EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE UNIT: DISASSEMBLY; 2020 - 2023 MY Corolla Corolla Hatchback [03/2019

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001HS4J
Model Year Start: 2020	Model: Corolla Hatchback	Prod Date Range: [03/2019 - 11/2022]
Title: EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE UNIT: DISASSEMBLY; 2020 - 2023 MY Corolla Corolla Hatchback [03/2019 - 11/2022]

DISASSEMBLY

PROCEDURE

1. SECURE MANUAL TRANSAXLE ASSEMBLY

(a) Place the manual transaxle assembly on wooden blocks.

*a	Wooden Block

2. REMOVE MANUAL TRANSMISSION FILLER PLUG

(a) Remove the manual transmission filler plug and gasket from the manual transmission case.

3. REMOVE MANUAL TRANSMISSION DRAIN PLUG

(a) Remove the manual transmission drain plug and gasket from the manual transmission case.

4. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

(a) Using a 27 mm deep socket wrench, remove the back-up light switch assembly and gasket from the manual transmission case.

5. REMOVE MANUAL TRANSMISSION CASE PLUG (w/o Neutral Position Switch)

(a) Remove the manual transmission case plug and gasket from the manual transmission case.

6. REMOVE NEUTRAL POSITION SWITCH (w/ Neutral Position Switch)

(a) Using SST, remove the neutral position switch and gasket from the manual transmission case.

SST: 09816-30010

7. REMOVE TRANSMISSION REVOLUTION SENSOR

(a) Remove the bolt and transmission revolution sensor from the manual transmission case.

(b) Remove the O-ring from the transmission revolution sensor.

8. REMOVE RELEASE CYLINDER BLEEDER PLUG CAP

(a) Remove the release cylinder bleeder plug cap from the release cylinder bleeder plug.

9. REMOVE RELEASE CYLINDER BLEEDER PLUG

(a) Remove the release cylinder bleeder plug from the clutch release bleeder sub-assembly.

10. REMOVE CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

Click here

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

Click here

12. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

Click here

13. REMOVE LOCK BALL PIN

(a) Using a 10 mm hexagon socket wrench, remove the shift and select lever shaft straight screw with head plug from the manual transmission case.

*1	Shift and Select Lever Shaft Straight Screw with Head Plug
*2	No. 2 Lock Ball Pin Return Spring
*3	Lock Ball Pin

(b) Using a Magnet Hand, remove the No. 2 lock ball pin return spring and lock ball pin from the manual transmission case.

14. REMOVE NO. 2 LOCK BALL PIN

(a) Using a 10 mm hexagon socket wrench, remove the shift and select lever shaft straight screw with head plug from the transaxle(MTM) case sub-assembly.

*1	Shift and Select Lever Shaft Straight Screw with Head Plug
*2	No. 1 Lock Ball Pin Return Spring
*3	No. 2 Lock Ball Pin

(b) Using a Magnet Hand, remove the No. 1 lock ball pin return spring and No. 2 lock ball pin from the transaxle(MTM) case sub-assembly.

15. REMOVE SHIFT DETENT BALL

(a) Using a 6 mm hexagon socket wrench, remove the shift detent ball plug from the transaxle(MTM) case sub-assembly.

*1	Shift Detent Ball Plug
*2	No. 2 Shift Detent Ball Compression Spring
*3	Shift Detent Ball

(b) Using a Magnet Hand, remove the No. 2 shift detent ball compression spring and shift detent ball from the transaxle(MTM) case sub-assembly.

*1	Shift Detent Ball Plug
*2	Shift Detent Ball Compression Spring
*3	Shift Detent Ball

(d) Using a Magnet Hand, remove the 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.

16. REMOVE MANUAL TRANSMISSION CASE

(a) Remove the 18 bolts.

(b) Using a plastic hammer, separate the manual transmission case from the transaxle(MTM) case sub-assembly.

NOTICE:

Do not damage the manual transmission case.

(c) While turning the outer No. 1 shift lever counterclockwise, remove the manual transmission case from the transaxle (MTM) case sub-assembly as shown in the illustration.

*1	Outer No. 1 Shift Lever
*a	Turn Counterclockwise

NOTICE:

As the outer No. 1 shift lever will turn clockwise strongly under its own weight when the manual transmission case is lifted a certain amount and the inner No. 1 shift lever and inner No. 2 shift lever become disengaged, make sure to hold the outer No. 1 shift lever firmly.

*1	Inner No. 1 Shift Lever
*2	Inner No. 2 Shift Lever
*3	Outer No. 1 Shift Lever
*a	Movement Inside Manual Transaxle Assembly

17. REMOVE INNER SELECT LEVER SET BOLT

(a) Using a 6 mm hexagon socket wrench, remove the inner select lever set bolt.

18. REMOVE OUTER SELECT LEVER

(a) Remove the outer select lever from the transaxle(MTM) case sub-assembly.

19. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Rotate the shift and select lever shaft assembly counterclockwise to the position shown in the illustration and remove it from the transaxle (MTM) case sub-assembly.

20. REMOVE INNER SELECT LEVER

(a) Remove the inner select lever from the transaxle(MTM) case sub-assembly.

21. REMOVE OUTER SELECT LEVER OIL SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the outer select lever oil seal from the transaxle(MTM) case sub-assembly.

NOTICE:

Do not damage the transaxle(MTM) case sub-assembly.

*a	Protective Tape

22. REMOVE INPUT SHAFT ASSEMBLY

(a) Remove the input shaft assembly together with the output shaft assembly, No. 1 fork shaft assembly, No. 2 gear shift fork assembly and No. 3 gear shift fork assembly from the transaxle(MTM) case sub-assembly.

NOTICE:

To prevent damage to the front output shaft bearing (inner race), slightly raise the differential case assembly.

*1	Input Shaft Assembly
*2	Output Shaft Assembly
*3	No. 1 Fork Shaft Assembly
*4	No. 2 Gear Shift Fork Assembly
*5	No. 3 Gear Shift Fork Assembly

(b) Remove the No. 1 fork shaft assembly, No. 2 gear shift fork assembly and No. 3 gear shift fork assembly from the input shaft assembly and output shaft assembly.

23. REMOVE NO. 1 GEAR SHIFT HEAD

(a) Using a 5 mm pin punch and hammer, remove the shift head set slotted spring pin and No. 1 gear shift head from the No. 1 gear shift fork shaft.

24. REMOVE NO. 1 GEAR SHIFT FORK ASSEMBLY

(a) Using a 5 mm pin punch and hammer, remove the shift fork slotted pin and No. 1 gear shift fork assembly from the No. 1 gear shift fork shaft.

25. REMOVE DIFFERENTIAL CASE ASSEMBLY

(a) Remove the differential case assembly together with the No. 2 output shaft assembly and No. 4 fork shaft assembly from the transaxle(MTM) case sub-assembly.

*1	Differential Case Assembly
*2	No. 2 Output Shaft Assembly
*3	No. 4 Fork Shaft Assembly

(b) Remove the No. 4 fork shaft assembly from the No. 2 output shaft assembly.

26. REMOVE NO. 4 GEAR SHIFT FORK

(a) Remove the bolt and No. 4 gear shift fork from the No. 4 gear shift fork shaft.

27. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING

(a) Using SST, remove the front differential case front tapered roller bearing (outer race) from the transaxle(MTM) case sub-assembly.

SST: 09308-36010

NOTICE:

Make sure that SST is not hooked on the front differential oil baffle.
Do not damage the transaxle(MTM) case sub-assembly.

*1	Front Differential Case Front Tapered Roller Bearing (Outer Race)
*2	Front Differential Oil Baffle

(b) Using SST, remove the front differential case front tapered roller bearing (inner race) from the differential case assembly.

SST: 09950-00020

SST: 09950-00030

SST: 09950-60011

09951-00500

*a	Hold
*b	Turn

28. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING

(a) Using SST, remove the front differential case rear tapered roller bearing (outer race) and front differential case rear shim from the manual transmission case.

SST: 09308-36010

NOTICE:

Do not damage the manual transmission case.

*1	Front Differential Case Rear Tapered Roller Bearing (Outer Race)
*2	Front Differential Case Rear Shim

(b) Using SST, remove the front differential case rear tapered roller bearing (inner race) from the differential case assembly.

SST: 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST: 09950-60011

09951-00500

*a	Hold
*b	Turn

29. REMOVE TRANSMISSION MAGNET

(a) Remove the transmission magnet from the transaxle(MTM) case sub-assembly.

30. REMOVE BREATHER PLUG

(a) Remove the breather plug from the transaxle(MTM) case sub-assembly.

31. REMOVE FRONT OUTPUT SHAFT BEARING (OUTER RACE)

(a) Using SST, remove the front output shaft bearing (outer race) from the transaxle(MTM) case sub-assembly.

SST: 09308-00010

NOTICE:

Do not damage the transaxle(MTM) case sub-assembly.

32. REMOVE OUTPUT SHAFT(MTM) COVER

(a) Remove the output shaft(MTM) cover from the transaxle(MTM) case sub-assembly.

33. REMOVE REVERSE GEAR SHAFT COVER

(a) Remove the reverse gear shaft cover from the transaxle(MTM) case sub-assembly.

34. REMOVE FRONT DIFFERENTIAL OIL BAFFLE

(a) Remove the front differential oil baffle from the transaxle(MTM) case sub-assembly.

35. REMOVE FRONT TRANSAXLE CASE OIL SEAL

(a) Using SST and a hammer, remove the front transaxle case oil seal from the transaxle(MTM) case sub-assembly.

SST: 09950-60011

09951-00360

SST: 09950-70010

09951-07150

36. REMOVE FRONT DRIVE SHAFT OIL SEAL RH

(a) Using SST and a hammer, remove the front drive shaft oil seal RH from the transaxle(MTM) case sub-assembly.

SST: 09950-60011

09951-00590

SST: 09950-70010

09951-07200

37. REMOVE TRANSAXLE CASE STRAIGHT PIN

(a) Remove the 3 transaxle case straight pins from the transaxle(MTM) case sub-assembly.

38. REMOVE REAR REVERSE GEAR SHAFT BEARING SHIM

(a) Remove the rear reverse gear shaft bearing shim from the manual transmission case.

39. REMOVE REAR INPUT SHAFT BEARING SHIM

(a) Remove the rear input shaft bearing shim from the manual transmission case.

40. REMOVE INPUT SHAFT(MTM) COVER

(a) Remove the input shaft(MTM) cover from the manual transmission case.

41. REMOVE NO. 1 OIL RECEIVER PIPE(MTM)

(a) Disengage the 2 guides and remove the No. 1 oil receiver pipe(MTM) from the manual transmission case.

42. REMOVE OUTER NO. 1 SHIFT LEVER

(a) Using a 5 mm pin punch and hammer, remove the inner shift lever slotted spring pin from the inner No. 1 shift lever.

NOTICE:

Perform this step carefully so that the inner shift lever slotted spring pin does not fly out.

HINT:

When removing the inner shift lever slotted spring pin, align the inner shift lever slotted spring pin with the hole in the neutral position switch.

Hole

(b) Remove the outer No. 1 shift lever and inner No. 1 shift lever from the manual transmission case.

*1	Outer No. 1 Shift Lever
*2	Inner No. 1 Shift Lever

43. REMOVE OUTER SHIFT LEVER OIL SEAL

(a) Using a screwdriver with its tip wrapped with protective tape, remove the outer shift lever oil seal from the manual transmission case.

NOTICE:

Do not damage the manual transmission case.

*a	Protective Tape

44. REMOVE REAR OUTPUT SHAFT BEARING (OUTER RACE)

(a) Using SST, remove the rear output shaft bearing (outer race) and rear output shaft bearing shim from the manual transmission case.

SST: 09308-00010

NOTICE:

Do not damage the manual transmission case.

*1	Rear Output Shaft Bearing (Outer Race)
*2	Rear Output Shaft Bearing Shim

45. REMOVE FRONT DRIVE SHAFT OIL SEAL LH

(a) Using SST and a hammer, remove the front drive shaft oil seal LH from the manual transmission case.

SST: 09950-60011

09951-00620

SST: 09950-70010

09951-07150