How to repair a manual transmission on a Toyota Corolla yourself?

The Japanese concern Toyota, by producing affordable versions of premium cars, has given many people the opportunity to feel like cool owners of a famous imported creation. But the manufacturer, when supplying cars to our market, did not take into account the difficult situation with the roads and the changeable, unpredictable weather. The Toyota Corolla transmission frankly suffers due to the difficult road situation, the driving style of reckless drivers, and constant long traffic jams. Repairing a manual transmission is not complicated, but it is labor-intensive.

Cost of work when repairing a TOYOTA Corolla gearbox:

A range of services for repairing a manual gearbox for TOYOTA Corolla:

• consultation with a repairman /by phone free of charge/
• delivery of the car for repair /within Moscow RUB 3,000. From the Moscow region and other regions of the Russian Federation - by agreement/
• comprehensive vehicle diagnostics / determination of the presence of a malfunction in the engine, manual transmission, ABS, brake system; checking the vehicle's electrical circuits for corrosion, checking the kinematic damage of the unit, checking the transmission oil level, checking the functionality of the clutch hydraulic system/ - free of charge during repairs
• visual inspection, body integrity check
• checking the transmission oil content for the presence of steel, aluminum or bronze chips
• opening the pallet /if necessary/
• removal from the car
• disassembly, washing of parts and assemblies
• defect detection /presence of the car owner is mandatory/
• agreement with the car owner on the cost of complete repairs and the completion date of the repairs
• receipt from the spare parts/repairs warehouse. kit, consumables, components/
• repair / argon welding / gearbox housing if necessary
• assembly
• clutch replacement /at the request of the car owner/
• car installation
• refilling with transmission oil
• output diagnostics and test drive of the car

Warranty from 3 to 24 months or 60,000 km. mileage

We have a stock of restored manual transmissions TOYOTA Corolla 1.3 1.4 1.5 1.6 1.8 2.0 2.2 /see article replacement/. If the car owner wishes, we can replace the faulty one with one taken from the exchange stock, which is often more economically feasible.

The need to initialize the box

It is not worthwhile to restore the box yourself; it is better to order professional repairs from a specialized car service center. Also, the workshop staff can offer such a service as initializing a 2008 Toyota Corolla box with a manual transmission. This process is a reset and zeroing of previous ECU settings. The procedure is relevant to carry out in case of malfunctions of the gearbox, if the Toyota gearbox was repaired, for example, its parts and switching mechanism sensors were replaced.

Spare parts for manual transmission repair:

• economy - from 3,000 to 8,000 rubles. /use, at the request of the car owner, only used parts to reduce the cost of repairs/
• business - from 8,000 to 28,000 rubles. /replacement of only directly damaged parts in the unit/
• executive - from 28,000 to 60,000 rub. /replacement, regardless of damage, as a set: oil seals, carrier bearings, needle bearings, synchronizers, stoppers, coupling hub locks - plus directly damaged parts/

Our own warehouse of spare parts necessary for the repair of manual transmissions. Bearings, seals, gears, synchronizers, gear couplings, shafts, differentials, manual transmission housings are in stock and on order for all brands of cars.

TOYOTA Corolla is a great car for the city. Economical, stylish, quite compact and reliable. Problems with a manual transmission stem from a weak bearing on the lower input shaft and similarly on the lower output shaft. Unfortunately, the designers included a small reserve of strength, or rather, a weak turnover capacity of the inner race of these bearings. Out of ten TOYOTA Corolla cars requiring transmission repair, 8 are due to the characteristic hum produced by these bearings. The remaining 2 cars have a lack of transmission oil, resulting in burnt out 5th or 5th and 6th gear (with a six-speed gearbox installed).

Toyota Corolla gearbox diagram

gear selection block (gearbox forks)

TOYOTA Corolla is the most popular and best-selling car in history and has been around for over 50 years. The compact sedan has gained immense popularity due to its stylish classic design, reliability, safety and high degree of comfort. The eleventh generation of the iconic model began selling in 2012; the sedan is offered with a 1.3 or 1.5-liter engine. Buyers have access to a 5-speed manual transmission and a continuously variable transmission.

Features of a manual transmission

These cars are equipped with a 5-speed manual C150, as well as a C50, C52 or C56, depending on the engine modification. Structurally, all varieties are similar: the gearbox and differential are placed in a common aluminum housing. However, they differ in the first gear ratio and some other features.

Unlike other models of the Japanese manufacturer, the TOYOTA Corolla gearbox is not highly reliable. Its service life rarely exceeds 150 thousand km, but in most cases you have to contact the workshop earlier. The weak point of the manual transmission has become the satellite group, which usually breaks down after approximately 100,000 kilometers traveled.

Any manual transmission requires timely maintenance: changing the oil protects parts from increased friction and premature wear. It is recommended to fill the transmission of Toyota cars with the original TOYOTA Getriebeoil LV 75W transmission fluid, since it is specially adapted for this type and features of the box. However, you can try to save money by choosing a similar high-quality lubricant; drivers often choose Castrol products.

Changing the oil and carrying out any other work on the gearbox can only be done in a specialized workshop. Do not try to disassemble the unit yourself and change parts - this does not guarantee reliability, and there is a high risk of repeated breakdowns.

Signs and causes of manual transmission failure

Appearance of the manual transmission
The comfort of movement is directly dependent on the serviceability of the Toyota manual transmission. Despite the fact that the components of the box are of high quality, neglecting the maintenance of this unit leads to its rapid failure; repair of the Toyota manual transmission is required.

Problems with a manual transmission arise due to its improper operation, for example, frequent transportation of heavy luggage, untimely replacement of transmission oil. As a result, the elements of the gearbox exhaust their working life, and malfunctions are noted during its operation.

Toyota Corolla manual transmission repair must be carried out if:

• spontaneous switching off of gears occurs;
• the occurrence of extraneous noise from the gearbox;
• oil leak;
• the appearance of vibrations during operation of the box.

The Toyota Corolla 150 manual transmission must be diagnosed if inaccurate gear shifting is noted. Primary diagnostics of a manual transmission includes a visual inspection of its component mechanisms, and the degree of wear of its surfaces is determined. Also, it is necessary to check the level of transmission fluid and sealing elements, and the clutch may need to be replaced.

A problem with shaft bearings in a Toyota Corolla E 120 manual transmission can occur after 150,000 km. As a rule, a hum is noted. The noise may occur when there is insufficient transmission fluid. If extraneous noise is observed only in one gear, the synchronizer may be damaged.

An oil leak occurs when oil seals and O-rings are destroyed, or the integrity of the gearbox housing is damaged.

Compared to automatic transmission, the Toyota Corolla manual transmission is more reliable. On an automatic transmission, the ECU may fail prematurely and the clutches may burn out.

A major overhaul of the gearbox involves removing it from its original location. This requires dismantling the subframe and attachments, after which you need to drain the transmission oil and unscrew the bolts that hold the gearbox to the engine. The Toyota manual transmission weighs approximately 40 kg, and its removal requires care.

Source

Toyota Corolla 120 manual clutch replacement

All parts of the transmission are closely interconnected. Therefore, clutch problems will disable the car in the same way as a faulty gearbox. Moreover, malfunctions in the clutch can cause breakdown and repair of the Toyota Corolla 120 manual transmission. It can be difficult to determine offhand which of these units has broken down due to the similarity of symptoms. To accurately identify the causes, diagnostics at a car service is required.

Symptoms such as:

• Jerking and vibration when switching.
• The clutch “leads” is a problem of incomplete disengagement.
• The clutch “slips” - a problem of incomplete engagement.
• Difficult, tight shifting.
• Noises when shifting gears.

Such manifestations of problems most often occur due to wear and tear. This problem is mainly typical for cars with a mileage of 130-150 thousand km or more. Aggressive control, slipping in snow, mud, off-road driving, and shifting errors lead to premature clutch replacement.

Toyota Corolla gearbox rebuild

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Dismantling manual transmission, manual, example C56

I looked through the FAQ and didn't find the topic I was looking for. I think it will be very useful for various front-wheel drive cars. Written in my own hand based on my experience. If anyone has any questions about repairs or spare parts, please contact me, I can also repair any manual transmission

The gearbox removed from the vehicle must be cleaned of dirt and oil. Using a wrench or a wrench, whichever is more convenient for you, or whatever you have))) we begin to disassemble. 1 Use a 14-mm socket to unscrew the bolts (marked in blue, photo 1), do not lose the plastic or metal bushing (gray arrow in photo 1), boxes produced after 95 may not have this bushing. 2 Using a 17 socket (another is possible, white photo 1) we unscrew the bolt that locks the gear selection mechanism and remove it, if possible without damaging the gasket. 3 Using a 12mm head, unscrew all the bolts marked in orange (photos 1, 2 and 3) 4 Using a 6mm hexagon, unscrew the three covers (yellow, photo 1), using a magnet, remove the springs and balls from there. (photo 4) 5 Using a hammer, remove top cover, knock on the castings on the cover marked in black (photo 1).

Stage I. We remove the subframe.

1. We hang the car. I won’t describe the process, there’s a lot to do here. It turned out like this for me.

2. Remove the wheels. 3. Unscrew the ball joints where they fit on the lever.

4. Remove the plates that secure the subframe to the body.

5. Unscrew the steering rack. It is held on by studs; the bolt on top must be held with a 14 key. 6. Unscrew the subframe from the rear cushion. 8. We deal with the rods from the gearshift lever. It is necessary to disconnect the connection (bolt with cotter pin x 2) and remove their fastening from the gearbox housing. 7. Now remove the CV joint boot (wide side) and pull it off. Carefully remove the CV joint and immediately pull the bag over it to prevent dust and dirt from getting inside. Same thing on the other side.

8. Now you need to deal with the stabilizer. You can pull out its struts, you can unscrew it from the subframe at the bushings. I couldn’t cope with the racks, everything was very cleverly arranged there, there was no WD to unwind it. So I pulled it away from the bushings and it was done.

9. There are 2 studs left on which the subframe hangs. This is where the long 19mm socket comes in handy. Jack up the subframe. We unscrew the nuts (I was only able to unscrew them with a 2-meter amplifier). We call an assistant and carefully remove the subframe. Ready.

10. Remove the longitudinal beam.

Toyota Corolla (SOLD) › Logbook › Manual transmission repair

Who remembers from the last BZ, my manual transmission was noisy, those who don’t know, welcome to the last BZ.

This event happened and actively developed until the end of December, the holidays were just around the corner, I didn’t decide anything at the end of the year, I drove the car into the garage and only on January 3 did I disassemble and repair the box with my father, photo of the work process:

What eventually happened was that the rear bearing of the secondary shaft began to hum, it even jammed in the hands when turning, it made quite a decent noise and had inadequate play. This is the asshole:

Judging by the reviews on the Internet, the rear bearings on our manual transmissions are weak; by the way, you can pull them off without removing the box, but only by unscrewing the back cover. I decided to remove everything and do a complete troubleshooting, and the mileage is no longer low, I wonder what’s inside.

As a result, in addition to the above-mentioned bearing, they also replaced the front bearing of the input shaft, since there were small grooves on the rollers, most likely a speck had gotten in, and out of harm’s way they also waved it away. Also, since they climbed so deep, they removed the oil seal on the crankshaft, the old one was very oak and already covered in oil, they did the same with the input shaft seal, it was also oak and covered in oil. The release bearing also needed to be replaced, because it began to make noise in the cold and sometimes creaked, a photo of it disappeared somewhere from the phone or was deleted due to obtuseness, but the number will be lower.

Old input shaft oil seal:

Crankshaft oil seal, new/old:

Also, for disassembly, we bought a couple of pullers, made a symbiosis out of them and everything was taken apart perfectly, I don’t recommend going there without pullers, pry bars and other crap are not for this unit, maybe it will work, but such jokes will be very expensive if something happens... Purchased pullers :

In the end, if the hands grow from the right place, nothing complicated, I was more afraid, the following disassembly video betrayed my courage, by the way, in this video the crumbling bearing is exactly the same bearing that failed for me:

The hardest part is, as usual, putting the box back in, everything else is nonsense and ordinary working issues; before reassembling, I washed the entire box of shavings with gasoline and dried it. Filled with Castrol oil.

I also attach a list of materials and their catalog numbers that were used: 1) Release bearing - RCT3300SA 2) Rear bearing, secondary shaft - B25163ZNXC3 3) Front bearing, primary shaft - VP254 4) Primary shaft oil seal - 9031125028 5) Crankshaft oil seal, rear - 9031176003 6) Castrol gear oil - 1557C3

Well, something like this, thank you all, if you ask anything, I’ll be glad to help)

Problems with manual transmission Toyota Corolla 120: reviews

Most often, owners of Corolla 120 cars complain about noise in the gearbox, knocking out of gears, wear of bearings and clutches. However, in most cases, breakdowns occur after 100 thousand km due to natural wear and tear. Some examples of manual transmission malfunctions that we have encountered are given below.

• Corolla 120 2002 – wear of the rear bearing of the secondary shaft, noise in the box.
• Sedan 120,000 km - replacement of oil seal bearings and clutch.
• Toyota Corolla E120 2004 – damage to the manual transmission housing, oil leak. The defect was eliminated by argon-arc welding, and the manual transmission was filled with new lubricant.
• Toyota Corolla 120 4zz – the 3rd gear began to slip out, the transmission began to make noise at idle and make a crackling sound when shifting.
• A sedan with a mileage of 180 thousand km - strong vibration, noise, knocking out of gears. Deterioration of the clutch, wear of the gear shift mechanism, bearings.
• Toyota Corolla 120 manual transmission (1.6) – problem of spontaneous gear shifting.

In most cases, problems are solved by repairing the manual transmission, replacing the clutch, and consumables. If the unit has completely exhausted its service life and cannot be restored, we install a new gearbox.

Toyota Corolla gearbox repair

The gearbox is one of the key units of the Toyota Corolla. It includes many high-precision elements and is one of the most technologically advanced components. Over the course of one year, when driving in urban conditions, several dozen gear changes, forced stops and subsequent accelerations occur. Heavy start-stop operation and increased loads cause damage, premature wear and incorrect operation.

The service areas of the Toyota Lyubertsy and Toyota Izmailovo dealer centers are equipped with modern specialized equipment for diagnosing all generations of gearboxes. Specialists determine the cause of the problem, perform a test drive in motion, disassemble, troubleshoot and complex overhaul of the Toyota Corolla gearbox with replacement of faulty components.

When is gearbox repair needed?

Depending on the year of manufacture, your car may be equipped with a continuously variable transmission, automatic and manual transmission. The operation of the gearbox is influenced by various factors - from excess/insufficient level or poor quality of transmission fluid and wear of the friction components of the gearbox to an unregulated engine and the condition of the control valves.

Diagnostics and repair of the Toyota Corolla transmission are required if:

• The gear temporarily disappears when turning, shifts are “delayed” or there are jerks when performing them.
• Vibrations, rattling, metallic grinding, and a characteristic howling sound appear as the speed increases.
• Extraneous noise is heard when driving in only one gear, which disappears when shifting.
• The car slips, stalls and stalls, accelerates sluggishly, or acceleration stops completely when reaching a certain speed.
• There is no reverse speed, no forward movement, no noticeable push when changing gears.
• The shiftmatic mode indicator does not turn on even when the lever is switched to position M.
• The lever does not switch from position P when the brake pedal is pressed.

Symptoms of a Toyota Corolla 120 manual transmission failure

A faulty gearbox can cause an accident. This is the main reason why it is important to recognize problems early. Moreover, the sooner measures are taken to eliminate them, the less damage will be done to the box. Generally speaking, damage to the manual transmission manifests itself in noise and incorrect operation. And to make it easier to recognize them, we will discuss this in more detail.

7 symptoms of Toyota Corolla manual transmission malfunction

1. The smoothness of gear shifting has disappeared. The lever began to move with difficulty. To engage the desired gear, you need to make an effort and make several attempts.
2. There were clicks and grinding noises when switching.
3. Knocks out gears. The handle returns to neutral, even if you make an effort to keep it in the desired position. The problem may be with one or more gears.
4. The transmission is noisy and buzzes when driving or idling.
5. There is a problem with the car's delayed response to manual transmission commands.
6. The gearbox is jammed and not a single gear is engaged.

Malfunctions can also manifest themselves in increased vibration when turning on, the clutch pedal sinking, and unclear gear locking. Any signs of gearbox failure cannot be ignored, even if they are periodic. After all, even small defects can ultimately lead to immobilization of the car.

When does it become necessary to replace a robotic gearbox with an automatic one?

Replacing a robot with an automatic occurs when a car enthusiast has a clutch failure. The malfunction appears at 80,000 life resource. Clutch and fork elements are expensive, about 70,000 rubles.

To extend the life of a manual transmission with a wet clutch, change the oil every 50,000 kilometers. Regularly use the mechanical mode of riding the robot. Stop driving aggressively and making sudden starts. This way, you will be able to delay the overhaul of the robot, which is caused by mechanical failures or electrical problems.

Toyota Corolla manual transmission repair

A Toyota Corolla manual transmission can only be repaired using high-precision tools. This is the main reason that such a technically complex unit cannot be trusted to incompetent craftsmen. But your visit to the service center can be significantly delayed if you follow the basic rules of transmission maintenance: the Toyota Corolla manual transmission requires periodic checking of the oil level and its replacement, as well as regular installation of a new filter.

Weaknesses of a car's manual transmission

The Toyota Corolla manual transmission cannot be considered one of the most reliable transmissions in the model range, and the most vulnerable point in it is the satellite group. Toyota Corolla transmission repair specialists claim that its “life” is 100 thousand km. mileage This relatively short period can be significantly shortened by such undesirable actions as sudden acceleration and braking, as well as regular slippage. This will speed up the forced repair of the Toyota Corolla transmission, as well as any other manual transmission.

Features of Toyota Corolla manual transmission repair

When repairing a Toyota Corolla gearbox, you most often have to change:

• crankshaft oil seal;
• crankshaft bearing;
• primary or secondary shaft;
• drive or input shaft oil seal;
• release bearing;
• regular or damper clutch (depending on the type of repair of the Toyota Corolla manual transmission);
• gear shift cables.

Regardless of what set of operations is required, repair of the Toyota Corolla transmission should be entrusted to experienced craftsmen.

Tech - honest work and guarantee

The Moscow service center, which specializes in servicing Japanese equipment, will perform professional repairs of the Toyota Corolla gearbox, regardless of the transmission modification. We guarantee honest work in replacing the necessary parts, so the invoice presented to you will not contain unnecessary items. We will restore the functionality of the Toyota Corolla manual transmission in the shortest possible time, since our technicians are armed with experience and all the necessary equipment. We also guarantee the installation of original components, because only in this case the repair of a Toyota Corolla manual transmission can be called high-quality. We are professionals who value our reputation! Therefore, for Toyota Corolla gearbox repairs, only go to Autopilot!

What kind of oil is required for Toyota Corolla?

Dexron III

Gearbox care involves changing the fuel. Wear of the bearings of the primary and secondary shaft is often due to the fact that poor quality oil was used. When changing this fluid, you should pay attention to its consistency, whether metal shavings are present or not. For a 4-speed automatic transmission, it is recommended to use original transmission fuel (Toyota ATF T-IV or Dexron III). It lubricates the moving parts of the gearbox well and reduces their wear. These oils are characterized by high thermal stability and fluidity. The use of a different fluid causes damage to the Toyota gearbox.

In the case of a partial replacement, about 4 liters are required. oil, when full - 8 liters. When carrying out this procedure, it is necessary to install a new oil filter and pan gasket. Replacement is necessary every 60,000 km.

For manual transmissions, the use of original Toyota Getriebeoil LV 75W oil is required (change interval 40,000 km). Approximately 2.0-2.5 liters are added. This transmission fluid can protect the gearbox structure from rust.

Repairing a Toyota transmission yourself in most cases leads to aggravation of the existing problem. This is why it is worth turning to the services of professionals. It is possible to order manual transmission repairs at many service centers in Moscow.

Disassembling the Toyota Avensis manual transmission

Manual transmissions are simpler than automatic ones, and disassembling such a device is easier.

Required tools and equipment

• wrenches for 10, 13, 19 and 24;
• set of hexagons;
• screwdriver;
• pliers.

detailed instructions

Dismantling the manual gearbox is carried out as follows:

1. Remove the transmission from the vehicle and clean it.
2. Place the device vertically and unscrew the nuts from the back cover.
3. Remove the clutch bracket.
4. Remove the back cover and seal.
5. Engage 3rd or 4th gear.
6. Remove the 5th gear bolt and engage it.
7. Try turning the shafts. They must not give in.
8. Unscrew the nuts from both shafts.
9. Remove the 5th gear synchronizer by prying it off with a screwdriver.
10. Remove the blocker from the synchronizer and the driven gear.
11. Remove the thrust ring and bearing.
12. Twist the drive gear.
13. Remove the bearing plate by unscrewing the retaining screws.
14. Remove the needle bearing bushing and the output shaft thrust washer.
15. Remove the retaining rings from the primary and secondary shaft bearings.
16. Unscrew the clamps, remove the plugs and remove the springs.
17. Remove the power unit support.
18. Unscrew the nuts and mounting bolt, disconnect the clutch housing and gearbox.
19. Remove the bolt connecting the 1st and 2nd gear forks.
20. Remove the rod with the shift fork.
21. Remove the rod.
22. Remove the 5th gear rod.
23. Remove the retaining ring and reverse fork. Remove the gear.
24. Remove both shafts at the same time.
25. Remove the main drive driven gear.
26. Remove the switching mechanism and seal.
27. Remove the front bearing and oil seal from the secondary shaft.
28. Press the bearing into the crankcase.
29. Remove the magnet from the crankcase.
30. Dismantle the speed sensor housing and remove the driven gear from it, remove the seal.
31. Unscrew the rear light switch from the housing.
32. Remove the rod joint and cover from the rod.
33. Remove the bolt securing the lever to the switch rod.
34. Remove the rod and lever from the crankcase.
35. Check all parts for wear and damage. Replace damaged parts.