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

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)

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

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