41–17

MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSAXLE ASSY

4107D–02

REPLACEMENT
HINT:
COMPONENTS: See page 41–15
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE EXHAUST PIPE (See page 15–2)
6. DRAIN TRANSAXLE OIL
7. REMOVE HOOD SUB–ASSY
8. REMOVE CYLINDER HEAD COVER NO.2
9. REMOVE AIR CLEANER ASSY
10. REMOVE BATTERY CLAMP SUB–ASSY
11. REMOVE BATTERY
12. REMOVE BATTERY TRAY

13. REMOVE BATTERY CARRIER

(a) Remove the 4 bolts and battery carrier.

C80159

14. REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) (See page 82–4)

15. DISCONNECT WIRE HARNESS

(a) Disconnect the wire harness clamp.
(b) Remove the 2 bolts and disconnect the 2 wire harness
brackets.

C95746

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(c) Remove the 2 bolts and 2 ground cables.

C95747

16. DISCONNECT CONNECTOR

(a) Disconnect the back–up lamp switch connector.

D11552

(b) w/o ABS:

Disconnect the speed sensor connector.

D11558

17. SEPARATE CLUTCH RELEASE CYLINDER ASSY

(a) Remove the 5 bolts, separate the release cylinder assy
with clutch piping from the transaxle.

D26730

18. SEPARATE FLOOR SHIFT CABLE TRANSMISSION

CONTROL SHIFT
(a) Remove the clip, washer and disconnect the shift cable
from the transaxle.
(b) Remove the clip and disconnect the shift cable from the
bracket.

D26696

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MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSAXLE ASSY

19. SEPARATE FLOOR SHIFT CABLE TRANSMISSION

CONTROL SELECT
(a) Remove the clip, washer and disconnect the select cable
from the transaxle.
(b) Remove the clip and disconnect the select cable from the
bracket.

D26768

20. REMOVE STARTER ASSY

(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.

D11561

21. SEPARATE STEERING INTERMEDIATE SHAFT (See page 51–18)

22. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30–6)
SST 09520–01010, 09520–24010 (09520–32040)
23. REMOVE FRONT DRIVE SHAFT ASSY RH
HINT:
Remove the RH side by the same procedures as LH side.
SST 09520–01010, 09520–24010 (09520–32040)
24. SEPARATE RETURN TUBE SUB–ASSY (See page 51–18)
SST 09023–12700
25. SEPARATE PRESSURE FEED TUBE ASSY (See page 51–18)

26. SUSPEND ENGINE ASSY

(a) Remove the 2 PCV hoses.
(b) Install the 2 hangers in the correct direction.
Parts No.:
Engine hanger: 12281–22021
No.1 engine hanger: 12281–15040
Bolt: 91512–B1016
Torque: 38 N⋅m (387 kgf⋅cm, 28 ft⋅lbf)
F16861 (c) Attach the engine chain hoist to the hangers.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
27. REMOVE FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–13)
28. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the transaxle with a transmission jack.

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29. REMOVE TRANSVERSE ENGINE ENGINE

MOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator
LH from the body.

D26699

30. REMOVE TRANSVERSE ENGINE ENGINE

MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from
the transaxle.

D26700

31. REMOVE MANUAL TRANSAXLE ASSY

(a) Remove the 6 bolts and transaxle from the engine.

C70065

32. REMOVE TRANSVERSE ENGINE ENGINE

MOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FR
from the engine mounting bracket FR.
(b) Remove the 2 bolts and engine mounting bracket FR from
the transaxle.

C70063

33. REMOVE TRANSVERSE ENGINE ENGINE

MOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR from
the engine mounting bracket RR.
(b) Remove the 3 bolts and engine mounting bracket RR
from the transaxle.

C70061

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(a) 34. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

(b) BRACKET
(a) Install the engine mounting bracket RR and 3 bolts to the
transaxle.
Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf)
(b) Install the engine mounting insulator RR and bolt to the
engine mounting bracket RR.
(a)
Torque: 87 N⋅m (888 kgf⋅cm, 64 ft⋅lbf)
C70061

35. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

BRACKET
(a)
(a) Install the engine mounting bracket FR and 2 bolts to the
transaxle.
Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf)
(b) Install the engine mounting insulator FR, bolt and nut to
the engine mounting bracket FR.
(b) Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
C70063

A A 36. INSTALL MANUAL TRANSAXLE ASSY

(a) Align the input shaft with the clutch disc and install the
B
transaxle to the engine.
B (b) Install the 6 bolts.
Torque:
Bolt A: 64 N⋅m (650 kgf⋅cm, 47 ft⋅lbf)
Bolt B: 47 N⋅m (480 kgf⋅cm, 35 ft⋅lbf)
C
Bolt C: 23 N⋅m (230 kgf⋅cm, 17 ft⋅lbf)
C C70065

37. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

BRACKET
(a) Install the engine mounting bracket LH to the transaxle
with the 3 bolts.
Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)

D26700

38. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

A A INSULATOR
(a) Install the engine mounting insulator LH with the 5 bolts
and nut.
Torque:
Bolt A: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf)
Bolt B: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf)
B A
A D26699

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MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSAXLE ASSY

39. INSTALL FRONT SUSPENSION CROSSMEMBER SUB–ASSY (See page 26–13)

SST 09670–00010
40. CONNECT STEERING INTERMEDIATE SHAFT (See page 51–18)
41. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 51–18)
42. CONNECT RETURN TUBE SUB–ASSY (See page 51–18)
SST 09023–12700
43. CONNECT PRESSURE FEED TUBE ASSY (See page 51–18)
SST 09023–12700
44. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–6)
45. INSTALL FRONT DRIVE SHAFT ASSY RH
HINT:
Install the RH side by the same procedures as LH side.

46. INSTALL STARTER ASSY

(a) Install the starter assy and 2 bolts to the transaxle.
(c) Torque: 37 N⋅m (378 kgf⋅cm, 27 ft⋅lbf)
(a) (b) Connect the starter connector.
(b) (c) Install the wire and nut to starter assy.
(a) Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf)

D11561

47. CONNECT FLOOR SHIFT CABLE TRANSMISSION

CONTROL SHIFT
(a) Connect the shift cable end, and install the washer and
clip.

D26696

48. CONNECT FLOOR SHIFT CABLE TRANSMISSION

CONTROL SELECT
(a) Connect the select cable end, and install the washer and
clip.

D26768

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MANUAL TRANSMISSION/TRANSAXLE – MANUAL TRANSAXLE ASSY

49. CONNECT CLUTCH RELEASE CYLINDER ASSY

(a) Install the release cylinder with the 5 bolts.
A
Torque:
C Bolt A: 25 N⋅m (250 kgf⋅cm, 19 ft⋅lbf)
A Bolt B: 12 N⋅m (120 kgf⋅cm, 9 ft⋅lbf)
B Bolt C: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
B

D26730

50. CONNECT CONNECTOR

(a) Connect the back–up lamp switch connector.

D11552

(b) w/o ABS:

Connect the speed sensor connector.

D11558

51. CONNECT WIRE HARNESS

(a) Install the 2 wire harness clamps to the transaxle with the
A 2 bolts.
B
Torque:
Bolt A: 25.5 N⋅m (260 kgf⋅cm, 19 ft⋅lbf)
Bolt B: 12.8 N⋅m (131 kgf⋅cm, 9 ft⋅lbf)
(1) Connect the wire harness clamp.

F16859

(b) Install the 2 bolts and 2 ground cables.

Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)

F16860

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52. INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) (See page 82–4)

53. INSTALL BATTERY CARRIER

(a) Install the battery carrier and 4 bolts.
Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)

C80159

54. INSTALL BATTERY TRAY

55. INSTALL BATTERY
56. INSTALL BATTERY CLAMP SUB–ASSY
Torque:
Bolt: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf)
Nut: 3.5 N⋅m (36 kgf⋅cm, 31 in.⋅lbf)
57. INSTALL AIR CLEANER ASSY
Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf)
58. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf)
59. INSTALL HOOD SUB–ASSY
Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf)
60. INSPECT HOOD SUB–ASSY
61. ADJUST HOOD SUB–ASSY (See page 75–1)
62. ADD TRANSAXLE OIL (See page 41–2)
63. INSPECT TRANSAXLE OIL (See page 41–2)
64. BLEED POWER STEERING FLUID (See page 51–3)
65. INSTALL FRONT WHEELS
Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf)
66. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
67. INSTALL EXHAUST PIPE (See page 15–2)
68. INSTALL ENGINE UNDER COVER LH
69. INSTALL ENGINE UNDER COVER RH
70. INSPECT FRONT WHEEL ALIGNMENT (See page 26–5)
71. CHECK ABS SPEED SENSOR SIGNAL (See page 05–297)

2004 COROLLA (RM1037U)

Author: Date: 1424