Руководство по эксплуатации Toyota Manual Transmission — Обслуживание (EN)

MANUAL TRANSMISSIONS & TRANSAXLES Course 302 Technician Handbook © 2012 Toyota Motor Sales, U.S.A., Inc. All rights reserved. This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc. Revision Date: June 12, 2012 TOYOTA Technical Training

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Table of Contents 302 Manual Transmissions & Transaxles Manual Transmissions Course Menu ........................................................................................ 3 & Transaxles Drivetrain Configurations & Components Section 1: Section 1 Topics ................................................................................... 5 Drivetrain Configurations and Components .......................................... 6 Front Engine, Rear Drive .................................................................. 6 Front Engine, Front Drive ................................................................. 6 Section 2:

Section 2 Topics ................................................................................... 7 Clutch Components .............................................................................. 8 Clutch Assembly Flywheel ............................................................................................ 9 Pilot Bearing ..................................................................................... 9 Flywheel Inspection .......................................................................... 9 Clutch Disc ......................................................................................

10 Clutch Hub and Damper Assembly ................................................. 11 Clutch Cover Assembly ...................................................................12 Diaphragm Spring ........................................................................... 12 Clutch Release Bearing & Clutch Release Fork ............................. 13 Conventional Release Bearing ....................................................... 13 Self-centering Release Bearing ...................................................... 14 Hydraulic Clutch System .....................................................................

15 Master Cylinder ............................................................................... 16 Self-adjusting Release Cylinder ...................................................... 17 Clutch System Bleeding .................................................................. 18 Clutch Operation ............................................................................. 19 Concentric Slave Cylinder .............................................................. 20 Mechanical Clutch System ................................................................. 21 Clutch Pedal Adjustment ....................................................................

22 Clutch Pedal Height ........................................................................ 22 Clutch Pedal Freeplay .................................................................... 22 Clutch Component Inspection ............................................................. 24 Clutch Cover Assembly Inspection ................................................. 24 Clutch Disc Inspection .................................................................... 25 Release Bearing Inspection ............................................................ 26 Clutch Diagnosis .................................................................................

27 Clutch Slippage Stationary Check .................................................. 27 Clutch Slippage Road Test ............................................................. 28 Clutch Chatter ................................................................................. 28 Clutch Drag ..................................................................................... 29 Clutch Assembly Noise Check ........................................................ 29 Clutch Installation ................................................................................ 30 Install Clutch Disc ...........................................................................

30 Install Clutch Cover Assembly ........................................................ 31 Greasing Components .................................................................... 32 Transmission Installation .................................................................... 33 Technical Training i

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Table of Contents 302 Manual Transmissions & Transaxles Manual Transmission Section 3: Section 3 Topics ................................................................................. 35 Transmission Fundamentals ............................................................... 36 Torque ............................................................................................ 36 Determining Gear Ratios ................................................................ 37 Torque Multiplication ....................................................................... 38 Gear Types .....................................................................................

39 Bearings .......................................................................................... 40 Manual Transmission Components .................................................... 41 Shafts .............................................................................................. 41 Gears .............................................................................................. 42 Forward Gears ................................................................................ 42 Reverse Gears ................................................................................ 42 Simple Transmission ......................................................................

43 Transmission Powerflow ..................................................................... 44 Synchronizer Assembly ...................................................................... 45 Synchronizer Components ............................................................. 46 Synchronizer Gear Shift .................................................................. 47 1 st Stage – Synchronization ........................................................ 48 2 nd Stage – Synchronizing .......................................................... 50 3 rd Stage – Synchronized Meshing .............................................

51 Synchronizer Hub and Sleeve Splines ........................................... 52 Inertia Lock ..................................................................................... 52 Synchronizer Hub and Sleeve and Spline Damage ........................ 53 2-Cone Synchronizer ...................................................................... 54 3-Cone Synchronizer ...................................................................... 55 Synchronizer Cone Damage or Wear ............................................. 56 Synchronizer Inspection .................................................................

57 Gear Shift Mechanism ........................................................................ 58 Shift Detent Mechanism .................................................................. 59 Shift Interlock Mechanism ............................................................... 60 Shift Interlock Operation ................................................................. 60 Mis-Shift Prevention ........................................................................ 61 Reverse Mis-shift Prevention .......................................................... 62 Reverse One-way Mechanism ........................................................

63 Operation .................................................................................... 64 Reverse Pre-balk Mechanism ......................................................... 65 Operation .................................................................................... 65 Transmission Lubrication .................................................................... 66 Gear Lubrication ............................................................................. 66 Types of Lubricant .......................................................................... 67 Case Sealants .....................................................................................

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Table of Contents 302 Manual Transmissions & Transaxles Section 4: Manual Transaxle Section 4 Topics ................................................................................. 71 Transaxle Components ....................................................................... 72 Input and Output Shafts .................................................................. 72 Differential ....................................................................................... 73 Open Differential ............................................................................. 73 C140 and C150 Series Construction ..............................................

74 C60 Series 6-Speed Transaxle Construction ................................. 75 E Series Transaxle ......................................................................... 76 Lubrication .......................................................................................... 77 S & C Series Lubrication ................................................................. 77 E Series Lubrication ........................................................................ 77 Transaxle Powerflow ........................................................................... 78 Gears ..................................................................................................

79 Gear Shift Controls ............................................................................. 80 Shift Control Cable Adjustment ....................................................... 81 Shift and Select Assembly .............................................................. 82 Shift Mechanisms ................................................................................ 83 Shift Detent Mechanisms ................................................................ 83 Double Meshing Prevention ............................................................ 84 Mis-shift Prevention ........................................................................

84 C & E Series Reverse One-way Mechanism .................................. 85 Operation .................................................................................... 86 Bearings .............................................................................................. 87 Synchronizer Assemblies ................................................................... 88 Key Type Synchronizer Assembly .................................................. 88 Key-less Type Synchronizer Assembly .......................................... 88 Key-less Type Synchronizer Operation ..........................................

89 1 st Stage – Initial Synchronizer ................................................... 89 2 nd Stage – Synchronizing ........................................................... 90 3 rd Stage – Synchronized Mesh .................................................. 91 Section 5: Diagnostic Procedures Section 5 Topics ................................................................................. 93 Introduction ......................................................................................... 94 Six-step Diagnosis .............................................................................. 94 1. Verify the Customer Concern ..................................................... 95 2.

Identify the Symptoms ................................................................ 95 3. Isolate the Cause ........................................................................ 95 4. List Recommended Repairs ....................................................... 96 5. Perform Repair ........................................................................... 96 6. Verify Operation .......................................................................... 96 Common Transmission/Transaxle Problems ...................................... 97 Symptom Diagnosis Chart ...............................................................

97 Diagnostic Flowcharts ......................................................................... 98 Hard to Shift or Will Not Shift .......................................................... 98 Technical Training iii

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