Get MANUAL TRANSAXLE (E351) Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MANUAL TRANSAXLE (E351)

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

MX–1

MX–2

MX–9

MANUAL TRANSAXLE UNIT . . . . . . . . . . . . . .

MANUAL TRANSAXLE ASSEMBLY . . . . . . . .

INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . MX–23

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . MX–29

SHIFT AND SELECT LEVER SHAFT . . . . . . . MX–37

DIFFERENTIAL CASE . . . . . . . . . . . . . . . . . . . . MX–38

SHIFT LEVER AND CONTROL CABLE . . . . . MX–45

MX–1

MANUALTRANSAXLE (E351)

–

TROUBLESHOOTING

MX01Z–07

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

cause of the problem. Check each part in order. If necessary, replace these parts.

Symptom

Suspect Area

See page

1. Oil (Level low)

2. Oil (Wrong)

MX–4

MX–9

Noise

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

1. Oil (Level too high)

MX–4

MX–9

2. Gasket (Damaged)

Oilleakage

3. Oil seal (Worn or damaged)

4. O–Ring (Worn or damaged)

1. Control cable (Faulty)

MX–45

MX–9

2. Synchronizer ring (Worn or damaged)

MX–23

MX–29

MX–9

Hard to shift or will not shift

3. Shift key spring (Damaged)

MX–23

MX–29

1. Locking ball spring (Damaged)

2. Shift fork (Worn)

MX–9

Jumps out of gear

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

AVENSIS/CORONA SUP (RM781E)

MX–2

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

COMPONENTS

MX096–03

VSV Connector for EGR

Air Cleaner Case

Assembly

with Air Hose

Air Flow Meter

Connector

No.1 Air Tube Assembly

25 (255, 18)

Clip

ControlCable

Turbo Pressure

Sensor Connector

Clip

Washer

15 (153, 11)

25 (255, 18)

Starter

39 (400, 29)

Battery

Clutch Release

Cylinder

and Line

Stay

Tray

Throttle Full

12 (120, 9)

Switch Connector

52(530,38)

z Gasket

87(890, 64)

12(120,9)

Engine Left

Mounting Bracket

Throttle Control

Motor Connector

21(214,15)

4.9 (50, 43 in.·lbf)

25 (255, 18)

Intake Air Temperature

Sensor Connector

Diesel Throttle Body

with No.2 Air Tube Assembly

: Specified torque

N·m (kgf·cm, ft·lbf)

25 (255, 18)

z Non–reusable part

D06619

AVENSIS/CORONA SUP (RM781E)

MX–3

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

64(650, 47)

Speed Sensor

Connector

RH Drive Shaft

Back–Up Light

Switch Connector

LH Drive

Shaft

z Snap Ring

8.0(82, 71in.·lbf)

Ground Cable

20(204, 15)

46 (470, 34)

216(2,200, 159)

29(300,22)

Lock Nut Cap

64 (650, 47)

z Cotter Pin

98 (1,000, 72)

64 (650, 47)

49 (500, 36)

Tie Rod End

40(408,30)

87(890, 64)

Engine Rear

Mounting Bracket

127 (1,300, 94)

43 (440, 32)

Transaxle Case

Protector

64 (650, 47)

Engine Front

Mounting Bracket

z Gasket

18 (185, 13)

Engine Front

Mounting

Engine Mounting

z Gasket

Front Exhaust Pipe

Center Member

64(650, 47)

40(408,30)

Suction Pipe

Bolt with Spring

73 (740, 54)

52 (540, 38)

62 (630, 46)

Hole Plug

Hole Cover

73 (740, 54)

Hole Plug

Front Transport

Hook

x 10

39 (400, 29)

RH Engine Under Cover

: Specified torque

x 10

N·m (kgf·cm, ft·lbf)

LH Engine Under Cover

z Non–reusable part

D06618

AVENSIS/CORONA SUP (RM781E)

MX–4

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

MX097–03

REMOVAL

1.

2.

REMOVE BATTERY AND TRAY

REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR

HOSE

3.

REMOVE LH AND RH ENGINE UNDER COVERS

4.

REMOVE NO.1 AIR TUBE ASSEMBLY

(a) Disconnect the No.2 vacuum hose from the E–VRV for

EGR.

(b) Disconnect the No.2 vacuum hose from the VSV for EGR.

(c) Disconnect the VSV connector for EGR.

(d) Disconnect the turbo pressure sensor connector and vac-

uum hose.

(b)

(a)

D06626

(e) Remove the 2 bolts as shown in the illustration.

Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)

(f)

Disconnect the 2 hose clips, and remove the No.1 air tube

assembly.

5.

REMOVE DIESEL THROTTLE BODY WITH NO.2 AIR

TUBE ASSEMBLY

(a) Disconnect the intake air temperature sensor connector.

(b) Disconnect the throttle control motor connector.

(c) Disconnect the full opener switch connector.

(d) Remove the 3 bolts from the diesel throttle body.

Torque: 21 N·m (214 kgf·cm, 15 ft·lbf)

D06627

(e) Remove the 2 bolts as shown in the illustration.

Torque: 25 N·m (255 kgf·cm, 18 ft·lbf)

(f)

Disconnect the 2 hose clips, and remove the diesel

throttle body assembly with the No.2 air tube assembly.

D06628

AVENSIS/CORONA SUP (RM781E)

MX–5

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

6.

REMOVE STARTER

(a) Remove the 2 bolts and disconnect the radiator reservoir

from the radiator.

(b) Disconnect the starter connector.

(c) Remove the nut, and disconnect the starter wire.

Torque: 15 N·m (153 kgf·cm, 11 ft·lbf)

(d) Remove the 2 bolts and starter.

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

D06629

D06639

D06633

7.

DISCONNECT CLUTCH RELEASE CYLINDER AND

LINE

(a) Remove the 2 set bolts of the clutch line bracket.

Torque:

Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)

Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)

(b) Remove the 2 bolts and disconnect the release cylinder

and line.

A

B

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

8.

DISCONNECT GROUND CABLE

Remove the set bolt of the ground cable from the transaxle.

9.

DISCONNECT VEHICLE SPEED SENSOR AND

BACK–UP LIGHT SWITCH CONNECTORS

10. DISCONNECT CONTROL CABLE

(a) Remove the 2 clips and washers.

(b) Remove the 2 clips from the cables.

11. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING

A

BOLTS

Torque:

Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)

Bolt B: 29 N·m (296 kgf·cm, 21 ft·lbf)

A

B

D06636

12. INSTALL ENGINE SUPPORT FIXTURE

Install the engine hanger in the correct direction.

Parts No.:

Engine hanger: 12281–27010

Bolt: 96122–61020

Torque: 37 N·m (377 kgf·cm, 27 ft·lbf)

D06634

AVENSIS/CORONA SUP (RM781E)

MX–6

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

13. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET

BOLTS AND NUT

B

Torque:

Bolt A: 52 N·m (530 kgf·cm, 38 ft·lbf)

Nut B: 87 N·m (890 kgf·cm, 64 ft·lbf)

A

D06632

D06638

D08920

14. REMOVE ENGINE LEFT MOUNTING BRACKET

Lower the transaxle side and remove the bolt and bracket.

Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)

15. REMOVE FRONT WHEEL

Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)

16. RAISE VEHICLE

NOTICE:

Make sure that the vehicle is securely supported.

17. DRAIN TRANSAXLE OIL

Oil Level

0 – 5 mm

Filler Plug

Oil grade: API GL–4 or GL–5

Viscosity: SAE 75W–90

Capacity: 2.5 liters (2.6 US qts, 2.2 Imp. qts)

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

18. REMOVE FRONT EXHAUST PIPE

(a) Remove the 2 bolts, 2 nuts and gasket from the exhaust

manifold.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)

(b) Remove the 2 bolts, 2 springs, gasket and pipe.

Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)

19. REMOVE LH AND RH FRONT DRIVE SHAFTS

(See page SA–1)

Drain Plug

20. REMOVE ENGINE MOUNTING CENTER MEMBER

(a) Remove the 2 bolts and front transport hook.

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

(b) Support the suspension crossmember with a jack.

(c) Remove the nuts, and disconnect the suction pipe.

D06631

AVENSIS/CORONA SUP (RM781E)

MX–7

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

(d) Remove the 2 hole plugs and hole cover.

(e) Remove the 7 bolts and center member.

Torque:

A

B

Bolt A: 73 N·m (740 kgf·cm, 54 ft·lbf)

Bolt B: 52 N·m (540 kgf·cm, 38 ft·lbf)

21. JACK UP TRANSAXLE SLIGHTLY

Using a transmission jack, support the transaxle.

A

D06630

22. REMOVE ENGINE REAR MOUNTING BRACKET

Remove the 4 bolts and bracket.

Torque:

Bolt A: 98 N·m (1,000 kgf·cm, 72 ft·lbf)

Bolt B: 64 N·m (650 kgf·cm, 47 ft·lbf)

A

B

D02167

23. REMOVE ENGINE FRONT MOUNT AND MOUNTING

BRACKET

(a) Remove the bolt and nut.

Torque: 87 N·m (890 kgf·cm, 64 ft·lbf)

(b) Remove the 2 bolts.

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

D06635

24. REMOVE TRANSAXLE LOWER SIDE MOUNTING

BOLT

Remove the 5 bolts.

A

Torque:

Bolt A: 40 N·m (408 kgf·cm, 30 ft·lbf)

Bolt B: 40 N·m (408 kgf·cm, 30 ft·lbf)

Bolt C: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

Bolt D: 20 N·m (204 kgf·cm, 15 ft·lbf)

Bolt E: 46 N·m (470 kgf·cm, 34 ft·lbf)

25. REMOVE TRANSAXLE

Lower engine left side and remove the transaxle from the en-

gine.

B

C

E

D

D06637

HINT:

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

S

Align the input shaft with the clutch disc and install the

transaxle to the engine.

S

Temporarily tighten the transaxle mounting bolts.

26. REMOVE TRANSAXLE CASE PROTECTOR

Remove the 2 bolts and protector.

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

AVENSIS/CORONA SUP (RM781E)

MX–8

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLE UNIT

MX05P–03

INSTALLATION

Installation is in the reverse order of removal (See page MX–4).

HINT:

After installation, check and inspect items as follows.

S

Front wheel alignment (See Pub. No. RM599E on page SA–4).

Do the road test.

S

AVENSIS/CORONA SUP (RM781E)

MX–9

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

MANUAL TRANSAXLE ASSEMBLY

MX098–03

COMPONENTS

Clutch Release Assembly

with Bearing

Clutch Release Fork Support

17 (175, 13)

Boot

17 (175, 13)

Speed Sensor

L Straight Screw Plug

25 (250, 18)

Control Cable Bracket

Transaxle Case Receiver

Clutch Tube Bracket

7.4 (75, 65 in.·lbf)

17 (175, 13)

Transaxle Case

Magnet

z Output Shaft Cover

z

Output Shaft Front

Bearing

Input Shaft Front

Bearing

z

z Front Oil Seal

Differential Case Assembly

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

L Precoated part

D10263

AVENSIS/CORONA SUP (RM781E)

MX–10

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

Reverse Shift Arm Bracket Assembly

Reverse Shift Fork

No. 1 Shift Fork

24 (240, 17)

L Straight Screw Plug

25 (250, 18)

No. 1 Shift Fork Shaft

Snap Ring

17(175,13)

No. 2 Shift Fork Shaft

25 (250, 18)

L

Interlock Roller

Snap Ring

Shift Head

24 (240, 17)

Snap Ring

No. 3 Shift Fork Shaft

No. 3 Shift Fork

Back–Up Light Switch

24 (240, 17)

No. 2 Shift Fork

40 (410, 30)

L Straight Screw Plug

13(130, 9)

z Gasket

20(200, 14)

L

Lock Ball Assembly

29 (300, 22)

Reverse

Restrict Pin

No. 2 Oil

Slotted

L

Breather Plug

49 (500, 36)

Spring Pin

L

z Gasket

Receiver Pipe

z Gasket

L

20 (200, 14)

x 17

17 (175, 13)

Shift and Select Lever

Shaft Assembly

No. 1 Oil Receiver Pipe

29 (300, 22)

Selecting Bellcrank

Assembly

z Gasket

Filler Plug

49(500, 36)

z Gasket

29 (300, 22)

Transmission Case

49 (500, 36)

Drain Plug

x 10

: Specified torque

N·m (kgf·cm, ft·lbf)

Transmission Case Cover

z Non–reusable part

L Precoated part

D10264

AVENSIS/CORONA SUP (RM781E)

MX–11

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

Input Shaft Assembly

Output Shaft Assembly

Reverse Idler Gear

Output Shaft Rear

Bearing Outer Race

z

Shim

Thrust Washer

Reverse Idler

Gear Shaft

L Lock Bolt

29 (300, 22)

L

42 (430, 31)

x 7

Rear Bearing Retainer

Snap Ring

Needle Roller Bearing

5th Gear

Inner Synchronizer

Ring

Key Spring

z Output Shaft

Lock Nut

Middle Synchronizer

Ring

123 (1,250, 90)

Outer Synchronizer Ring

Synchronizer Pull Ring

5th Driven Gear

Snap Ring

Key Spring

No. 3 Clutch Hub

No. 3 Hub Sleeve

: Specified torque

Snap Ring

N·m (kgf·cm, ft·lbf)

z Non–reusable part

L Precoated part

D09632

AVENSIS/CORONA SUP (RM781E)

MX–12

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

MX099–03

DISASSEMBLY

1.

2.

REMOVE RELEASE FORK AND BEARING

REMOVE BACK–UP LIGHT SWITCH WITH GASKET

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

3.

4.

REMOVE BOLT AND VEHICLE SPEED SENSOR

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

REMOVE SELECTING BELLCRANK ASSEMBLY

Remove the 2 bolts and No.2 selecting bellcrank with the se-

lecting bellcrank support.

Sealant:

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

242 or equivalent

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

5.

6.

REMOVE LOCK BALL ASSEMBLY WITH GASKET

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

REMOVE SHIFT AND SELECT LEVER SHAFT AS-

SEMBLY WITH GASKET

Remove the 4 bolts, the shift, select lever shaft assembly and

gasket.

Sealant:

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

242 or equivalent

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

7.

REMOVE TRANSMISSION CASE COVER

Remove the 10 bolts and transmission case cover.

FIPG:

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

FIPG

lent

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

8.

9.

REMOVE BREATHER PLUG WITH GASKET

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

Q05816

REMOVE OUTPUT SHAFT LOCK NUT

(a) Remove the lock nut.

(b) Engage the gear double meshing.

(c) Remove the lock nut.

Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)

(d) Disengage the gear double meshing.

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

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

Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)

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

Q00449

AVENSIS/CORONA SUP (RM781E)

MX–13

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

11. REMOVE 5TH DRIVEN GEAR

Using SST, remove the 5th driven gear.

SST 09950–30011

SST

Q05849

Z01304

Z01306

Q00299

12. MEASURE 5TH GEAR THRUST CLEARANCE AND

RADIAL CLEARANCE

(a) Using a dial indicator, measure the thrust clearance.

Minimum clearance:

0.10 mm (0.0039 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

(b) Using a dial indicator, measure the radial clearance.

Maximum clearance:

0.050 mm (0.0020 in.)

13. 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 the reassembly, please refer to the following item.

Select a snap ring that allows the minimum axial play.

Mark

Thickness mm (in.)

1.75(0.0689)

1.80(0.0709)

1.85(0.0729)

1.90(0.0748)

1.95(0.0768)

Mark

Thickness mm (in.)

2.00(0.0787)

2.05(0.0807)

2.10(0.0827)

2.15(0.0847)

–

a

b

c

d

e

f

g

h

j

–

AVENSIS/CORONA SUP (RM781E)

MX–14

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

(b) Using SST, remove the No.3 clutch hub with the synchro-

nizer ring and 5th gear.

SST

SST 09950–30011

14. REMOVE NEEDLE ROLLER BEARING AND SPACER

15. REMOVE REAR BEARING RETAINER

Using a torx socket wrench (T45), remove the 7 torx screws and

rear bearing retainer.

Sealant:

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

242 or equivalent

Z01308

Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

16. REMOVE SNAP RING

(a) Using a snap ring expander, remove the input shaft rear

bearing snap ring.

(b) Using 2 screwdrivers and a hammer, remove the 2 snap

rings.

Q06190

Q01615

Q00056

17. REMOVE STRAIGHT SCREW PLUG

Using a hexagon wrench (6 mm), remove the plug.

Sealant:

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

242 or equivalent

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

18. REMOVE REVERSE IDLER GEARSHAFTLOCKBOLT

Sealant:

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

242 or equivalent

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

AVENSIS/CORONA SUP (RM781E)

MX–15

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

19. REMOVE TRANSMISSION CASE

Remove the 17 bolts and tap the case with a plastic hammer.

FIPG:

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

FIPG

lent

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

D10267

MT0669

MT0693

D08951

Z17557

20. REMOVE SHIM

HINT:

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

Install the previously selected shim by adjusting output shaft

preload.(See page MX–21)

21. REMOVE OUTPUT SHAFT REAR TAPER ROLLER

BEARING OUTER RACE

Using SST and a hammer, remove the output shaft rear taper

roller bearing outer race.

SST

SST 09316–60011 (09316–00011)

22. REMOVE REVERSE SHIFT ARM BRACKET AS-

SEMBLY

Remove the bolt and pull off the reverse shift arm and bracket.

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

23. REMOVE REVERSE IDLER GEAR AND SHAFT

Pull out the shaft, remove the reverse idler gear and thrust

washer.

HINT:

Matchmarks

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

Align the matchmarks, as shown.

AVENSIS/CORONA SUP (RM781E)

MX–16

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

24. REMOVE STRAIGHT SCREW PLUG

Using a hexagon wrench (6 mm), remove the 2 plugs.

Sealant:

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

242 or equivalent

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

D09368

Q08124

Q08125

Q08126

Z00182

25. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD

SET BOLT

Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)

26. REMOVE NO.1 SHIFT FORK SHAFT

Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.

HINT:

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

When it is difficult to push the fork shaft through the reverse shift

fork, pull up the No.3 shift fork shaft.

27. REMOVE INTERLOCK ROLLER

Using a magnetic finger, remove the interlock roller from the re-

verse shift fork.

28. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD

AND NO.1 SHIFT FORK

(a) Pull out the No.2 shift fork shaft.

(b) Remove the shift head and No.1 shift fork.

29. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE

SHIFT FORK AND NO.2 SHIFT FORK

(a) Pull out the No.3 shift fork shaft with the reverse shift fork.

(b) Remove the No.2 shift fork.

30. REMOVE SNAP RING

(a) Using 2 screwdrivers and a hammer, remove the snap

ring and reverse shift fork from the No.3 shift fork shaft.

(b) Using 2 screwdrivers and a hammer, remove the 3 snap

rings from the No.1, No.2 and No.3 shift fork shafts.

AVENSIS/CORONA SUP (RM781E)

MX–17

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

31. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY

(a) Leaning the output shaft to the differential side, remove

the input shaft assembly.

(b) Lift up the differential case assembly, remove the output

shaft assembly.

32. REMOVE MAGNET FROM TRANSAXLE CASE

33. REMOVE NO.5 SYNCHRONIZER RING WITH KEY

SPRING FROM NO.3 CLUTCH HUB

(a) Remove the No.5 synchronizer ring with the key spring

from the No.3 clutch hub.

(b) Using a screwdriver, remove the snap ring.

HINT:

Wrap vinyl tape on the screwdriver to prevent damaging the

synchronizer ring.

(c) Remove the synchronizer rings.

MT0781

AVENSIS/CORONA SUP (RM781E)

MX–18

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

MX05W–03

INSPECTION

1.

INSPECT NO.5 SYNCHRONIZER RING

(a) Check for wear or damage.

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

middle No.5 synchronizer ring in one direction while push-

ing it to the outer No.5 synchronizer ring. Check that the

ring locks.

If it does not lock, replace the synchronizer ring.

MT0782

WM0066

D09369

Z00194

D09370

2.

MEASURE No.3 SHIFT FORK AND HUB SLEEVE

CLEARANCE

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.

3.

IF NECESSARY, REPLACE INPUT SHAFT BEARING

AND OIL SEAL

(a) Remove the 3 bolts and transaxle case receiver.

(b) Using SST, pull out the bearing.

SST 09612–65014

SST

(c) Using a screwdriver, remove the oil seal.

(d) Using SST, drive in a new oil seal.

SST 09608–00081, 09950–70010 (09951–07150)

(e) Coat the lip of seal with MP grease.

SST

(f)

Using SST, drive in a new bearing.

SST 09950–60010 (09951–00580), 09950–70010

(09951–07150)

SST

(g) Install the transaxle case receiver.

(h) Install and torque the 3 bolts.

Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–19

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

(i)

Using SST and a press, remove the inner race.

SST 09950–00020

SST

Q05164

(j)

Using SST and a press, install a new input shaft front

bearing inner race.

SST 09316–60011 (09316–00021)

SST

Q00141

Q00338

D09371

D09372

4.

IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING OUTER RACE AND OUTPUT SHAFT

FRONT COVER

SST

(a) Using SST, pull out the output shaft front bearing outer

race.

SST 09308–00010

(b) Remove the output shaft cover.

(c) Install a new output shaft cover.

HINT:

Install the output shaft cover projection into the case side

groove.

(d) Using SST and a hammer, drive in a new output shaft front

bearing outer race.

SST

SST 09316–60011 (09316–00011, 09316–00021)

AVENSIS/CORONA SUP (RM781E)

MX–20

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

(e) Using SST and a socket wrench, remove the output shaft

front bearing.

SST 09950–00020, 09950–00030

Socket Wrench

SST

Q00245

(f)

Using SST and a press, install a new output shaft front

bearing.

SST 09316–60011 (09316–00071)

SST

Z00199

Q01611

Z00201

5.

IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using a hexagon wrench (6 mm), remove the screw plug.

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

spring pin.

(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 (6 mm), install and torque the

screw plug.

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–21

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

MX05X–04

REASSEMBLY

Reassembly is in the reverse order of disassembly.

(See page MX–12)

NOTICE:

When working with FIPG material, you must observe the follow-

ing items.

S

Using a razor blade and gasket scraper, remove all the old

FIPG material from the gasket surfaces.

Thoroughly clean all components to remove all the loose

material.

S

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.

S

Parts must be assembled within 10 minutes of application.

Otherwise, the FIPG material must be removed and reap-

plied.

HINT:

S

Before reassembly, select a shim by adjusting output

shaft preload.

S

Coat all of the sliding and rotating surfaces with gear oil

before reassembly.

ADJUST OUTPUT SHAFT PRELOAD

(a) Install the output shaft assembly to the transaxle case.

(b) Install the transmission case to the transaxle case.

HINT:

If necessary, tap on the case with a plastic hammer.

(c) Install and torque the 17 bolts.

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

(d) Install the output shaft rear taper roller bearing outer race.

(e) Install the adjusting shim.

HINT:

When reusing the output shaft bearing, first install a shim of the

same thickness as before. If installing a new taper roller bear-

ing, first select and install a shim of lesser thickness than be-

fore.

(f)

Install the rear bearing retainer.

(g) Using a torx wrench (T45), install and torque the 7 torx

screws.

Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

(h) Install a new lock nut to the output shaft.

(i)

Turn the output shaft right and left 2 or 3 times to allow the

bearing to settle.

AVENSIS/CORONA SUP (RM781E)

MX–22

MANUALTRANSAXLE (E351)

–

MANUALTRANSAXLEASSEMBLY

(j)

Using a torque wrench, measure the preload.

Preload (at starting):

New bearing

0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)

Reused bearing

0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)

If the preload is not within the specification, select an appropri-

ate adjusting shim.

Z12593

Mark

0

Thickness mm (in.)

1.30(0.0512)

1.35(0.0531)

1.40(0.0551)

1.45(0.0571)

1.50(0.0591)

1.55(0.0610)

1.60(0.0630)

1.65(0.0650)

1.70(0.0669)

1.75(0.0689)

1.80(0.0709)

1.85(0.0728)

1.90(0.0748)

Mark

D

E

Thickness mm (in.)

1.95(0.0768)

2.00(0.0787)

2.05(0.0807)

2.10(0.0827)

2.15(0.0846)

2.20(0.0866)

2.25(0.0886)

2.30(0.0906)

2.35(0.0925)

2.40(0.0945)

2.45(0.0965)

2.50(0.0984)

–

1

2

F

3

G

H

J

4

5

6

K

7

L

8

M

N

P

9

A

B

C

Q

–

(k) Remove the lock nut.

(l)

Remove these parts. Removal is in the reverse order of

installation.

S

Rear bearing retainer

Shim

Transmission case

Output shaft assembly

Output shaft rear bearing outer race

AVENSIS/CORONA SUP (RM781E)

MX–23

MANUALTRANSAXLE (E351)

–

INPUT SHAFT

MX028–06

COMPONENTS

Synchronizer Ring

Spacer

4th Gear

Snap Ring

Needle Roller Bearing

3rd Gear

NeedleRoller

Bearing

Rear Bearing

Spring

Snap Ring

Synchronizer Ring

Input Shaft

No. 2 Hub Sleeve

No. 2 Clutch Hub

Shifting Key

z Input Shaft Front Bearing Inner Race

z Non–reusable part

D08963

AVENSIS/CORONA SUP (RM781E)

MX–24

MANUALTRANSAXLE (E351)

–

INPUT SHAFT

MX029–04

DISASSEMBLY

1.

MEASURE 3RD AND 4TH GEARS THRUST CLEAR-

ANCE

Using a feeler gauge, measure the thrust clearance.

Minimum clearance:

3rd gear and 4th gear: 0.10 mm (0.0039 in.)

Maximum clearance:

3rd gear: 0.40 mm (0.0157 in.)

4th gear: 0.60 mm (0.0236 in.)

3rd Gear

4th Gear

Q06369

Q00111

Q05165

Q00115

2.

CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Maximum clearance:

3rd gear: 0.053 mm (0.0021 in.)

4th gear: 0.051 mm (0.0020 in)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

3.

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

4. REMOVE REAR BALL BEARING AND 4TH GEAR

Using SST and a press, remove the rear bearing.

SST 09950–00020

5.

REMOVE SNAP RING

SST

REMOVE NEEDLE ROLLER BEARING, SPACER AND

SYNCHRONIZER RING

REMOVE SNAP RING

6.

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

7.

REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRO-

NIZER RING AND 3RD GEAR

Using a press, remove the No.2 hub sleeve, 3rd gear and syn-

chronizer rings.

8.

REMOVE NEEDLE ROLLER BEARING

AVENSIS/CORONA SUP (RM781E)

MX–25

MANUALTRANSAXLE (E351)

–

INPUT SHAFT

MX02A–04

INSPECTION

1.

INSPECT 3RD 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 it does not lock, replace the synchronizer ring.

MT0780

WM0065

WM0064

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

the synchronizer ring back and gear spline end.

Minimum clearance: 0.65 mm (0.026 in.)

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

nizer ring.

2.

INSPECT 4TH 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:

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 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

AVENSIS/CORONA SUP (RM781E)

MX–26

MANUALTRANSAXLE (E351)

–

INPUT SHAFT

3.

MEASURE NO.2 SHIFT FORK AND HUB SLEEVE

CLEARANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.69 mm (0.027 in.)

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

hub sleeve.

WM0066

Z19371

Q00173

4.

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.

B

A

Minimum outer diameter:

Part A: 27.957 mm (1.1007 in.)

Part B: 35.984 mm (1.4167 in.)

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

Maximum runout: 0.03 mm (0.0012 in.)

AVENSIS/CORONA SUP (RM781E)

MX–27

MANUALTRANSAXLE (E351)

–

INPUT SHAFT

MX0D2–01

REASSEMBLY

HINT:

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

reassembly.

1.

INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE

(a) Install the 3 springs and shifting keys to the clutch hub.

(b) Install the hub sleeve to the clutch hub.

HINT:

Direct identification groove of the hub sleeve to front of the

transmission.

Press

D09373

2.

INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,

SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-

SEMBLY TO INPUT SHAFT

(a) Apply MP grease to the needle roller bearing.

(b) Assemble the needle roller bearings into the 3rd gear.

(c) Place the synchronizer rings on the gear and align the

ring slots with the shifting keys.

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

sleeve.

SST 09506–35010

SST

D09374

3.

INSTALL SNAP RING

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

Mark

Thickness mm (in.)

2.30(0.0906)

Mark

M

Thickness mm (in.)

2.50(0.0984)

2.55(0.1004)

2.60(0.1024)

–

H

J

2.35(0.0925)

N

K

L

2.40(0.0945)

P

2.45(0.0965)

–

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

Q00116

4.

MEASURE 3RD GEAR THRUST CLEARANCE

(See page MX–24)

AVENSIS/CORONA SUP (RM781E)

MX–28

MANUALTRANSAXLE (E351)

–

INPUT SHAFT

5.

INSTALL SPACER, SYNCHRONIZER RING, NEEDLE

ROLLER BEARING, 4TH GEAR AND REAR BALL

BEARING

(a) Install the spacer.

(b) Apply MP grease to the needle roller bearings.

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

slots with the shifting keys.

(d) Install the 4th gear.

SST

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

SST 09506–35010

N00494

6.

INSTALL SNAP RING

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

Mark

Thickness mm (in.)

2.35(0.0925)

2.40(0.0945)

2.45(0.0965)

2.50(0.0984)

Mark

Thickness mm (in.)

2.55(0.1004)

2.60(0.1024)

2.65(0.1043)

2.70(0.1063)

1

2

3

4

5

6

7

8

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

Q00118

7.

MEASURE 4TH GEAR THRUST CLEARANCE

(See page MX–24)

AVENSIS/CORONA SUP (RM781E)

MX–29

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

MX02C–06

COMPONENTS

Needle Roller Bearing

3rd Driven Gear

4th Driven Gear

Spacer

1st Gear Bearing Inner Race

Inner Race

2nd Gear

No.1 Hub Sleeve

Spacer

Spring

Needle Roller

Bearing

Output Shaft

Rear Bearing

z

1st Gear

Synchronizer Ring

No.1 Clutch Hub

Ball

Shifting Key

Output Shaft Front

Bearing

z

Synchronizer Ring

Output Shaft

z Non–reusable part

D08964

AVENSIS/CORONA SUP (RM781E)

MX–30

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

MX02D–05

DISASSEMBLY

1.

MEASURE 1ST AND 2ND GEARS THRUST CLEAR-

ANCE

Using a feeler gauge, measure the thrust clearance.

Minimum clearance:

1st Gear

1st gear: 0.25 mm (0.0098 – 0.0138 in.)

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

Maximum clearance:

2nd Gear

Q06370

1st gear: 0.40 mm (0.0157 in.)

2nd gear: 0.35 mm (0.0137 in.)

2.

CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Maximum clearance:

1st and 2nd gears: 0.053 mm (0.0020 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

Z00218

Z00219

Z00220

3.

REMOVE OUTPUT SHAFT REAR BEARING, 4TH

DRIVEN GEAR AND SPACER

(a) Using a press, remove the bearing and 4th driven gear.

(b) Remove the spacer.

4.

REMOVE 3RD DRIVEN GEAR AND 2ND GEAR

Using a press, remove the 3rd driven gear and 2nd gear.

5.

6.

REMOVE NEEDLE ROLLER BEARING, SPACER AND

SYNCHRONIZER RING

REMOVE INNER RACE AND BALL FROM OUTPUT

SHAFT

AVENSIS/CORONA SUP (RM781E)

MX–31

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

7.

REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST

GEAR

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

8.

REMOVE SYNCHRONIZER RING AND NEEDLE

ROLLER BEARING

Z00222

9.

REMOVE 1ST GEAR BEARING INNER RACE

Using SST and a press, remove the 1st gear bearing inner race.

SST 09950–00020

SST

Q06202

10. REMOVE OUTPUT SHAFT FRONT BEARING

Using SST, remove the output shaft front bearing.

SST 09950–00020, 09950–00030

SST

Q00296

AVENSIS/CORONA SUP (RM781E)

MX–32

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

MX02E–04

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:

D09375

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: 0.7 mm (0.028 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.

D09376

MT0780

MT0787

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 it does not lock, replace the synchronizer ring.

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

the synchronizer ring back and gear spline end.

Minimum clearance: 0.7 mm (0.028 in.)

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

nizer ring.

AVENSIS/CORONA SUP (RM781E)

MX–33

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

3.

MEASURE NO.1 SHIFT FORK AND HUB SLEEVE

CLEARANCE

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.

WM0066

Q06203

Q06191

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.

A

B

A

Minimum outer diameter:

Part A: 37.610 mm (1.4807 in.)

Part B: 34.502 mm (1.3584 in.)

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

Maximum runout: 0.03 mm (0.0012 in.)

AVENSIS/CORONA SUP (RM781E)

MX–34

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

MX02F–07

REASSEMBLY

HINT:

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

reassembly.

1.

INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE

(a) Install the 3 springs and shifting keys to the clutch hub.

(b) Install the hub sleeve to the clutch hub.

HINT:

Direct identification groove of the hub sleeve to the front of the

transmission.

Front

Q06204

2.

INSTALL 1ST GEAR BEARING INNER RACE

Using SST and a press, install the 1st gear bearing inner race.

SST 09506–35010

HINT:

Align the holes

SST

Align the hole of the output shaft and inner race.

Q06205

3.

INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,

SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO

OUTPUT SHAFT

(a) Apply MP grease to the needle roller bearing.

(b) Install the 1st gear.

(c) Place the synchronizer ring (for the 1st gear) on the gear

and align the ring slots with the shifting keys.

D08965

(d) Using SST and a press, install the 1st gear and No.1 hub

sleeve.

SST 09316–60011 (09316–00041)

4.

MEASURE 1ST GEAR THRUST CLEARANCE

(See page MX–30)

SST

Q06206

AVENSIS/CORONA SUP (RM781E)

MX–35

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

5.

INSTALL BALL ANDINNERRACETO OUTPUT SHAFT

HINT:

Align the groove of the inner race and ball.

Q06314

D09377

N00495

Z00390

Z00391

6.

INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-

CHRONIZER RING, 2ND GEAR AND 3RD DRIVEN

GEAR

(a) Install the spacer.

(b) Apply MP grease to the needle roller bearing.

(c) Place the synchronizer rings (for the 2nd gear) on the

gear.

NOTICE:

Do not install the synchronizer ring for the 1st gear.

(d) Install the 2nd gear.

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

NOTICE:

Align the clutch hub grooves with the projections on the

synchronizer ring.

7.

MEASURE 2ND GEAR THRUST CLEARANCE

(See page MX–30)

8.

INSTALL SPACER AND 4TH DRIVEN GEAR

(a) Install the spacer.

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

9.

INSTALL OUTPUT SHAFT REAR BEARING

Using SST and a press, install the bearing.

SST 09506–30012

SST

AVENSIS/CORONA SUP (RM781E)

MX–36

MANUALTRANSAXLE (E351)

–

OUTPUT SHAFT

10. INSTALL OUTPUT SHAFT FRONT BEARING

Using SST and a press, install a new output shaft front bearing.

SST 09316–60011 (09316–00071)

SST

Z00392

AVENSIS/CORONA SUP (RM781E)

MX–37

MANUALTRANSAXLE (E351)

–

SHIFTAND SELECT LEVER SHAFT

SHIFT AND SELECT LEVER SHAFT

MX02I–06

COMPONENTS

Control Shaft Cover

z

Oil Seal

Dust Boot

Shift Interlock Plate

Transmission Oil Baffle

No. 1 Compression Spring

Snap Ring

No. 1 Select Spring Seat

Slotted Spring Pin

No. 2 Shift Inner Lever

No. 2 Compression Spring

Slotted Spring Pin

No. 2 Select Spring Seat

Snap Ring

No. 1 Shift Inner Lever

Shift and Select Lever Shaft

z Non–reusable part

Apply MP grease

D10265

AVENSIS/CORONA SUP (RM781E)

MX–38

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

DIFFERENTIAL CASE

MX060–04

COMPONENTS

Pinion Thrust Washer

z Oil Seal

Pinion Gear

Straight Pin

Pinion Shaft

Side Gear

Side Gear Thrust

Washer

z Tapered Roller Bearing

and Outer Race

x16

106(1,080, 78)

Oil Baffle

Diferential

Case

Speed Sensor

Drive Gear

Ring Gear

z Tapered Roller Bearing and Outer Race

Shim

z Oil Seal

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

D10266

AVENSIS/CORONA SUP (RM781E)

MX–39

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

MX09A–03

DISASSEMBLY

1.

Speed sensor drive gear side:

SST

REMOVE TAPERED ROLLER BEARING FROM DIF-

FERENTIAL CASE

(a) Using SST, remove the tapered roller bearing.

SST 09950–00020, 09950–00030, 09950–40011

(09957–04010), 09950–60010 (09951–00530)

HINT:

Set the claw of SST to the bearing inner race securely.

(b) Remove the speed sensor drive gear.

SST

D08953

2.

REMOVE RING GEAR

x16

Matchmarks

(a) Place matchmarks on the ring gear and differential case.

(b) Remove the 16 bolts.

(c) Using a copper hammer, tap on the ring gear to remove

it from the differential case.

D08954

3.

Ring gear side:

REMOVE TAPERED ROLLER BEARING FROM DIF-

FERENTIAL CASE

Using SST, remove the tapered roller bearing.

SST 09950–00020, 09950–00030, 09950–40011

(09957–04010), 09950–60010 (09951–00450)

HINT:

SST

Set the claw of SST to the bearing inner race at the position

where the differential case is indented.

SST

Q04969

4.

INSPECT SIDE GEAR BACKLASH

Using a dial indicator, measure the backlash of one side gear

while holding one pinion toward the differential case.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install the correct

thrust washer to the side gears.

Q00807

AVENSIS/CORONA SUP (RM781E)

MX–40

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

5.

DISASSEMBLE DIFFERENTIAL CASE

(a) Using a pin punch and hammer, drive out the straight pin.

(b) Remove the pinion shaft from the differential case.

(c) Remove the 2 pinions and side gears with the 4 thrust

washers from each gear.

6.

Transmission Case Side:

IF NECESSARY, REPLACE OIL SEAL AND TAPERED

ROLLER BEARING OUTER RACE

(a) Using a screwdriver and a hammer, remove the oil seal.

(b) Using a brass bar and hammer, drive out the tapered roll-

er bearing outer race lightly and evenly.

(c) Remove the shim.

(d) Install the shim.

HINT:

D09378

D09379

D08955

D08956

First select and install a shim of lesser thickness than before.

(e) Using SST and a press, install a new tapered roller bear-

ing outer race.

SST 09316–60011 (09316–00011, 09316–00041)

NOTICE:

SST

When replacing the tapered roller bearing outer race, re-

place the tapered roller bearing along with it.

(f)

Using SST and a hammer, drive in a new oil seal.

SST 09316–60010 (09316–00011, 09316–00031)

Drive in depth: 3.5 ± 0.5 mm (0.138 ± 0.020 in.)

SST

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

3.5 ± 0.5 mm

7.

Transaxle Case Side:

IF NECESSARY, REPLACE OIL SEAL AND TAPERED

ROLLER BEARING OUTER RACE

(a) Using a screwdriver and hammer, drive out the oil seal

from the transaxle case.

(b) Using SST, remove the tapered roller bearing outer race.

SST 09316–60011 (09316–00011, 09316–00021)

(c) Remove the oil baffle.

SST

AVENSIS/CORONA SUP (RM781E)

MX–41

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

(d) Install the oil baffle.

HINT:

Install the oil baffle projection into the case side cutout.

(e) Using SST and a press, install a new tapered roller bear-

ing outer race.

SST 09950–60020 (09951–00890), 09950–70010

(09951–00150)

SST

D08957

(f)

Using SST and a hammer, drive in a new oil seal.

SST 09316–60011 (09316–00011, 09316–00041)

Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)

(g) Coat the oil seal lip with MP grease.

SST

D08958

AVENSIS/CORONA SUP (RM781E)

MX–42

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

MX09B–03

REASSEMBLY

HINT:

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

reassembly.

1.

ASSEMBLE DIFFERENTIAL CASE

(a) Install the correct thrust washers and side gears.

Refer to the table below, select thrust washers which will

ensure that the backlash is within the specification. Try to

select washers of the same size for both sides.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

Thickness mm (in.)

1.00(0.0394)

Thickness mm (in.)

1.20(0.0472)

D06021

1.10(0.0433)

1.30(0.0512)

(b) Install the thrust washers and side gears in the differential

case.

(c) Install the pinion shaft.

(d) Using a dial indicator, check the side gear backlash.

Measure the side gear backlash while holding one pinion

toward the differential case.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install a thrust

washer of different thickness.

(e) Using a pin punch and hammer, drive in the straight pin

through the differential case and hole in the pinion shaft.

Q00807

(f)

Using a chisel and hammer, caulk the pin holes around

the circumference of the differential case.

AVENSIS/CORONA SUP (RM781E)

MX–43

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

2.

INSTALL RING GEAR ON DIFFERENTIAL CASE

(a) Clean the contact surface of the differential case.

(b) Heat the ring gear in boiling water.

(c) Carefully take the ring gear out of the water.

(d) After the moisture on the ring gear has completely evapo-

rated, quickly install the ring gear to the differential case.

HINT:

Case Side

Align the matchmarks on the differential case and contact the

ring gear.

D08961

(e) Temporarily install the 16 set bolts.

CAUTION:

The ring gear set bolts should not be tightened until the

ring gear has cooled sufficiently.

(f)

After the ring gear has cooled sufficiently, torque the ring

gear set bolts uniformly at a time.

Torque: 106 N·m (1,080 kgf·cm, 78 ft·lbf)

3.

Ring gear side:

INSTALL TAPERED ROLLER BEARING

Using SST and a press, install a new tapered roller bearing.

SST 09316–60011 (09316–00011)

NOTICE:

SST

When replacing the tapered roller bearing outer race, re-

place the tapered roller bearing along with it.

HINT:

Set SST to the bearing inner race securely.

D08959

D08960

D08962

4.

Speed sensor drive gear side:

INSTALL TAPERED ROLLER BEARING

(a) Place the speed sensor drive gear in position to stop it

turning, and install the speed sensor drive gear.

NOTICE:

Be sure to install the speed sensor drive gear in the correct

direction, as shown in the illustration.

Case Side

(b) Using SST, a steel plate and press, install a new tapered

roller bearing.

SST 09316–20011, 09316–60011 (09316–00011)

NOTICE:

When replacing the tapered roller bearing outer race, re-

place the tapered roller bearing along with it.

HINT:

SST

Set SST to the bearing inner race securely.

AVENSIS/CORONA SUP (RM781E)

MX–44

MANUALTRANSAXLE (E351)

–

DIFFERENTIALCASE

5.

INSPECT DIFFERENTIAL TAPERED ROLLER BEAR-

ING PRELOAD

NOTICE:

Perform this only when replacing the tapered roller bearing

and outer race of the differential case.

(a) Install the differential case assembly to the transaxle

case.

(b) Install the transmission case to the transaxle case with

the 17 bolts.

CM0061

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

(c) Using SST and a torque wrench, turn the differential case

assembly right and left 2 or 3 times to allow the bearings

to settle.

SST 09564–32011

(d) Using SST and a torque wrench, measure the preload.

SST 09564–32011

SST

Preload (at starting):

New bearing

0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)

Reused bearing

D09380

0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)

If the preload is not within the specification, remove the trans-

mission case side outer race of the tapered roller bearing with

SST (See page MX–39). Select an appropriate shim.

Mark

Thickness mm (in.)

2.00(0.0787)

2.05(0.0807)

2.10(0.0827)

2.15(0.0846)

2.20(0.0866)

2.25(0.0886)

2.30(0.0906)

2.35(0.0925)

2.40(0.0945)

Mark

9

Thickness mm (in.)

2.45(0.0965)

2.50(0.0984)

2.55(0.1004)

2.60(0.1024)

2.65(0.1043)

2.70(0.1063)

2.75(0.1083)

2.80 (0.1102)

2.85 (0.1122)

0

1

2

3

4

5

6

7

8

A

B

C

D

E

F

G

H

(e) Remove the 17 bolts and transmission case.

(f) Remove the differential case assembly.

AVENSIS/CORONA SUP (RM781E)

MX–45

MANUALTRANSAXLE (E351)

–

SHIFT LEVER AND CONTROL CABLE

MX09C–02

COMPONENTS

Air Flow Meter

Connector

Air Cleaner Case

Assembly

with Air Hose

D06624

Console Box Assembly

Shift Lever Knob

Parking Brake Cover

Shift Lever Assembly

Front Ash Receptacle

Cap

12 (120, 9)

Clip

Cap

4.9 (50, 43 in.·lbf)

Clip

Washer

Air Duct

Transmission Control Cable Bracket

Select Control Cable

Shift Cable Grommet

Shift Control Cable

Clip

Shift Cable Grommet

Retainer

Washer

Clip

4.9 (50, 43 in.·lbf)

Washer

: Specified torque

N·m (kgf·cm, ft·lbf)

D06625

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (E351) for Your Toyota Avensis 4 Door First Generation (1997-2003)

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