Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM1000000026XS4
Model Year Start: 2023 Model: GR Corolla Prod Date Range: [09/2022 -           ]
Title: EA67F / EA68F (MANUAL TRANSMISSION / TRANSAXLE): OUTPUT SHAFT: INSPECTION; 2023 - 2025 MY Corolla Corolla Hatchback GR Corolla [09/2022 -        ]

INSPECTION

PROCEDURE

1. INSPECT NO. 1 OUTPUT SHAFT

(a) Check the No. 1 output shaft for wear and damage.

(b) Using a dial indicator, check the No. 1 output shaft runout.

Maximum Runout:

0.01 mm (0.000394 in.)

If the runout exceeds the maximum, replace the No. 1 output shaft.

(c) Using a micrometer, measure the outer diameter of the No. 1 output shaft journal surface.

Standard:

Measured Part

Outer Diameter mm (in.)

A

32.002 to 32.018 (1.2599 to 1.2605)

B

35.984 to 36.000 (1.4167 to 1.4173)

C

41.984 to 42.000 (1.6529 to 1.6535)

D

41.989 to 42.000 (1.6531 to 1.6535)

E

46.984 to 47.000 (1.8498 to 1.8504)

F

36.002 to 36.018 (1.4174 to 1.4180)

If the outer diameter is below the minimum, replace the No. 1 output shaft.

2. INSPECT 1ST DRIVEN GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 1st driven gear.

Standard Inside Diameter:

53.015 to 53.040 mm (2.0872 to 2.0882 in.)

Maximum Inside Diameter:

53.040 mm (2.0882 in.)

If the inside diameter exceeds the maximum, replace the 1st driven gear.

3. INSPECT 2ND DRIVEN GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 2nd driven gear.

Standard Inside Diameter:

56.015 to 56.030 mm (2.2053 to 2.2059 in.)

Maximum Inside Diameter:

56.030 mm (2.2059 in.)

If the inside diameter exceeds the maximum, replace the 2nd driven gear.

4. INSPECT 3RD DRIVEN GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 3rd driven gear.

Standard Inside Diameter:

42.015 to 42.040 mm (1.6541 to 1.6551 in.)

Maximum Inside Diameter:

42.040 mm (1.6551 in.)

If the inside diameter exceeds the maximum, replace the 3rd driven gear.

5. INSPECT 4TH DRIVEN GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 4th driven gear.

Standard Inside Diameter:

48.015 to 48.040 mm (1.8904 to 1.8913 in.)

Maximum Inside Diameter:

48.040 mm (1.8913 in.)

If the inside diameter exceeds the maximum, replace the 4th driven gear.

6. INSPECT 1ST DRIVEN GEAR SYNCHRONIZER RING SET

(a) Coat the 1st driven gear synchronizer ring set with gear oil.

(b) Install the inner ring to the 1st driven gear.

*a

Inner Ring

(c) Install the middle ring to the 1st driven gear.

*a

Middle Ring

(d) Install the outer ring to the 1st driven gear.

*a

Outer Ring

(e) Coat the 1st driven gear with gear oil.

(f) Check that the 1st driven gear synchronizer ring set does not turn when the 1st driven gear synchronizer ring set is pushed to the 1st driven gear.

(g) Using a feeler gauge, measure the clearance between the 1st driven gear synchronizer ring set back and the gear spline end.

Standard Clearance:

0.98 to 1.82 mm (0.0386 to 0.0717 in.)

Minimum Clearance:

0.98 mm (0.0386 in.)

If the clearance is below the minimum, replace the 1st driven gear synchronizer ring set.

7. INSPECT 2ND DRIVEN GEAR SYNCHRONIZER RING SET

(a) Coat the 2nd driven gear synchronizer ring set with gear oil.

(b) Install the inner ring to the 2nd driven gear.

*a

Inner Ring

(c) Install the middle ring to the 2nd driven gear.

*a

Middle Ring

(d) Install the outer ring to the 2nd driven gear.

*a

Outer Ring

(e) Coat the 2nd driven gear with gear oil.

(f) Check that the 2nd driven gear synchronizer ring set does not turn when the 2nd driven gear synchronizer ring set is pushed to the 2nd driven gear.

(g) Using a feeler gauge, measure the clearance between the 2nd driven gear synchronizer ring set back and the gear spline end.

Standard Clearance:

1.28 to 2.12 mm (0.0504 to 0.0835 in.)

Minimum Clearance:

1.28 mm (0.0504 in.)

If the clearance is below the minimum, replace the 2nd driven gear synchronizer ring set.

8. INSPECT 3RD DRIVEN GEAR SYNCHRONIZER RING SET

(a) Coat the 3rd driven gear synchronizer ring set with gear oil.

(b) Install the inner ring to the 3rd driven gear.

*a

Inner Ring

(c) Install the middle ring to the 3rd driven gear.

*a

Middle Ring

(d) Install the outer ring to the 3rd driven gear.

*a

Outer Ring

(e) Coat the 3rd driven gear with gear oil.

(f) Check that the 3rd driven gear synchronizer ring set does not turn when the 3rd driven gear synchronizer ring set is pushed to the 3rd driven gear.

(g) Using a feeler gauge, measure the clearance between the 3rd driven gear synchronizer ring set back and the gear spline end.

Standard Clearance:

1.00 to 2.00 mm (0.0394 to 0.0787 in.)

Minimum Clearance:

1.00 mm (0.0394 in.)

If the clearance is below the minimum, replace the 3rd driven gear synchronizer ring set.

9. INSPECT 4TH DRIVEN GEAR SYNCHRONIZER RING SET

(a) Coat the 4th driven gear synchronizer ring set with gear oil.

(b) Install the inner ring to the 4th driven gear.

*a

Inner Ring

(c) Install the middle ring to the 4th driven gear.

*a

Middle Ring

(d) Install the outer ring to the 4th driven gear.

*a

Outer Ring

(e) Coat the 4th driven gear with gear oil.

(f) Check that the 4th driven gear synchronizer ring set does not turn when the 4th driven gear synchronizer ring set is pushed to the 4th driven gear.

(g) Using a feeler gauge, measure the clearance between the 4th driven gear synchronizer ring set back and the gear spline end.

Standard Clearance:

0.92 to 1.88 mm (0.0362 to 0.074 in.)

Minimum Clearance:

0.92 mm (0.0362 in.)

If the clearance is below the minimum, replace the 4th driven gear synchronizer ring set.

10. INSPECT NO. 1 TRANSMISSION HUB SLEEVE

(a) Using a vernier caliper, measure the clearance between the No. 1 transmission hub sleeve and the No. 1 gear shift fork.

Standard Clearance (A - B):

0.10 to 0.50 mm (0.00394 to 0.0197 in.)

If the clearance is outside the specifications, replace the No. 1 transmission hub sleeve and No. 1 gear shift fork.

11. INSPECT NO. 2 TRANSMISSION HUB SLEEVE

(a) Using a vernier caliper, measure the clearance between the No. 2 transmission hub sleeve and the No. 2 gear shift fork.

Standard Clearance (A - B):

0.35 to 0.75 mm (0.0138 to 0.0295 in.)

If the clearance is outside the specifications, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork.

12. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 1st driven gear thrust clearance.

Standard Clearance:

0.10 to 0.35 mm (0.00394 to 0.0138 in.)

Maximum Clearance:

0.35 mm (0.0138 in.)

If the clearance exceeds the maximum, replace the 1st driven gear, needle roller bearing or No. 1 output shaft.

13. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 1st driven gear radial clearance.

Standard Clearance:

0.015 to 0.068 mm (0.000591 to 0.00268 in.)

Maximum Clearance:

0.068 mm (0.00268 in.)

If the clearance exceeds the maximum, replace the 1st driven gear, needle roller bearing or No. 1 output shaft.

14. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 2nd driven gear thrust clearance.

Standard Clearance:

0.11 to 0.46 mm (0.00433 to 0.0181 in.)

Maximum Clearance:

0.46 mm (0.0181 in.)

If the clearance exceeds the maximum, replace the 2nd driven gear, needle roller bearing or No. 1 output shaft.

15. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 2nd driven gear radial clearance.

Standard Clearance:

0.015 to 0.048 mm (0.000591 to 0.00189 in.)

Maximum Clearance:

0.048 mm (0.00189 in.)

If the clearance exceeds the maximum, replace the 2nd driven gear, needle roller bearing or No. 1 output shaft.

16. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 3rd driven gear thrust clearance.

Standard Clearance:

0.11 to 0.54 mm (0.00433 to 0.0213 in.)

Maximum Clearance:

0.54 mm (0.0213 in.)

If the clearance exceeds the maximum, replace the 3rd driven gear, needle roller bearing or No. 1 output shaft.

17. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 3rd driven gear radial clearance.

Standard Clearance:

0.015 to 0.066 mm (0.000591 to 0.0026 in.)

Maximum Clearance:

0.066 mm (0.0026 in.)

If the clearance exceeds the maximum, replace the 3rd driven gear, needle roller bearing or No. 1 output shaft.

18. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 4th driven gear thrust clearance.

Standard Clearance:

0.10 to 0.65 mm (0.00394 to 0.0256 in.)

Maximum Clearance:

0.65 mm (0.0256 in.)

If the clearance exceeds the maximum, replace the 4th driven gear, needle roller bearing or No. 1 output shaft.

19. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 4th driven gear radial clearance.

Standard Clearance:

0.015 to 0.066 mm (0.000591 to 0.0026 in.)

Maximum Clearance:

0.066 mm (0.0026 in.)

If the clearance exceeds the maximum, replace the 4th driven gear, needle roller bearing or No. 1 output shaft.