丰田雅力士手动变速器驱动桥部分修理手册(英文版)

1、丰田雅力士手动变速器驱动桥部分修理手册（英文版）MXC50MANUAL TRANSAXLEMANUAL TRANSAXLE SYSTEMMANUAL TRANSAXLE SYSTEMPROBLEM SYMPTOMS TABLEUse the table below to help find the cause of the problemThe numbers indicate the likelihood of the possible causes in descending order Check each part in order Replace parts asnecessary5

2、Bearing Input shaft Worn or damagedMX-76SymptomSuspected areaLevel lowWrongInput shaft Worn or damagedNoiseOutput shaft Worn or damagedSee page1 OilMX-22 OilMX-23 GearMX-784 GearMX-896Bearing Differential caseLevel too highOil leakageDamagedseal Worn or damagedControl cable Faultyfork WornMX-86Beari

3、ng Output shaft Worn or damaged7Worn or damagedMX-1011OilMX-22GasketMX-413OilMX-41MX-162 ShiftMX-5610HubMX-78Synchronizer ring Input shaft Worn or damaged4Synchronizer ring Output shaft Worn or damaged MX-895 Shiftkey spring Input shaft damagedMX-76Hard or impossible to shift6 Shiftkey spring Output

4、 shaft damagedMX-86Gear7Input shaft damagedMX-78Gear8Output shaft damagedMX-89sleeve Output shaft damagedMX-891 Shiftfork WornMX-56Gear2Input shaft Worn or damagedMX-78Jumps out of gear3 GearOutput shaft Worn or damagedMX-89MX4Bearing Input shaft Worn or damagedMX-765Bearing Output shaft Worn or dam

5、agedMX-86MX 2C50MANUAL TRANSAXLEMANUAL TRANSAXLE OILMANUALTRANSAXLE OILON-VEHICLEINSPECTION1INSPECTTRANSAXLE OILaStop the vehicle in a level placebRemove the transmission filler plug and the gasket0 to 5 mmcCheck that the oil surface is within 5 mm 020 in of0 to 020 inthebottom of the transmission f

6、iller plug openingD025304E01NOTICEExcessively large or small amounts of oil maycause problemsAfter replacing the oil drive the vehicle andcheck the oil level againdCheck for oil leakage when the oil level is loweInstall the transmission filler plug and a new gasketTorque 39 Nm 400 kgfcm 29 ftlbfMXMX

7、 3C50MANUAL TRANSAXLEDIFFERENTIAL OIL SEALTRANSMISSIONC50 MANUAL TRANSAXLEDIFFERENTIAL OIL SEALCOMPONENTSFRONT DRIVE SHAFT HOLESNAP RING RHFRONTDRIVESHAFTASSEMBLYRHFRONT DRIVE SHAFT HOLESNAP RING LHFRONTASSEMBLY LHDRIVE SHAFT29 300 22wABSSPEED SENSORFRONTSTABILIZERFRONT LHLINK ASSEMBLY LH5574755MX85

8、 87 75 inlbfCOTTER PIN49 500 36TIE ROD END SUB-ASSEMBLY LHCLIP216 2203 1609899972FRONT AXLE HUB LH NUTSpecified torqueNmkgfcm ftlbfFRONT SUSPENSION ARMSUB-ASSEMBLY LOWER NO1 LHNon-reusable partC115301E13MX -4C50MANUAL TRANSAXLE -DIFFERENTIAL OIL SEALTRANSMISSION CASE OIL SEALMXTRANSAXLE CASE OIL SEA

9、LNon-reusable partApply MP greaseC108463E01MX 5C50 MANUAL TRANSAXL EDIFFERENTIAL OIL SEALREMOVAL1 DISCONNECT CABLE FROM NEGATIVE BATTERYTERMINAL2 DRAIN TRANSAXLE OILa Remove the filler plug and the gasketb Remove the drain plug and gasket andthen drainthe manual transaxle oilc Installa new gasket an

10、d the drain plugTorque 39 Nm 400 kgfcm 29 ftlbf3 REMOVE FRONT WHEELS4 REMOVE FRONT AXLE HUB LH NUT See page DS-5 REMOVE FRONT AXLE HUB RH NUTHINTThe removal procedure for the RH side is thesame asthat for the LH side6 SEPARATE SPEED SENSOR FRONT LH w ABSSee page DS-37 SEPARATE SPEED SENSOR FRONT RH

11、w ABSHINTThe separation procedure for the RH side isthe same asthat for the LH side8 SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO1 LH See page DS-49 SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO1 RHHINTThe separation procedure for the RH side isthe same asthat for the LH sideSee10SEPARA

12、TETIE RODEND SUB-ASSEMBLYLHMXpage DS-311 SEPARATE TIE ROD END SUB-ASSEMBLY RHHINTThe separation procedure for the RH side isthe same asthat for the LH side12 SEPARATE FRONT STABILIZER LINK ASSEMBLY LHSee page DS-413 SEPARATE FRONT STABILIZER LINK ASSEMBLYRHHINTThe separation procedure for the RH sid

13、e isthe same asthat for the LH side14 SEPARATE FRONT AXLE ASSEMBLY LH See pageDS-4MX -6C50MANUAL TRANSAXLE -DIFFERENTIAL OIL SEAL15SEPARATE FRONT AXLE ASSEMBLY RHHINTThe separation procedure for the RH side is the same asthat for the LH sideREMOVE FRONT DRIVE SHAFT ASSEMBLY LH See16page DS-517REMOVE

14、 FRONT DRIVE SHAFT ASSEMBLY RH Seepage DS-518REMOVE TRANSAXLE CASE OIL SEALaUsing SST remove the oil sealSST 09308-00010SSTC094266E01#REMOVE TRANSMISSION CASE OIL SEALUsing SST remove the oil sealSST 09308-00010SSTD025305E01INSTALLATION1INSTALL TRANSMISSION CASE OIL SEALSSTMXCoat the lip of a new oi

15、l seal with MP greasebUsing SST and a hammer install the new oil sealSST 09309-37010Drive in depth96 to 102 mm 0378 to 8>0402 in96to102mmNOTICE0378to 0402 inDonot damage the oil seal lipC070067E01#INSTALL TRANSAXLE CASE OIL SEALaCoat the lip of a new oil seal with MP greaseSSTbUsing SST and a ham

16、mer install the new oil sealSST 09710-26011 09710-05061Drive in depth16 to 22 mm 0063 to 0087 inNOTICE16to22mmDo not damage the oil seal lip0063 to 0087 in3INSTALL FRONT DRIVE SHAFT ASSEMBLY LH SeeC070068E01page DS-134INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Seepage DS-14MX 7C50 MANUAL TRANSAXL EDIFFER

17、ENTIAL OIL SEAL5 INSTALLFRONTAXLEASSEMBLLYH See page DS-146 INSTALL FRONT AXLE ASSEMBLY RHHINTThe installation procedure for the RH sideis the same asthat for the LH side7 INSTALL FRONT STABILIZER LINK ASSEMBLY LHSee page DS-148 INSTALL FRONT STABILIZER LINK ASSEMBLY RHHINTThe installation procedure

18、 for the RH sideis the same asthat for the LH side9 INSTALL TIE ROD END SUB-ASSEMBLY LH Seepage DS-1510 INSTALL TIE ROD END SUB-ASSEMBLY RHHINTThe installation procedure for the RH sideis the same asthat for the LH side11 INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO1 LH See page DS-1412 INSTAL

19、L FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO1 RHHINTThe installation procedure for the RH sideis the same asthat for the LH sideSee13 INSTALL SPEED SENSOR FRONT LH w ABSpage DS-1514 INSTALL SPEED SENSOR FRONT RH w ABSHINTThe installation procedure for the RH sideis the same asMXthatfortheLHsideSee p

20、age SP-215 INSTALL FRONT AXLE HUB LH NUT See page DS-1516 INSTALL FRONT AXLE HUB RH NUTHINTThe installation procedure for the RH sideis the same asthat for the LH side17 INSTALL FRONT WHEELS18 CONNECT CABLE TO NEGATIVE BATTERYTERMINALTorque 54 Nm 55 kgfcm 48 inlbf19 ADD TRANSAXLE OIL20 INSPECT AND A

21、DJUST TRANSAXLE OIL See pageMX-221 INSPECT ABS SPEED SENSOR SIGNALSee page BC-14MX - 8C50 MANUAL TRANSAXLE DIFFERENTIALOIL SEAL22FRONT WHEEL ALIGNMENTINSPECT AND ADJUST23CHECKFOR TRANSAXLEOIL LEAKAGEMXMX -8C50MANUALTRANSAXLE -FLOOR SHIFT LEVER ASSEMBLYTRANSMISSIONC50 MANUAL TRANSAXLEFLOOR SHIFT LEVE

22、R ASSEMBLYCOMPONENTSfor HatchbackSHIFT LEVER KNOB SUB-ASSEMBLYCONSOLEBOX REARCOVERCONSOLE BOXCARPETCONSOLEBOX ASSEMBLY REARMXCLIPCLIPTRANSMISSION CONTROLCABLE ASSEMBLYx4FLOOR SHIFT SHIFT LEVER ASSEMBLYNm kgfcm ftlbf Specified torqueC106956E05MX 9FLOOR SHIFT LEVERC50 MANUAL TRANSAXLEASSEMBLYfor Sedan

23、CENTERINSTRUMENTPANEL FINISH PANEL LOWERSHIFTLEVERKNOBSUB-ASSEMBLYUPPERCONSOLE PANELSUB-ASSEMBLYCONSOLE BOX CARPETCONSOLE UPPER REARPANEL SUB-ASSEMBLYMXREAR CONSOLE BOX ASSEMBLYC136395E01MX 10C50MANUAL TRANSAXLE -FLOOR SHIFT LEVER ASSEMBLYREMOVAL1REMOVESHIFT LEVER KNOB SUB-ASSEMBLY forHatchback See

24、page IP-68 2REMOVECONSOLE BOX ASSEMBLY REAR forHatchback See page IP-69 3REMOVEINSTRUMENT PANEL FINISH PANELLOWERCENTER for Sedan See page ME-138REMOVESHIFT LEVER KNOB SUB-ASSEMBLY forSedanSee page IP-84REMOVEUPPER CONSOLE PANEL SUB-ASSEMBLYforSedan See page IP-84REMOVECONSOLE UPPER REAR PANEL SUB-A

25、SSEMBLY for Sedan See page IP-847REMOVECONSOLE BOX CARPET for Sedan SeepageIP-858REMOVEREAR CONSOLE BOX ASSEMBLY forSedanSee page IP-859DISCONNECT TRANSMISSION CONTROL CABLEASSEMBLYaRemove the clip and disconnect the control selectcable from the shift leverbTurn the lock to release it and separate t

26、he controlselect cable from the shift lever retainercDisconnect the control shift cable from the shiftleverdTurn the lock to release it and separate the controlshift cable from the shift lever retainer10REMOVEFLOOR SHIFT SHIFT LEVER ASSEMBLYRemove the 4 bolts and remove the shift leverMXC106358INSTA

27、LLATION1INSTALLFLOOR SHIFT SHIFT LEVER ASSEMBLYaInstall the shift lever with the 4 boltsTorque 12 Nm 122 kgfcm 89 ftlbfC106358MX 11C50 MANUAL TRANSAXLEFLOORCONNECTSHIFT LEVER ASSEMBLYTRANSMISSION CONTROL CABLEASSEMBLYProtruding Portion Lock AaInstall the control shift cable onto the shift leverretai

28、nerNOTICEInstall the cable with the protruding portion ofthe cable outer facing upwardAfter installing check that the lock of thecable outer is protruding beyond portion AC106359E01as shown in the illustrationbConnect the control shift cable to the shift levercInstall the control select cable onto t

29、he shift lever retainerNOTICEInstall the cable with the protruding portion ofthe cable outer facing upwardProtrudingPortionLockAfter installing check that the lock of theAcable outer is protruding beyond portion Aas shown in the illustrationC106360E01Connect the control select cable to the shift lev

30、erNOTICEConnect the control select cable so that the adjusting mechanism lock of the control select cable is installed on the left side of the vehicleInsert the clip in the direction shown in the illustrationC106361E01eAdjust the length of the control select cableCoverLock Piece1Slide the adjuster c

31、ase cover in the direction MXshown in the illustration Illustration A2Gently pull the cable rod toward the rear of theAvehicle by hand to pull the cable taut3Press the lock piece into the adjuster case andAdjuster Caselock it Illustration B4Slide the cover in the direction shown in the illustration

32、Illustration CNOTICESlide the cover past the protrusion of the lock piece Illustration D3INSTALLHatchbackSee page IP-794INSTALLSHIFT LEVER KNOB SUB-ASSEMBLY forHatchbackSee page IP-80D5 INSTALLREAR CONSOLE BOX ASSEMBLY forSedanSee page IP-88C108468E02MX 12C50MANUATRANSAXLE FLOOR SHIFTLEVER ASSEMBLY6 INSTALL CONSOLEBOX CARPET for Seda