EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE ASSEMBLY: REMOVAL; 2020 - 2021 MY Corolla Corolla Hatchback [03/2019

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001HS4A
Model Year Start: 2020	Model: Corolla Hatchback	Prod Date Range: [03/2019 - 06/2021]
Title: EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE ASSEMBLY: REMOVAL; 2020 - 2021 MY Corolla Corolla Hatchback [03/2019 - 06/2021]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during manual transaxle assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
1: If the vehicle height has changed due to suspension or tire replacement. 2: for Hatchback 3: w/ Smart Key System 4: w/o Smart Key System
Disconnect cable from negative battery terminal	Perform steering sensor zero point calibration	Lane Control System (for Gasoline Model)
		Pre-collision System (for Gasoline Model)
		Lighting System (w/ AFS)(EXT)
	Initialize back door lock*2	Power Door Lock Control System (for Hatchback, Gasoline Model)
Replacement of ECM	Vehicle Identification Number (VIN) registration	MIL comes on
Replacement of ECM	ECU communication ID registration (Immobiliser system)	Engine start function
Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.
Replacement of ECM*3	Code registration (Smart Key System (for Gasoline Model, Start Function))	Wireless Door Lock Control System (for Gasoline Model with Smart Key System) Smart Key System (for Gasoline Model, Entry Function) Smart Key System (for Gasoline Model, Start Function) Steering lock function
Replacement of ECM*4	Code registration (Immobiliser system)	Engine start
Suspension, tires, etc.*1	Perform headlight ECU sub-assembly LH initialization	Lighting system (w/ AFS)(EXT)
Front wheel alignment adjustment	Perform "Reset Memory". Perform acceleration sensor zero point calibration and store system information memorization.	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates

CAUTION:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

Because the manual transaxle assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

*a	Heavy object exceeding the capacity of the transmission jack

If work is not performed according to the procedures described in the repair manual, there is a danger that the transmission jack could drop and components could fall down.

NOTICE:

After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Navigation System and Audio and Visual System (for Gasoline Model))
When the manual transaxle assembly is removed, be sure to use a new clutch release cylinder with bearing assembly and new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release cylinder with bearing assembly to return to its original position. Dust from the moving section may damage the seal of the clutch release cylinder with bearing assembly, possibly causing clutch fluid leaks.

PROCEDURE

1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

2. REMOVE FRONT DRIVE SHAFT ASSEMBLY

Click here

3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click here

5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) Remove the 9 bolts, 4 nuts and outer cowl top panel sub-assembly.

(b) Install the 4 nuts.

Torque:

50 N·m {510 kgf·cm, 37 ft·lbf}

6. REMOVE ECM

Click here

7. REMOVE BATTERY

Click here

8. REMOVE BATTERY CLAMP SUB-ASSEMBLY

Click here

9. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

Click here

10. REMOVE FRONT FLOOR COVER LH

Click here

11. REMOVE FRONT FLOOR COVER RH

Click here

12. REMOVE FRONT FLOOR CENTER BRACE

Click here

13. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

Click here

14. DISCONNECT WIRE HARNESS

(a) Disconnect the engine coolant temperature sensor connector.

(b) Remove the bolt and 2 nuts.

(d) Disconnect the back-up light switch assembly connector.

(e) Remove the bolt.

(f) Disengage the 2 clamps.

(g) w/ Neutral Position Switch:

(1) Disconnect the neutral position switch connector.

*a	Neutral Position Switch Connector
*b	Transmission Revolution Sensor Connector

(h) Disconnect the transmission revolution sensor connector.

(i) Remove the earth bolt.

(j) Disengage the 2 clamps.

(k) Disengage the 3 clamps.

15. REMOVE FUEL DELIVERY GUARD

Click here

16. INSTALL ENGINE HANGER

Click here

17. REMOVE STARTER ASSEMBLY

Click here

18. INSTALL ENGINE SUPPORT BRIDGE

(a) Remove the clip and disconnect the neck from the windshield washer jar assembly.

(b) Install SST to the vehicle body as shown in the illustration.

*a	Support Shaft	*b	Front Side Member
*c	Nut	*d	Cloth

SST: 09940-10020

CAUTION:

Make sure that no oil or grease is on the front side member, and set the support shaft on the level surface of the front side member.

*a	Support Shaft
*b	Front Side Member

The engine support bridge may fall off if any oil or grease is still on or it is installed on the unlevel surface.

NOTICE:

Prevent SST from contacting the vehicle body exterior and windshield glass.
To prevent damage to the engine hood, place pieces of cloth between the engine hood and SST.
Lightly shake SST by hand to make sure it is securely installed before performing work.

*a	Support Shaft
*b	Sub Beam
*c	Front Side Member
*d	Threaded Portion

(d) Install the chain block assembly to the sling bracket.

*a	Chain Block Assembly	*b	Sling Bracket
*c	Fuse Shackle	-	-

(e) Install the division bar to the chain block assembly with the shackle (A).

CAUTION:

Make sure the fuse shackle is on the chain block assembly side and the shackle (A) is on the division bar side as shown in the illustration so that the fuse bolt is visible and can be checked for deformation easily.

*a	Fuse Shackle
*b	Shackle (A)

If the fuse shackle is installed upside down, deformation of the fuse bolt will not be visible and cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with transaxle assembly may fall.

Make sure that the fuse bolt of the fuse shackle is free of damage, such as deformation or cracks. If damaged, replace the fuse shackle.

*a	Fuse Shackle
*b	Fuse Bolt

If a deformed fuse bolt is used, it cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with transaxle assembly may fall.

(f) Connect the division bar to the No. 1 engine hanger with the shackle (B).

*1	No. 1 Engine Hanger	*2	No. 2 Engine Hanger
*a	Division Bar	*b	Shackle (A)
*c	Shackle (B)	*d	Chain

(g) Connect the division bar to the No. 2 engine hanger with the shackle (A) and chain.

NOTICE:

Connect the 2nd link of the chain to the No. 2 engine hanger.

(h) Make sure the distance between the chain block assembly and suspension ring is 120 mm (4.72 in.) or more.

HINT:

If the suspension height is less than 120 mm (4.72 in.), adjust the links of the chain which connect the division bar and engine hanger.

*a	120 mm (4.72 in.) or more

(i) Adjust the positions of the chain block assembly, support brackets and main beam so that the chain of the chain block assembly is perpendicular to the main beam and the length of the main beam on the outer side of the support bracket LH and RH is the same as shown in the illustration.

*a	Chain Block Assembly	*b	Main Beam
*c	Dimension (A)	*d	Dimension (B)
*e	Right to Left Adjustment	*f	Support Bracket LH
*g	Support Bracket RH	*h	Front to Rear Adjustment

CAUTION:

To prevent the engine with transaxle assembly from falling, make sure that the length of dimension (A) and dimension (B) are equal.

*a	Main Beam
*b	Sub Beam
*c	Dimension (A)
*d	Dimension (B)

Do not perform any procedures if the length of dimension (A) and dimension (B) are not equal.
Performing any procedure when the length of dimension (A) and dimension (B) are not equal may cause the engine assembly with transaxle assembly and engine support bridge to fall, possibly causing serious injury.

Do not perform any procedures if the chain of the chain block assembly is not straight.
When removing the engine mount, if the chain of the chain block assembly is not straight, the engine assembly or transaxle assembly may contact the vehicle body.

(j) Confirm the appropriate installation state of the engine support bridge and tighten the 6 wing bolts and 2 bolts.

Wing Bolt

Bolt

Torque:

Bolt :

30 N·m {306 kgf·cm, 22 ft·lbf}

CAUTION:

Do not perform any procedures before tightening the bolts to the specified torque.
Performing procedures without tightening the bolts to the specified torque, may cause the engine support bridge to fall.

(k) Tighten the chain block assembly until it cannot be moved any further by hand.

Turn

*a	41 Nm (418 kgfcm, 30 ft.*lbf) or more

When suspending the engine with transaxle assembly, do not tighten the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf).
Tightening the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf) will cause the load capacity (400 kg (881.8 lb)) to be exceeded and may cause damage to the engine support bridge and vehicle body.

19. SECURE STEERING WHEEL

Click here

20. REMOVE COLUMN HOLE COVER SILENCER SHEET

Click here

21. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

22. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click here

23. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

Click here

24. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

Click here

25. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Remove the bolt and separate the engine moving control rod.

(b) Support the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.

*a	Engine Lifter
*b	Attachment
	Attachment placement location

CAUTION:

The front suspension crossmember sub-assembly is a very heavy component. Make sure that it is supported securely.
If the front suspension crossmember sub-assembly is not securely supported, it may drop, resulting in serious injury.

NOTICE:

Use attachments to keep the front suspension crossmember sub-assembly level.

(d) Slowly lower the front suspension crossmember sub-assembly.

NOTICE:

When lowering the front suspension crossmember sub-assembly, be careful not to damage the vehicle body or other components installed to the vehicle.

26. REMOVE MANIFOLD STAY

Click here

27. REMOVE DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

(a) Remove the 3 bolts and drive shaft heat insulator sub-assembly from the cylinder block sub-assembly.

28. REMOVE NO. 2 ENGINE MOVING CONTROL ROD

(a) Remove the 5 bolts and No. 2 engine moving control rod from the manual transmission case.

29. SUPPORT MANUAL TRANSAXLE ASSEMBLY

(a) Using a transmission jack, support the manual transaxle assembly.

NOTICE:

Adjust the attachment of the transmission jack to securely fix the manual transaxle assembly to the transmission jack.
Using a lashing belt or a rope, fix the manual transaxle assembly to the transmission jack.

*a	Lashing Belt

30. REMOVE ENGINE MOUNTING INSULATOR LH

(a) Remove the bolt (A) and nut.

	Bolt (A)
	Nut
	Bolt (B)

NOTICE:

While holding the nut in place, loosen the bolt (A).

(b) Remove the 4 bolts (B) and separate the engine mounting insulator LH from the engine mounting bracket LH.

31. REMOVE ENGINE MOUNTING STAY LH

HINT:

Perform this procedure only when replacement of the engine mounting stay LH is necessary.

(a) Remove the 2 bolts and 2 engine mounting stays LH from the engine mounting bracket LH.

32. REMOVE ENGINE MOUNTING BRACKET LH

(a) Remove the 6 bolts and engine mounting bracket LH from the manual transmission case.

33. DISCONNECT NO. 1 CLUTCH HOSE

Click here

34. REMOVE MANUAL TRANSAXLE ASSEMBLY

(a) Remove the 8 bolts and engine assembly from the manual transaxle assembly.

NOTICE:

To prevent damage to the 2 knock pins, do not pry between the manual transaxle assembly and engine assembly.

HINT:

Bolt (A): Remove from the manual transaxle assembly side.
Bolt (B): Remove from the engine assembly side.

35. REMOVE BLEEDER TO FLEXIBLE HOSE TUBE

Click here

36. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

Click here

37. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY TO BLEEDER TUBE

Click here

38. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

Click here

39. REMOVE CLUTCH FLEXIBLE HOSE BRACKET

(a) Remove the bolt and clutch flexible hose bracket from the manual transmission case.

40. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the bolt and wire harness clamp bracket from the manual transmission case.

(b) Remove the bolt and wire harness clamp bracket from the manual transmission case.

(d) Remove the bolt and wire harness clamp bracket from the transaxle(MTM) case sub-assembly.

41. REMOVE CONTROL CABLE BRACKET ASSEMBLY

(a) Remove the 3 bolts and control cable bracket assembly from the manual transmission case and transaxle(MTM) case sub-assembly.