearance:
0.10 – 0.40 mm (0.0039 – 0.0157 in.)
C68252
2. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clear-
ance.
Standard clearance:
0.10 – 0.45 mm (0.0039 – 0.0177 in.)
C68312
C68309
C68254
3. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clear-
ance.
Standard clearance:
Bearing Clearance: m m (in.)
KOYO made 0.015 – 0.058 (0.0006 – 0.0023)
NSK made 0.015 – 0.056 (0.0006 – 0.0022)
If the clearance is out of specification, replace the 1st gear
needle roller bearing.
4. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clear-
ance.
Standard clearance:
Bearing Clearance: m m (in.)
KOYO made 0.015 – 0.058 (0.0006 – 0.0023)
NSK made 0.015 – 0.056 (0.0006 – 0.0022)
If the clearance is out of specification, replace the 2nd gear
needle roller bearing.
2004 COROLLA (RM1037U)
1474Author: Date:
SST
C80539
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–MANUAL TRANSMISSION/TRANSAXLE OUTPUT SHAFT ASSY (C59)
5. REMOVE 4TH DRIVEN GEAR
(a) Using SST and a press, remove the output shaft
rear
bearing with 4th driven gear from the output shaft.
SST 09950–00020
6. REMOVE OUTPUT GEAR SPACER
(a) Remove the output gear spacer from the output shaft.
SST
C68005
7. REMOVE 2ND GEAR
(a) Using SST and a press, remove the 3rd driven gear with
2nd gear from the output shaft.
SST 09950–00020
C80540
8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing from the out-
put shaft.
C68008
2004 COROLLA (RM1037U)
9. REMOVE SYNCHRONIZER RING SET NO.2
(a) Remove the synchronizer ring set No.2 from the output
shaft.
C68010
1475Author: Date:
41–76
SST
–MANUAL TRANSMISSION/TRANSAXLE OUTPUT SHAFT ASSY (C59)
10. REMOVE 1ST 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.
C68011
(b) Using SST and a press, remove the transmission clutch
hub No.1 with 1st gear from the output shaft.
SST 09950–00020
NOTICE:
Do not tighten SST excessively.
Support the input shaft by hand so that it will not be
dropped off.
C94308
C68516
C68012
11. REMOVE SYNCHRONIZER RING NO.1
(a) Remove the synchronizer ring No.1 from the 1st gear.
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
2004 COROLLA (RM1037U)
13. REMOVE 1ST GEAR THRUST WASHER
(a) Remove the 1st gear thrust washer from the output shaft.
C68013
1476Author: Date:
C68014
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–MANUAL TRANSMISSION/TRANSAXLE OUTPUT SHAFT ASSY (C59)
14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
(a) Remove the 1st gear thrust washer pin or ball from the
output shaft.
15. REMOVE REVERSE GEAR
(a) Remove the 3 synchromesh shifting keys, 3 synchro-
mesh shifting key springs and reverse gear.
NOTICE:
Using a waste to prevent the synchromesh shifting key and
spring from being scattered.
V–block
C68015
16. INSPECT OUTPUT SHAFT
(a) Using a dial indicator and 2 V–blocks, measure the shaft
runout.
Maximum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the output shaft.
C80545
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Outer diameter:
Part A: 31.985 mm (1.2592 in.)
Part B: 37.985 mm (1.4955 in)
Part C: 32.985 mm (1.2986 in)
If the outer diameter is below the minimum, replace the output
shaft.
2004 COROLLA (RM1037U)
AB C
C80439
1477Author: Date:
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