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Vehicle:
Year/Prod. Date:
Engine
Transmission:
Worksheet Objectives
With this worksheet, you will follow the disassembly of a front-drive transmission to remove the case
using the required special tools, make measurements where appropriate, retrieve and apply the
needed service information, identify components using the technician handbook and repair manual.
Tools and Equipment
5th Gear Puller SST (P/N 09310-17010)
5th Gear Replacer SST (P/N 09309-12020-01)
Hand Tool Set
Dial Indicator and Stand
Micrometer, 0-1 in.
Corolla RM (C Series Transaxle)
Camry RM (E Series Transaxle)
Section 1: Case Removal
4W1-1
Worksheet 4-1
Specification:
Radial Clearance:
Specification:
7. Remove the fifth gear synchronizer hub and 5th gear from the input shaft.
8. What SSTs are used to remove 5th gear and the synchronizer hub from the input shaft?
9. Remove the three snap rings from the shift shafts and remove the spring and detent balls.
10. Remove transaxle case
4W1-2
1. 1st gear
6. Input shaft
2. 2nd gear
7. Output shaft
3. 3rd gear
8. Differential
4. 4th gear
5. 5th gear
4W1-3
Worksheet 4-1
Section 3: Powerflow
1. With the transmission in neutral, tip the transmission up to rotate the input shaft while holding the
differential from rotating. What are the speed gears on the output shaft doing?
3. With the transmission in neutral, hold the input shaft and rotate the differential. What are the
speed gears on the input and output shaft doing?
4. How are the speed gears lubricated when the vehicle is being towed with the front wheels on the
ground? (Dingy tow)
5. What does the owners manual recommend about dingy towing a front wheel drive vehicle with
manual transmission?
6. Trace the power flow from the input shaft through the transmissions to the output shaft. Be
prepared to demonstrate power flow to your instructor.
7. The rear wheel drive transmission has a direct drive in 4th gear. Does the transaxle have a direct
drive?
8. Describe how the output shafts direction of rotation changes from the input shafts rotation in
reverse gear.
4W1-4
Date:
Review this sheet as you are doing the TransaxleCase Removal & Component Identification
worksheet. Check each category after viewing the instructors presentation and completing the
worksheet. Ask the instructor if you have questions regarding the topics provided below. Additional
space is provided under Topic for you to list any other concerns that you would like your instructor to
address. The comments section is provided for your personal comments, information, questions, etc.
I have questions
I know I can
Topic
Comment
4W1-5
Worksheet 4-1
4W1-6
WORKSHEET 4-2
TransaxleShaft Removal and Inspection
Vehicle:
Year/Prod. Date:
Engine
Transmission:
Worksheet Objectives
With this worksheet, you will follow the disassembly of a front-drive transmission shift mechanism and
shafts using the required special tools, make measurements where appropriate, retrieve and apply
the needed service information, retrieve and interpret service specification information from the repair
manual.
Tools and Equipment
Hand Tool Set
Dial Indicator and Stand
Micrometer, 0-1 in.
Feeler Gauge
Corolla RM (C Series Transaxle)
Camry RM (E Series Transaxle)
Section 1: Remove Shift Mechanism
1. Remove the shift rail snap rings, screw plugs, locking balls and springs.
2. What function do the locking balls and springs serve in the shift mechanism?
3. Remove the shift shafts from the shift fork and slide the shift forks out of the synchronizer sleeves.
4. Remove the input and output shafts and differential assembly.
4W1-7
Worksheet 4-1
Specification:
Specification:
Specification:
Specification:
3. If the radial (oil) clearance is greater than the maximum, how is it repaired?
Specification:
Specification:
Specification:
Specification:
Specification:
Specification:
Specification:
4W1-8
Date:
Review this sheet as you are doing the TransaxleShaft Removal and Inspection worksheet. Check
each category after viewing the instructors presentation and completing the worksheet. Ask the
instructor if you have questions regarding the topics provided below. Additional space is provided
under Topic for you to list any other concerns that you would like your instructor to address. The
comments section is provided for your personal comments, information, questions, etc.
I have questions
I know I can
Topic
Comment
4W1-9
Worksheet 4-1
4W1-10
WORKSHEET 4-3
TransaxlePreload Check and Reassembly
Vehicle:
Year/Prod. Date:
Engine
Transmission:
Worksheet Objectives
With this worksheet, you will follow the reassembly of a front-drive transmission using the required
special tools, make measurements where appropriate, retrieve and apply the needed service
information, retrieve and interpret service specification information from the repair manual.
Tools and Equipment
Hand Tool Set
Dial Indicator Torque Wrench
Preload Adapter SST (P/N 09564-32011)
5th Gear Replacer SST (P/N 09309-12020-01)
5th Gear Remover & Replacer SST (P/N 09310-17010-01)
Corolla RM (C Series Transaxle)
Camry RM (E Series Transaxle)
Section 1: E Series Transaxle Differential Preload Check and Adjustment
1. Install the output shaft alone into the lower case and install the upper case half.
2. Install the bearing race, adjusting shim and bearing retainer.
3. Secure the case bolts and retainer bolts, and record their torque specifications below.
a. Transmission case bolt torque:
4W1-11
Worksheet 4-1
4. Using an inch pound torque (in-lbf) wrench with sweeping dial, measure the starting torque.
a. Starting torque:
5. Remove the bearing retainer and measure the shim thickness and determine the Mark
designation from the repair manual chart.
Shim Thickness:
Mark Designation:
6. According to the chart in the repair manual, if starting torque required and additional 8 in-lbf of
torque, what shim mark designation would be required?
7. Install the differential, output shaft and bearing retainer and torque the case and bearing retainer.
8. Using the same inch pound torque wrench used above, measure the starting preload of both the
output shaft and differential.
9. If the starting torque of the output shaft was 8 in-lbf, in what torque range should the differential
and output shaft fall in for new differential bearings?
5. Remove the outer side bearing race from the transmission case.
6. What special service tool is used to remove the bearing race?
4W1-12
7. Measure the preload shim thickness and determine the size designation using the repair manual
chart. Shim thickness:
7. Install 5th drive gear and 5th synchronizer hub and shift fork.
8. What precaution is required when installing this assembly?
Specification:
4W1-13
Worksheet 4-1
4W1-14
Date:
Review this sheet as you are doing the TransaxlePreload Check and Reassembly worksheet.
Check each category after viewing the instructors presentation and completing the worksheet. Ask
the instructor if you have questions regarding the topics provided below. Additional space is provided
under Topic for you to list any other concerns that you would like your instructor to address. The
comments section is provided for your personal comments, information, questions, etc.
I have questions
I know I can
Topic
Comment
4W1-15
Worksheet 4-1
4W1-16