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

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)

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

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