Get MANUAL TRANSAXLE (C50, C250) -> Input Shaft Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MX–23

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00A–03

COMPONENTS

Input Shaft

3rd Gear

No.2 Hub Sleeve

Shifting Key

Shifting Key Spring

Needle Roller Bearing

4th Gear

Synchronizer Ring

Snap Ring

No.2 Clutch Hub

Synchronizer Ring

Snap Ring

Rear Ball Bearing

Q07849

AVENSIS/CORONA SUP (RM781E)

MX–24

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00B–03

DISASSEMBLY

1.

INSPECT 3RD AND 4TH GEARS THRUST CLEAR-

ANCE

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

3rd Gear

4th Gear

3rd gear: 0.10–0.35 mm (0.0039–0.0138 in.)

4th gear: 0.10–0.55 mm (0.0039–0.0217 in.)

Maximum clearance:

Q05793

3rd gear: 0.35 mm (0.0138 in.)

4th gear: 0.55 mm (0.0022 in.)

2.

INSPECT 3RD AND 4TH GEARS RADIAL CLEAR-

ANCE

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Standard clearance:

KOYO made:

0.015 – 0.058 mm (0.0006 – 0.0023 in.)

NSK made:

0.015 – 0.056 mm (0.0006 – 0.0022 in.)

Maximum clearance:

D00328

KOYO made: 0.058 mm (0.0023 in.)

NSK made: 0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

3.

REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring.

4.

REMOVE REAR BALL BEARING, 4TH GEAR, NEEDLE

ROLLER BEARING, SPACER AND SYNCHRONIZER

RING FROM INPUT SHAFT

SST

(a) Using SST and a press, remove the rear ball bearing.

SST 09950–00020

(b) Remove the 4th gear, needle roller bearings, spacer and

synchronizer ring.

5.

REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring.

Q04983

AVENSIS/CORONA SUP (RM781E)

MX–25

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

6.

REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR,

SYNCHRONIZER RING AND NEEDLE ROLLER BEAR-

ING

SST

Using SST and a press, remove the No.2 hub sleeve assembly,

3rd gear, synchronizer ring and needle roller bearings.

SST 09950–00020

CM0064

7.

REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND

SPRING FROM NO.2 CLUTCH HUB

Remove the 3 shifting keys, springs and No.2 hub sleeve from

the No.2 clutch hub.

Q00817

AVENSIS/CORONA SUP (RM781E)

MX–26

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00C–03

INSPECTION

1.

INSPECT SYNCHRONIZER RING

(a) Check wear or damage.

(b) Check the braking effect of the synchronizer ring.

Turn the synchronizer ring in one direction while pushing

it to the gear cone. Check that the ring locks.

If the braking effect is insufficient, apply a small amount of the

fine lapping compound between the synchronizer ring and gear

cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE:

Ensure the fine lapping compound is completely washed

off after rubbing.

(c) Check again the braking effect of the synchronizer ring.

WM0064

WM0065

WM0066

(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.

Minimum clearance:

3rd gear: 0.65 mm (0.0256 in.)

4th gear: 0.75 mm (0.0295 in.)

If the clearance is less than the minimum, replace the synchro-

nizer ring, and apply a small amount of the fine lapping com-

pound on gear cone.

NOTICE:

Ensure the fine lapping compound is completely washed

off after rubbing.

2.

INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-

ANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.35 mm (0.014 in.)

If the clearance exceeds the maximum, replace the shift fork or

hub sleeve.

AVENSIS/CORONA SUP (RM781E)

MX–27

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

3.

INSPECT INPUT SHAFT

(a) Check the input shaft for wear or damage.

(b) Using a micrometer, measure the outer diameter of the in-

put shaft journal surface.

A

B

C

D

Minimum outer diameter:

Part A: 24.885 mm (0.9797 in.)

Part B: 28.985 mm (1.1411 in.)

Part C: 30.985 mm (1.2199 in.)

Part D: 24.985 mm (0.9834 in.)

If the outer diameter is less than the minimum, replace the input

shaft.

CM0066

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the input shaft.

CM0013

AVENSIS/CORONA SUP (RM781E)

MX–28

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00D–03

REASSEMBLY

HINT:

Coat all of the sliding and rotating surfaces with gear oil before

reassembly.

Front

Side

1.

INSTALL NO.2 CLUTCH HUB INTO NO.2 HUB SLEEVE

(a) Install the 3 springs and shifting keys to the No.2 clutch

hub.

(b) Install the No.2 hub sleeve to the No. 2 clutch hub.

Q00909

Q02522

N00067

N00068

Q02525

2.

INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,

SYNCHRONIZER RING AND NO. 2 HUB SLEEVE AS-

SEMBLY TO INPUT SHAFT

(a) Apply gear oil to the needle roller bearings.

(b) Place the synchronizer ring on the gear and align the ring

slots with shifting keys.

(c) Using a press, install the 3rd gear and No.2 hub sleeve

assembly.

3.

INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play.

Mark

Thickness mm (in.)

2.30(0.0906)

Mark

Thickness mm (in.)

2.48(0.0976)

0

1

2

3

4

5

2.36(0.0929)

2.54(0.1000)

2.42(0.0953)

2.60(0.1024)

(b) Using a screwdriver and hammer, tap in the snap ring.

4.

INSPECT 3RD GEAR THRUST CLEARANCE

(See page MX–24)

5.

INSPECT SYNCHRONIZER RING, NEEDLE ROLLER

BEARING, SPACER, 4TH GEAR AND REAR BALL

BEARING

(a) Apply gear oil to the needle roller bearings.

(b) Place the synchronizer ring on the gear and align the ring

slots with the shifting keys.

AVENSIS/CORONA SUP (RM781E)

MX–29

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

(c) Using SST and a press, install the rear ball bearing.

SST 09608–03071

SST

SM0049

6.

INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play.

Mark

A

Thickness mm (in.)

2.29(0.0902)

Mark

D

Thickness mm (in.)

2.47(0.0972)

B

2.35(0.0925)

E

2.53(0.0996)

C

2.41(0.0949)

F

2.59(0.1020)

(b) Using a screwdriver and hammer, tap in the snap ring.

7.

INSPECT 4TH GEAR THRUST CLEARANCE

(See page MX–24)

SM0050

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (C50, C250) -> Input Shaft for Your Toyota Avensis 4 Door First Generation (1997-2003)

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