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

MX–8

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MANUAL TRANSAXLE ASSEMBLY

MX006–06

COMPONENTS

11 (115, 8)

Hole Cover

Control Cable Bracket

25 (250, 18)

29 (300, 22)

Transaxle Case Receiver

Transaxle Case

11 (115, 8)

Magnet

z Oil Seal

z Input Shaft Front Bearing

Output Shaft Cover

z Output Shaft Front Bearing

Differential Case Assembly

Bearing Lock Plate

11 (115, 8)

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

D10268

AVENSIS/CORONA SUP (RM781E)

MX–9

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

L Straight Screw Plug

No.1 Shift Fork

25 (250, 18)

Spring Seat

Spring

Reverse Shift Arm Bracket

Reverse Shift Fork

Snap Ring

16 (160, 12)

Ball

No.1 Shift Fork

Shaft

25 (250, 18)

L

17 (175, 13)

No.3 Shift Fork Shaft

Thrust Washer

16 (160, 12)

Ball

No.3 Shift Fork

Reverse Idler Gear

Idler Gear Shaft

Output Shaft Assembly

L

25 (250, 18)

Shift Head

16 (160, 12)

No.2 Shift Fork Shaft

29 (300, 22)

16 (160, 12)

No.2 Shift Fork

Snap Ring

5th Driven Gear

z Lock Nut

118 (1200, 87)

Input Shaft

Assembly

Spacer

Needle Roller Bearing

Snap Ring

Rear Bearing Retainer

Shifting Key Spring

Shifting Key

27 (280, 20)

x 5

5th Gear

Shifting Key Spring

Synchronizer Ring

No.3 Hub Sleeve

No.3 Clutch Hub

N·m (kgf·cm, ft·lbf) : Specified torque

Snap Ring

z Non–reusable part

L Precoated part

Z18280

AVENSIS/CORONA SUP (RM781E)

MX–10

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

L

20 (200, 14)

Back–Up

Light Switch

Control Shaft Cover

40 (410, 30)

Gasket

z

L Straight Screw Plug

39(400, 29)

L

20 (200, 14)

Gasket

z

Bearing

OilReceiverPipe

L Lock Ball Assembly

39 (400, 29)

L Straight Screw Plug

13 (130, 9)

Shift and Select Lever

Shaft Assembly

OilReceiverPipe

17 (175, 13)

Transmission Case

Filler Plug

39 (400, 29)

Gasket

z

z Bushing

29 (300, 22)

Dust Boot

Transmission Case

Cover

x 13

z Oil Seal

Gasket

z

Lever Lock Pin

x 9

Drain Plug

39 (400, 29)

25 (250, 18)

18 (185, 13)

Control Shaft

Assembly

12 (120, 9)

Selecting Bellcrank

Assembly

Wave Washer

Control Bellcrank Dust Cover

Wave Washer

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

AVENSIS/CORONA SUP (RM781E)

L Precoated part

D10269

MX–11

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MX0D0–01

DISASSEMBLY

1.

REMOVE RELEASE FORK AND BEARING

HINT:

At the time of reassembly, please refer to the following item.

Apply molybdenum disulphide lithium base grease.

(See page CL–12)

2.

3.

4.

REMOVE BOLT AND SPEED SENSOR

Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)

REMOVE BACK–UP LIGHT SWITCH

Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)

REMOVE CONTROL CABLE BRACKET

Remove the 2 bolts and control cable bracket.

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

5.

REMOVE CONTROL SHAFT ASSEMBLY

Remove the 2 nuts, wave washer and control shaft assembly.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D07393

6.

REMOVE SELECTING BELLCRANK ASSEMBLY

(a) Remove the 2 bolts and selecting bellcrank assembly.

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

NOTICE:

At the time of reassembly, please refer to the following

item.

Fit the selecting bellcrank assembly pin part with the dust

cover into a groove in the control shift lever.

(b) Remove the control bellcrank dust cover from the select-

ing bellcrank assembly.

D07394

NOTICE:

At the time of reassembly, please refer to the following

item.

Apply MP grease to the inside circumferential surface of

the control bellcrank dust cover.

AVENSIS/CORONA SUP (RM781E)

MX–12

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

7.

REMOVE CONTROL SHIFT LEVER AND DUST BOOT

(a) Remove the nut and wave washer.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D07395

(b) Using a pin punch and hammer, drive out the lever lock

pin.

NOTICE:

At the time of reassembly, please refer to the following

item.

When fixing the lever lock pin, properly position the shaft

groove.

(c) Remove the control shift lever and dust boot.

NOTICE:

D07396

At the time of reassembly, please refer to the following

items.

S

Install the dust boot into a groove in the control shift

lever.

S

Be sure to install the dust boot in the correct direc-

tion, as shown in the illustration.

8.

REMOVE PLUG, LOCK BALL ASSEMBLY AND CON-

TROL SHAFT COVER ASSEMBLY

(a) Using a hexagon wrench, remove the plug and gasket.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

(b) Remove the lock ball assembly.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

(c) Remove the 4 bolts and control shaft cover assembly with

the gasket.

D09357

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–13

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

9.

REMOVE SHIFT AND SELECT LEVER SHAFT AS-

SEMBLY

(a) Remove the shift and select lever shaft assembly.

NOTICE:

At the time of reassembly, please refer to the following

item.

Set the claws of the shift interlock plate into the shift head

part of the gear shift fork shaft securely.

(b) Remove the select spring seat and compression spring

from the shift and select lever shaft assembly.

10. REMOVE TRANSMISSION CASE COVER

(a) Remove the 9 bolts.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

(b) Using a brass bar and hammer, carefully tap the projec-

tion of the transmission case cover to remove the trans-

mission case cover from the transmission case.

FIPG:

D07398

Q07840

Q05783

FIPG

Part No. 08826–00090, THREE BOND 1281 or equiva-

lent

11. REMOVE LOCK NUT

(a) Engage the gear to the double meshing.

(b) Using a chisel and hammer, loosen the staked part of the

nut.

(c) Remove the lock nut.

Torque: 118 N·m (1,200 kgf·cm, 87 ft·lbf)

(d) Disengage the gear double meshing.

12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK

(a) Remove the bolt from the No.3 shift fork.

Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

(b) Remove the No.3 hub sleeve with the shift fork.

HINT:

Removal

Installation

SST

At the time of reassembly, please refer to the following item.

Using SST and a hammer, drive in the No.3 hub sleeve with the

shift fork.

SST 09636–20010

Q05825

NOTICE:

At the time of installation, please refer to the following item.

Align the synchronizer ring slots with the shifting keys.

AVENSIS/CORONA SUP (RM781E)

MX–14

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

13. INSPECT 5TH GEAR THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10–0.57 mm (0.0039–0.0024 in.)

Maximum clearance:

0.57 mm (0.0224 in.)

Q02519

14. INSPECT 5TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

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:

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.

Z00658

15. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR

(a) Using 2 screwdrivers and a hammer, tap out the snap

ring.

HINT:

At the time of reassembly, please refer to the following item.

Select a snap ring that allows the minimum axial play.

Mark

A

Thickness mm (in.)

2.25(0.0886)

2.31(0.0909)

2.37(0.0933)

2.43(0.0957)

Mark

Thickness mm (in.)

2.49(0.0980)

2.55(0.1004)

2.61(0.1028)

–

E

F

G

–

Z00659

B

C

D

(b) Using a screwdriver, remove the key spring.

AVENSIS/CORONA SUP (RM781E)

MX–15

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

(c) Install a bolt and washer to the tip of the input shaft and

using SST, remove the No.3 clutch hub.

SST 09950–30011

NOTICE:

Engine Side

Select a bolt whose outer diameter is smaller than the

screw hole of the input shaft so that it can be turned easily.

(d) Remove the synchronizer ring, 5th gear and needle roller

bearing.

SST

Q05790

16. REMOVE 5TH DRIVEN GEAR

Using SST, remove the 5th driven gear.

SST 09628–62011, 09950–40011 (09957–04010),

09950–60010 (09951–00230)

SST

Q07893

N00174

Q05785

Q05786

HINT:

At the time of reassembly, please refer to the following item.

Using SST, install the 5th driven gear.

SST 09309–12020

SST

17. REMOVE REAR BEARING RETAINER

Remove the 5 bolts and retainer.

Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)

18. REMOVE BEARING SNAP RING

Using a snap ring expander, remove the 2 snap rings.

HINT:

x 5

If it is difficult to remove and install the snap rings, pull up the

shafts.

19. REMOVE REVERSE IDLER GEARSHAFTLOCKBOLT

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

20. REMOVE SNAP RING FROM NO.2 SHIFT FORK

SHAFT

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

AVENSIS/CORONA SUP (RM781E)

MX–16

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

21. REMOVE PLUG, SEAT, SPRING AND BALL

(a) Using a hexagon wrench, remove the 3 plugs.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

(b) Using a magnetic finger, remove the 3 seats, springs and

balls.

Q07842

22. REMOVE TRANSMISSION CASE

(a) Remove the 16 bolts.

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

(b) Using a plastic hammer, carefully tap the projection of the

transmission case to remove the transmission case from

the transaxle case.

Z00668

HINT:

FIPG

At the time of reassembly, please refer to the following item.

Apply FIPG to the transaxle case, as shown in the illustration.

FIPG:

Part No. 08826–00090, THREE BOND 1281 or equiva-

lent

D07333

D07351

Q08151

23. REMOVE OIL RECEIVER PIPE

Remove the 2 bolts and oil receiver pipes from the transmission

case.

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

NOTICE:

At the time of reassembly, please refer to the following

items.

S

Prevent the oil receiver pipes from being deformed.

Install the oil receiver pipes while placing it against

the transmission case, as shown in the illustration.

S

24. REMOVE REVERSE IDLER GEAR, THRUST WASHER

AND SHAFT

AVENSIS/CORONA SUP (RM781E)

MX–17

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

25. REMOVE REVERSE SHIFT ARM BRACKET

Remove the 2 bolts and reverse shift arm bracket.

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

NOTICE:

At the time of reassembly, please refer to the following

items.

S

Set the pin on the top of the reverse shift arm into a

groove on the reverse idler gear.

Fit the claw of the reverse shift arm bracket with the

notch of the input shaft front bearing.

Install the reverse idler gear, thrust washer and shaft,

as shown in the illustration.

Align Alignment Mark

D07336

26. REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK

SHAFT

(a) Using 2 screwdrivers and a hammer, tap out the 3 snap

rings from each gear shift fork shaft.

(b) Remove the 3 bolts from the No. 1 gear shift head, No. 1

and No. 2 gear shift forks.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Q05789

Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

(c) Pull up the No. 3 gear shift fork shaft, remove the No. 2

gear shift fork shaft.

NOTICE:

At the time of reassembly, please refer to the following

item.

To avoid the interference of the 2 balls, lift up the No. 3 gear

shift fork shaft at the position shown in the illustration.

D03039

AVENSIS/CORONA SUP (RM781E)

MX–18

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

(d) Remove the No. 1 gear shift head.

D03038

(e) Using a magnetic finger, remove the 2 balls from the re-

verse shift fork.

(f)

Remove the No. 3 gear shift fork shaft and reverse shift

fork.

(g) Pull out the No. 1 gear shift fork shaft.

(h) Remove the No. 1 and No. 2 gear shift forks.

27. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER

FROM TRANSAXLE CASE

28. REMOVE DIFFERENTIAL CASE ASSEMBLY

NOTICE:

Z00674

At the time of reassembly, please refer to the following

item.

Before reassembly, inspect the differential tapered roller

bearing preload. (See page MX–42)

29. REMOVE MAGNET FROM TRANSAXLE CASE

30. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY

(a) Using a screwdriver, remove the shifting key spring.

NOTICE:

At the time of reassembly, please refer to the following

item.

Position the shifting key springs so that their end gaps are

not aligned.

(b) Remove the 3 No. 3 shifting keys from the No. 3 clutch

hub.

AVENSIS/CORONA SUP (RM781E)

MX–19

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MX06G–02

INSPECTION

1.

INSPECT 5TH GEAR 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:

WM0064

Ensure the fine lapping compound is completely washed

off after rubbing.

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

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

the synchronizer ring back and gear spline end.

Minimum clearance: 0.75 mm (0.030 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.

WM0065

WM0066

Z00675

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: 0.5 mm (0.020 in.)

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

hub sleeve.

3.

REMOVE TRANSAXLE CASE RECEIVER

Remove the bolt and transaxle case receiver.

4.

IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING

SST

(a) Using SST, pull out the bearing.

SST 09612–65014

AVENSIS/CORONA SUP (RM781E)

MX–20

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

(b) Using SST and a press, install a new bearing.

SST 09950–60010 (09951–00460), 09950–70010

(09951–07150)

SST

Q07845

5.

IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING

(a) Remove the bolt and bearing lock plate.

(b) Using SST, pull out the bearing.

SST 09308–00010

SST

(c) Remove the output shaft front cover.

Z00701

(d) Install the output shaft front cover.

HINT:

Case

Cover

Set the projection of the cover into the hollow in the case.

Z00703

Q07846

Q07847

(e) Using SST and a press, install a new bearing.

SST 09950–60010 (09951–00620), 09950–70010

(09951–07150)

SST

(f)

Install the bearing lock plate and torque the bolt.

Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)

6.

INSTALL TRANSAXLE CASE RECEIVER

Install the transaxle case receiver and torque the bolt.

Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)

7.

IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL

SEAL

(a) Using a screwdriver, pry out the oil seal.

(b) Using SST, drive in a new oil seal until its surface is flush

with the transaxle case.

SST 09950–60010 (09951–00400), 09950–70010

(09951–07150)

(c) Coat the lip of the oil seal with MP grease.

SST

AVENSIS/CORONA SUP (RM781E)

MX–21

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

8.

IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using a hexagon wrench, remove the straight screw plug.

(b) Using a pin punch and hammer, drive out the slotted

spring pin.

Q07850

(c) Replace the reverse restrict pin.

(d) Using a pin punch and hammer, drive in the slotted spring

pin.

(e) Apply sealant to the screw plug threads.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

(f)

Using a hexagon wrench, install the straight screw plug.

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

Z00707

AVENSIS/CORONA SUP (RM781E)

MX–22

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MX009–02

REASSEMBLY

Reassembly is in the reverse order of disassembly (See page MX–11).

HINT:

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

NOTICE:

When working with FIPG material, you must observe the following items.

S

Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-

faces.

S

Thoroughly clean all components to remove all the loose material.

Clean both sealing surfaces with a non–residue solvent.

Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.

Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must

be removed and reapplied.

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (C50, C250) -> Manual Transaxle Assembly for Your Toyota Avensis 4 Door First Generation (1997-2003)

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