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

MX–30

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX00E–03

COMPONENTS

Ball

Output shaft

Thrust Washer

Synchronizer Ring

Needle Roller Bearing

1st Gear

No.1 Clutch Hub

No.1 Hub Sleeve

Synchronizer Ring

Snap Ring

Shifting Key Spring

Shifting Key

Spacer

Needle Roller Bearing

2nd Gear

Output Gear Spacer

4th Driven Gear

Rear Ball Bearing

3rd Driven Gear

Q07853

AVENSIS/CORONA SUP (RM781E)

MX–31

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX00F–03

DISASSEMBLY

1.

INSPECT 1ST AND 2ND GEARS THRUST CLEAR-

ANCES

Using a feeler gauge, measure each thrust clearance.

Standard clearance:

2nd Gear

1st Gear

1st gear: 0.10–0.40 mm (0.0039–0.0157 in.)

2nd gear: 0.10–0.45 mm (0.0039–0.0177 in.)

Maximum clearance:

Q05794

SM0137

CM0065

1st gear: 0.40 mm (0.0157 in.)

2nd gear: 0.45 mm (0.0177 in.)

2.

INSPECT 1ST AND 2ND 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:

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 REAR BALL BEARING, 4TH DRIVEN GEAR

AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT

(a) Using SST and a press, remove the ball bearing and 4th

driven gear.

SST 09950–00020

(b) Remove the output spacer.

SST

AVENSIS/CORONA SUP (RM781E)

MX–32

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

4.

REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE

ROLLER BEARING, SYNCHRONIZER RING AND

SPACER

(a) Shift the No.1 hub sleeve into the 1st gear.

N00074

MT0063

N00076

Q00818

(b) Using SST and a press, remove the 3rd driven gear.

SST 09950–00020

(c) Remove the 2nd gear, needle roller bearing, synchronizer

ring and spacer.

SST

5.

REMOVE SNAP RING

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

6.

REMOVE NO.1 HUB SLEEVE ASSEMBLY 1ST GEAR,

SYNCHRONIZER RING, NEEDLE ROLLER BEARING,

THRUST WASHER AND BALL

(a) Using a press, remove the No.1 hub sleeve assembly, 1st

gear and synchronizer ring.

(b) Remove the needle roller bearing, thrust washer and ball.

7.

REMOVE NO.1 HUB SLEEVE, SHIFTING KEY AND

SPRING FROM NO.1 CLUTCH HUB

Remove the 3 shifting keys, springs and No.1 hub sleeve from

the No.1 clutch hub.

AVENSIS/CORONA SUP (RM781E)

MX–33

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX0D1–01

INSPECTION

1.

INSPECT 1ST GEAR SYNCHRONIZER RING

(a) Check for 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 (0.0295 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.

WM0065

D07357

D07358

2.

INSPECT 2ND GEAR SYNCHRONIZER RING

(a) Check for 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, replace the synchronizer ring.

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

the synchronizer ring back and gear spline end.

Minimum clearance: 0.70 mm (0.0276 in.)

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

nizer ring.

AVENSIS/CORONA SUP (RM781E)

MX–34

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

3.

INSPECT GEAR SHIFT FORK AND REVERSE GEAR

CLEARANCE

Using a feeler gauge, measure the clearance between the re-

verse gear and gear shift fork.

Maximum clearance: 0.35 mm (0.014 in.)

If the clearance exceeds the maximum, replace the gear shift

fork or hub sleeve.

WM0066

MT0071

CM0015

4.

INSPECT OUTPUT SHAFT

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

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

output shaft journal surface.

C

B

A

Minimum outer diameter:

Part A: 32.985 mm (1.2986 in.)

Part B: 37.985 mm (1.4955 in.)

Part C: 31.985 mm (1.2592 in.)

If the outer diameter is less than the minimum, replace the out-

put shaft.

(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 output shaft.

AVENSIS/CORONA SUP (RM781E)

MX–35

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX00H–03

REASSEMBLY

HINT:

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

reassembly.

Front

Side

1.

INSTALL NO.1 CLUTCH HUB INTO NO.1 HUB SLEEVE

(a) Install the 3 springs and shifting keys to the No.1 clutch

hub.

(b) Install the No.1 clutch hub to the No.1 hub sleeve.

Q00819

Q00805

Q00908

N00079

N00080

2.

INSTALL BALL, THRUST WASHER, 1ST GEAR,

NEEDLE ROLLER BEARING, SYNCHRONIZER RING

AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT

SHAFT

(a) Install the ball to the shaft.

(b) Fit the thrust washer groove securely over the locking ball

when installing the thrust on the shaft.

(c) Apply gear oil to the needle roller bearing.

(d) Install the needle roller bearing, 1st gear and synchroniz-

er ring.

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

clutch hub grooves with the projections on the synchro-

nizer ring.

Notch

(f)

Using a press, install the 1st gear and No.1 hub sleeve.

3.

INSTALL SNAP RING

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

Mark

A

Thickness mm (in.)

2.50(0.0984)

Mark

D

Thickness mm (in.)

2.68(0.1055)

B

2.56(0.1008)

E

2.74(0.1079)

C

2.62(0.1031)

F

2.80 (0.1102)

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

4.

INSPECT 1ST GEAR THRUST CLEARANCE

(See page MX–31)

AVENSIS/CORONA SUP (RM781E)

MX–36

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

5.

INSTALL SYNCHRONIZER RING, SPACER, NEEDLE

ROLLER BEARING, 2ND GEAR AND 3RD DRIVEN

GEAR

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

clutch hub grooves with the projections on the synchro-

nizer ring.

(b) Install the spacer.

(c) Apply gear oil to the needle roller bearing.

(d) Install the 2nd gear.

Q00806

Z00711

Z00712

Z00713

(e) Using a press, install the 3rd driven gear.

6.

INSPECT 2ND GEAR THRUST CLEARANCE

(See page MX–31)

7.

INSTALL OUTPUT GEAR SPACER AND 4TH DRIVEN

GEAR

(a) Install the output gear spacer.

(b) Using a press, install the 4th driven gear.

8.

INSTALL REAR BALL BEARING

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

SST 09316–60011 (09316–00021)

SST

AVENSIS/CORONA SUP (RM781E)

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

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