M/T - Grinds Shifting Into 3rd Gear
T-SB-0282-10October 6, 2010
Grinding Noise when Shifting into 3rd Gear (M/T)
Service Category
Drivetrain
Section
Manual Transmission/Transaxle
Market
USA
Applicability
Introduction
Some 2009 model year Corolla and Matrix vehicles equipped with the 2ZR-FE engine and C59 manual transaxle may exhibit a grinding noise/feeling when shifting into the 3rd gear position. The lock ball spring strength for the 3rd/4th gear shift fork shaft has been increased to reduce the stress on the 3rd gear synchronizer. Please follow the repair procedure below to address this issue.
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Parts Information
Required Tools & Equipment
Repair Procedure
1. Confirm there is an abnormal grind noise/feeling when shifting up or down to the 3rd gear position ONLY
^ YES - Proceed to step 2.
^ NO - Stop and refer to the applicable Repair Manual section for further diagnosis of the customer concern.
2. Remove the manual transaxle assembly from the vehicle.
Refer to the Technical Information System (TIS) applicable model and model year Repair Manual:
^ 2009 Corolla / Matrix:
Drivetrain - Manual Transmission/Transaxle - "059 Manual Transmission/Transaxle:
Manual Transaxle Assembly: Removal"
3. Remove the back-up light switch assembly.
A. Separate the back-up light switch wire harness from the 2 clamps.
B. Using the SST, remove the back-up light switch assembly and gasket from the manual transmission case.
SST: 09817-16011
4. Remove the selecting bellcrank assembly.
A. Remove the 2 bolts nut and selecting bellcrank assembly from the manual transmission case.
B. Remove the control bellcrank dust cover.
5. Remove the floor shift control shift lever.
A. Remove the nut and washer.
B. Using a brass bar and a hammer remove the lock pin.
C. Remove the floor shift control shift lever and dust boot.
6. Remove the shift lever damper.
A. Remove the nut and washer.
B. Using a brass bar and a hammer remove the lock pin.
C. Remove the shift lever damper and dust boot.
7. Prepare the manual transaxle assembly by placing it on wooden blocks.
8. Remove the No.1 lock ball assembly from the manual transmission case.
9. Remove the shift guide pin and washer from the manual transmission case.
10. Remove the control shaft cover.
Remove the 4 bolts control shaft cover and gasket from the manual transmission case.
11. Remove the control shaft cover oil seal.
Using a screwdriver remove the control shaft cover oil seal from the control shaft cover.
12. Remove the shift and select lever shaft assembly from the manual transmission case.
13. Remove the manual transmission case cover sub-assembly.
A. Remove the 9 bolts.
B. Using a plastic hammer carefully tap the projections of the manual transmission case cover sub-assembly to remove the manual transmission case cover from the manual transmission case.
NOTICE
Do NOT damage the manual transmission case.
14. Remove the manual transmission output shaft rear set nut.
A. Using a chisel and a hammer loosen the staked part of the manual transmission output shaft rear set nut.
B. Engage 2 gears simultaneously to lock the transmission.
C. Remove the manual transmission output shaft rear set nut.
D. Disengage the 2 gears.
15. Remove the No.3 gear shift fork.
A. Remove the gear shift fork lock bolt from the No. 3 gear shift fork.
B. Remove the No. 3 transmission hub sleeve with the No. 3 gear shift fork from the No. 3 transmission clutch hub.
16. Remove the No. 3 transmission clutch hub.
A. Using 2 screwdrivers and a hammer tap out the snap ring.
HINT
Place a cloth behind the shaft and snap ring to catch the snap ring when it is removed.
B. Using a screwdriver remove the synchromesh shifting key spring from the No. 3 transmission clutch hub.
C. Using the SSTs remove the No. 3 transmission clutch hub 5th gear and No. 3 synchronizer ring from the input shaft.
SST: 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031, 09957-04010)
SST: 09950-60010 (09951-00200)
17. Remove the 5th gear needle roller bearing and 5th gear bearing spacer from the input shaft.
18. Using the SST, remove the 5th driven gear from the output shaft.
SST: 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03021)
SST: 09950-60010 (09951-00180, 09952-06010)
19. Remove the rear bearing retainer from the manual transmission case by removing the 5 bolts.
20. Using a snap ring expander remove the output shaft rear bearing hole snap ring from the output shaft.
21. Using a snap ring expander remove the input shaft rear bearing hole snap ring from the input shaft.
22. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
23. Remove the shift fork shaft snap ring. Using 2 screwdrivers and a hammer tap out the snap ring from the No.2 gear shift fork shaft.
HINT
Place a cloth behind the shaft and snap ring to catch the snap ring when it is removed.
24. Remove the shift detent ball.
A. Using a hexagon wrench remove the 2 shift detent ball plugs from the manual transmission case.
NOTE
The circled shift detent ball is for the 3-4 shift shaft. Mark this hole to reference the installation of the new compression spring during reassembly.
B. Using a magnetic pick-up tool remove the 2 shift spring seats 2 shift detent ball springs and 2 shift detent balls from the manual transmission case.
C. Using a hexagon wrench remove the shift detent ball plug from the transaxle case.
D. Using a magnetic pick-up tool remove the seat spring and ball from the transaxle case.
25. Using a hexagon wrench remove the No.2 lock ball assembly from the manual transmission case.
26. Remove the manual transmission case.
A. Remove the 3 bolts from the transaxle case.
B. Remove the 13 bolts from the manual transmission case.
C. Using a brass bar and a hammer carefully tap the projections of the manual transmission case to remove the transmission case from the transaxle case.
NOTICE
Do NOT damage the manual transmission case or transaxle case.
27. Remove the reverse idler gear sub-assembly thrust washer and reverse idler gear shaft from the transaxle case.
28. Remove the No.2 gear shift fork shaft.
A. Remove the 2 bolts from the No.2 gear shift fork and No.1 gear shift head.
B. Remove the No.2 gear shift fork shaft and No.1 gear shift head from the transaxle case.
29. Remove the No.1 gear shift fork shaft.
A. Using 2 screwdrivers and a hammer tap out the snap ring.
HINT
Place a cloth behind the shaft and snap ring to catch the snap ring when it is removed.
B. Remove the shift fork set bolt and No.1 gear shift fork shaft from the No.1 gear shift fork.
C. Remove the No.1 gear shift fork.
30. Remove the input shaft assembly from the transaxle case.
A. Lift both the input and output shaft slightly until the lower section of the input shaft is removed from the case bearing.
B. Separate the input shaft from the output shaft and set it down on a clean shop towel.
31. Remove the 3rd gear 4th gear and No.2 hub assemblies.
A. Remove the 4th gear.
(1) Using 2 screwdrivers and a hammer remove the input shaft rear bearing shaft snap ring from the input shaft.
HINT
Place a cloth behind the shaft and snap ring to catch the snap ring when it is removed.
(2) Using the SST and a press remove the input shaft rear radial ball bearing and 4th gear from the input shaft.
SST: 09950-00020
NOTICE
^ Do NOT tighten the SST excessively.
^ Support the input shaft by hand to prevent it from dropping off.
B. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
C. Remove the 4th gear synchronizer ring from the No.2 transmission clutch hub.
D. Remove the 3rd gear.
(1) Using 2 screwdrivers and a hammer remove the No.2 clutch hub setting shaft snap ring from the input shaft.
HINT
Place a cloth behind the shaft and snap ring to catch the snap ring when it is removed.
(2) Using the SST and a press remove the No.2 transmission clutch hub and 3rd gear from the input shaft.
SST: 09950-00020
NOTICE
^ Do NOT tighten the SST excessively.
^ Support the input shaft by hand to prevent it from dropping off.
E. Remove the 3rd gear needle roller bearing from the input shaft.
32. Install the new 3rd gear 4th gear and No.2 hub assemblies with new bearings and reassemble the input shaft assembly.
Refer to TIS applicable model and model year Repair Manual:
^ 2009 Corolla / Matrix
Drivetrain - Manual Transmission/Transaxle - "059 Manual Transmission/Transaxle:
Input Shaft: Reassembly"
33. Reassemble the manual transaxle assembly.
A. Lift the output shaft slightly to allow the gears to mesh and lower both assemblies back down onto the transaxle case.
B. Install the No. 1 gear shift fork.
C. Install the No. 1 gear shift fork shaft.
Coat the No.1 gear shift fork shaft with gear oil and install it.
D. Apply sealant to the shift fork set bolt.
Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344, or equivalent
E. Install the shift fork set bolt.
Torque: 16 N*m (160 kgf*cm, 12 ft*lbf)
F. Using a brass bar and a hammer install a new shaft snap ring onto the No. 1 gear shift fork shaft.
G. Follow the Repair Manual for the remainder of the reassembly steps beginning with step 22 "1nstall No. 3 Gear Shift Fork Shaft" and continue to the end of the procedure.
HINT
During step 28 of Reassembly, "Install Shift Detent Ball", install the new compression spring in the hole that was marked during disassembly.
Refer to TIS applicable model and model year Repair Manual:
^ 2009 Corolla / Matrix:
Drivetrain - Manual Transmission/Transaxle - "059 Manual Transmission/Transaxle:
Manual Transaxle Unit: Reassembly"
34. Install the manual transaxle assembly into the vehicle.
Refer to TIS applicable model and model year Repair Manual:
^ 2009 Corolla / Matrix:
Drivetrain - Manual Transmission/Transaxle - "059 Manual Transmission/Transaxle:
Manual Transaxle Assembly: Installation"
35. Test drive and confirm the grinding noise/feeling is no longer present.