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

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)

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

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