Get MANUAL TRANSAXLE (S54, S55) Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MANUAL TRANSAXLE (S54, S55)

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

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

MANUAL TRANSAXLE ASSEMBLY . . . . . . . .

MX–1

MX–2

MX–8

INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . MX–19

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . MX–27

SHIFT AND SELECT LEVER SHAFT . . . . . . . MX–34

DIFFERENTIAL CASE . . . . . . . . . . . . . . . . . . . . MX–35

SHIFT LEVER AND CONTROL CABLE . . . . . MX–42

MX–1

MANUALTRANSAXLE (S54, S55)

–

TROUBLESHOOTING

MX030–04

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 parts.

Symptom

Suspect Area

See page

1. Oil (Level low)

2. Oil (Wrong)

MX–3

MX–8

Noise

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

1. Oil (Level too high)

MX–3

MX–8

2. Gasket (Damaged)

Oilleakage

3. Oil seal (Worn or damaged)

4. O–ring (Worn or damaged)

1. Control cable (Faulty)

MX–42

MX–8

2. Synchronizer ring (Worn or damaged)

MX–19

MX–27

MX–8

Hard to shift or will not shift

3. Shift key spring (Damaged)

MX–19

MX–27

1. Locking ball spring (Damaged)

2. Shift fork (Worn)

MX–8

Jumps out of gear

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

AVENSIS/CORONA SUP (RM781E)

MX–2

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

MX06M–02

COMPONENTS

Air Cleaner Case Assembly with Air Hose

RH Drive Shaft

Battery

64(650, 47)

Tray

64 (650, 47)

Back–Up Light SwitchConnector

Speed Sensor Connector

Engine Rear Mounting

Bracket

44(450,33)

87(890, 64)

64(650, 47)

Intake Manifold Stay

Stiffener Plate

64 (650, 47)

52 (530, 38)

Ground Cable

Clip

21(210,15)

25(250,18)

87 (890, 64)

Washer

43(440,32)

Control Cable

Transaxle

43(440,32)

Engine Left

Mounting Bracket

Snap Ring

12 (120, 9)

z

Clutch Release Cylinder

LH Drive Shaft

64 (650, 47)

216(2,200, 159)

Starter

Lock Nut Cap

z

Cotter Pin

z Gasket

43 (430, 32)

49 (500, 36)

39 (400, 29)

4.9(50,43in.·lbf)

12 (120, 9)

Tie Rod End

127(1,300, 94)

Engine Mounting

Center Member

43 (430, 32)

Spring

73 (740, 54)

Front Exhaust Pipe

Hole Plug

72 (740, 53)

62 (630, 46)

Hole Cover

Hole Plug

Front Transport Hook

LH Engine Under Cover

73 (740, 54)

39 (400, 29)

N·m (kgf·cm, ft·lbf)

zNon–reusable part

: Specifiedtorque

RHEngineUnderCover

D09355

AVENSIS/CORONA SUP (RM781E)

MX–3

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLE UNIT

MX06N–02

REMOVAL

1.

REMOVE BATTERY AND AIR CLEANER CASE AS-

SEMBLY WITH AIR HOSE

2.

REMOVE STARTER

Starter Set Bolt

(a) Disconnect the connector and wire from the starter.

(b) Remove the 2 bolts and starter.

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

D02128

D02129

D02130

D02131

3.

DISCONNECT CLUTCH RELEASE CYLINDER AND

LINE

A

(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 clutch release cyl-

inder and line.

B

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

4.

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

5. DISCONNECT CONTROL CABLE

(a) Remove the 2 clips and washers.

(b) Remove the 2 clips from the cables.

(c) Disconnect the 2 control cables from the transaxle.

DISCONNECT GROUND CABLE

6.

DISCONNECT BACK–UP LIGHT SWITCH AND SPEED

SENSOR CONNECTORS

7.

REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING

BOLTS

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

AVENSIS/CORONA SUP (RM781E)

MX–4

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLE UNIT

8.

INSTALL ENGINE SUPPORT FIXTURE

D02132

9.

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

D02133

10. 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)

11. REMOVE FRONT WHEEL

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

12. RAISE VEHICLE

NOTICE:

Make sure that the vehicle is securely supported.

13. REMOVE LH AND RH ENGINE UNDER COVERS

D02134

D02135

D02136

14. DRAIN TRANSAXLE OIL

Oil grade: API GL–4 or GL–5

Filler Plug

Viscosity: SAE 75W–90

Capacity: 2.2 liters (2.3 US qts, 1.9 lmp. qts)

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

15. REMOVE LH AND RH DRIVE SHAFTS

(See page SA–3)

Oil Level

0–5 mm

Drain Plug

16. REMOVE FRONT EXHAUST PIPE

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

manifold.

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

(b) Remove the 2 bolts, nuts, gasket and front exhaust pipe.

Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–5

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLE UNIT

17. 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.

D02165

D02137

D02138

D02139

D02140

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

(d) Remove the 7 bolts and center member.

Torque:

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

Bolt B: 72 N·m (730 kgf·cm, 53 ft·lbf)

18. JACK UP TRANSAXLE SLIGHTLY

Using a transmission jack, support the transaxle.

A

B

A

19. REMOVE ENGINE REAR MOUNTING BRACKET

Remove the 4 bolts and bracket.

Torque:

A

B

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

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

20. REMOVE INTAKE MANIFOLD STAY

Remove the bolt, nut and intake manifold stay.

Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)

21. REMOVE STIFFENER PLATE AND TRANSAXLE LOW-

ER SIDE MOUNTING BOLT

(a) Remove the 6 bolts and stiffener plate.

Torque:

Bolt A: 43 N·m (440 kgf·cm, 32 ft·lbf)

Bolt B: 21 N·m (210 kgf·cm, 15 ft·lbf)

(b) Remove the bolt of transaxle lower side.

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

A

B

AVENSIS/CORONA SUP (RM781E)

MX–6

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLE UNIT

22. REMOVE TRANSAXLE

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

gine.

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.

AVENSIS/CORONA SUP (RM781E)

MX–7

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLE UNIT

MX06O–02

INSTALLATION

Installation is in the reverse order of removal (See page MX–3).

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–8

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

MANUAL TRANSAXLE ASSEMBLY

MX034–04

COMPONENTS

Release Bearing

Retainer

L

Straight Screw Plug

13 (130, 9)

5.4 (55, 48 in.·lbf)

Shift and Select Lever

Assembly

L

Lock Ball

Assembly

Speed Sensor

37 (375, 27)

Reverse

Restrict Pin

29 (300, 22)

37 (380, 27)

Back–Up

7.4 (75, 65 in.·lbf)

Selecting Bellcrank

Light Switch

44 (450, 33)

Slotted

Spring Pin

Shim

z

O–Ring

Differential Side

Bearing Retainer

Transmission

Case Protector

x 6

18 (185, 13)

Release

Bearing

18 (185, 13)

L

Transmission

Case

Drain Plug

49 (500, 36)

Boot

Clutch Release

Fork Support

47 (480, 35)

zGasket

Release Fork

42 (430, 31)

L

Filler Plug

49 (500, 36)

x 5

x 17

Rear Bearing Retainer

z Lock Nut

29 (300, 22)

Lock Bolt

29 (300, 22)

123 (1,250, 90)

zGasket

Spacer

Snap Ring

Needle Roller Bearing

5th Driven Gear

5th Gear

No.3 Clutch Hub Assembly

No.3 Hub Sleeve

No.3 Shift Fork

18 (185, 13)

Transmission Case Cover

Snap Ring

x 8

: Specified torque

Non–reusable Part

N·m (kgf·cm, ft·lbf)

29 (300, 22)

L

z

L

Precoated Part

D02449

AVENSIS/CORONA SUP (RM781E)

MX–9

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

Reverse Shift Fork

Interlock Pin

No.1 Shift Fork

Transaxle Case

z

Oil Seal

No.2 Shift Fork Shaft

No.2 Shift Fork

Transaxle Case

Receiver

7.4 (75, 65 in.·lbf)

No.1 Shift Head

No.1 Shift Fork Shaft

Differential Case Assembly

Input Shaft Front Bearing

z

Bearing Lock Plate

Reverse Shift Arm

Input Shaft Assembly

Output Shaft Assembly

18 (185, 13)

Reverse Idler Gear

and Shaft

z

Output Shaft Front Bearing

Output Shaft Cover

N·m (kgf·cm, ft·lbf) : Specified torque

z

Non–reusable Part

Z18962

AVENSIS/CORONA SUP (RM781E)

MX–10

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

MX035–04

DISASSEMBLY

1.

2.

REMOVE RELEASE FORK AND BEARING

REMOVE BACK–UP LIGHT SWITCH

Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)

REMOVE BOLT AND SPEED SENSOR

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

REMOVE RELEASE BEARING RETAINER

3.

4.

Remove the 3 bolts and retainer.

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

5.

REMOVE SELECTING BELLCRANK

Remove the 2 bolts and selecting bellcrank.

Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

6.

REMOVE TRANSMISSION CASE COVER

(a) Remove the 8 bolts.

Sealant:

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

242 or equivalent

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

(b) Using a plastic hammer, tap the transmission case cover

and remove it.

FIPG:

FIPG

Z18142

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

lent

7.

REMOVE LOCK BALL ASSEMBLY

Sealant:

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

242 or equivalent

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

REMOVE SHIFT AND SELECT LEVER ASSEMBLY

8.

HINT:

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

Apply FIPG to the underside of the flanged portion of the control

shaft cover.

FIPG:

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

lent

Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–11

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

9.

REMOVE OUTPUT SHAFT LOCK NUT

(a) Unstake the nut.

(b) Engage the gear to the double meshing, with the gear into

1st and 3rd or 2nd and 4th.

Q02530

(c) Remove the lock nut clockwise and remove it.

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

HINT:

Install

The lock nut has LH threads.

(d) Disengage the double meshing of the gear.

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

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

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

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

Remove

Q05696

Q05200

Z00455

Q02695

11. REMOVE 5TH DRIVEN GEAR

Using SST, remove the 5th driven gear.

SST 09950–40011

SST

HINT:

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

Using SST, install the 5th driven gear.

SST 09309–12020

SST

12. MEASURE 5TH GEAR THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance.

Maximum clearance:

0.57 mm (0.0224 in.)

Minimum clearance:

0.10 mm (0.0039 in.)

AVENSIS/CORONA SUP (RM781E)

MX–12

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

13. MEASURE 5TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Maximum clearance:

0.048 mm (0.0019 in.)

Minimum clearance:

0.009 mm (0.0004 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or input shaft.

14. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR

(a) Using 2 screwdrivers and a hammer, tap out the snap

ring.

Q02696

HINT:

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

Select a snap ring that allows the minimum axial play.

Mark

Thickness mm (in.)

Mark

Thickness mm (in.)

2.20–2.25

2.60–2.65

13

21

(0.0866–0.0886)

(0.1024–0.1043)

2.25–2.30

2.65–2.70

14

15

16

17

18

19

20

22

23

24

25

26

27

–

(0.0886–0.0906)

(0.1043–0.1063)

2.30–2.35

2.70–2.75

(0.0906–0.0925)

(0.1063–0.1083)

2.35–2.40

2.75–2.80

(0.0925–0.0945)

(0.1083–0.1102)

2.40–2.45

2.80–2.85

(0.0945–0.0965)

(0.1102–0.1122)

2.45–2.50

2.85–2.90

(0.0965–0.0984)

(0.1122–0.1142)

2.50–2.55

2.90–2.95

(0.0984–0.1004)

(0.1142–0.1161)

2.55–2.60

–

(0.1004–0.1024)

(b) Using SST and a socket wrench, remove the No.3 clutch

hub with the synchronizer ring.

SST 09950–30011

SST

Socket Wrench

Q02726

AVENSIS/CORONA SUP (RM781E)

MX–13

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

HINT:

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

Using SST and a press, install the No.3 clutch hub assembly.

SST 09612–22011

SST

(c) Remove the 5th gear.

15. REMOVE NEEDLE ROLLER BEARING

Q02682

16. REMOVE REAR BEARING RETAINER

Remove the 5 bolts and retainer.

Sealant:

x 5

Part No.08833–00070, THREE BOND 1324 or equiva-

lent

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

17. REMOVE SNAP RING

Using a snap ring expander, remove the 2 snap rings.

HINT:

Q05785

If it is difficult to remove and install the snap rings, pull up the

shafts.

18. REMOVE REVERSE IDLER GEARSHAFTLOCKBOLT

AND GASKET

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

19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER

AND SHIM

x17

x 6

Remove the 6 bolts, retainer and shim.

Sealant:

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

242 or equivalent

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

Q05826

20. REMOVE TRANSMISSION CASE

(a) Remove the 17 bolts.

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

(b) Using a plastic hammer, tap the transmission case and re-

move it.

FIPG:

Part No. 08833–00090, THREE BOND 1281 or equiva-

lent

FIPG

Q09474

AVENSIS/CORONA SUP (RM781E)

MX–14

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

21. REMOVE REVERSE IDLER GEAR AND SHAFT

(a) Pull out the shaft.

(b) Remove the idler gear and thrust washer.

22. REMOVE REVERSE SHIFT ARM

(a) Shift the fork shaft into reverse.

(b) Remove the 2 bolts and pull off the reverse shift arm.

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

23. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT

HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE

SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUT-

PUT SHAFTS ASSEMBLY

Q05827

24. REMOVE DIFFERENTIAL CASE ASSEMBLY

25. REMOVE MAGNET FROM TRANSAXLE CASE

26. REMOVE NO.2 FORK SHAFT

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

Sealant:

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

242 or equivalent

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

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

spring pin.

(c) Pull out the shaft.

27. SEPARATE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT

HEAD, NO.1, NO.2 SHIFT FORKS AND REVERSE

SHIFT FORK

(a) Mount the shift forks to the vise.

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

spring pin from the No.1 fork shaft.

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

spring pin from the No.1 fork shaft, as shown in the il-

lustration.

Q03065

(d) Separate the No.1 shift fork shaft, No.1 shift head, No.1

and No.2 shift forks and reverse shift fork.

AVENSIS/CORONA SUP (RM781E)

MX–15

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

28. 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–16

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

MX06P–02

INSPECTION

1.

INSPECT NO.5 SYNCHRONIZER RING

(a) Check 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 the braking effect is insufficient, replace the synchronizer ring.

MT0782

2.

INSPECT NO.3 SHIFT FORK AND NO.3 HUB SLEEVE

CLEARANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.4 mm (0.0157 in.)

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

hub sleeve.

WM0066

3.

IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING

(a) Remove the 2 bolts and transaxle case receiver.

(b) Using SST, pull out the bearing.

SST 09308–00010

SST

Z00409

(c) Using SST and a press in a new bearing.

SST 09310–35010

(d) Install the transaxle case receiver and torque the 2 bolts.

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

SST

Z00410

4.

IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING

(a) Remove the bolt and bearing lock plate.

(b) Using SST, pull out the bearing.

SST 09308–00010

SST

Z00411

AVENSIS/CORONA SUP (RM781E)

MX–17

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

(c) Using SST and a press in a new bearing.

SST 09310–35010

SST

(d) Install the bearing lock plate and torque the bolt.

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

SST

Front

Z00593

5.

IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL

SEAL

0 – 0.5 mm

(a) Using a screwdriver, pry out the oil seal.

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

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

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

SST

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

Z00413

6.

IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using a hexagon wrench, remove the straight 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.

13.5 ± 0.5 mm

Drive in depth: 13.5±0.5 mm (0.531±0.020 in.)

(e) Apply sealant to the plug threads.

Sealant:

Z00596

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

242 or equivalent

(f)

Using a hexagon wrench, install and torque the straight

screw plug.

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–18

MANUALTRANSAXLE (S54, S55)

–

MANUALTRANSAXLEASSEMBLY

MX037–04

REASSEMBLY

Reassembly is in the reverse order of disassembly (See page MX–10).

HINT:

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

NOTICE:

When working with FIPG material, you must observe the following items.

S

Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-

faces.

S

Thoroughly clean all components to remove all the loose material.

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.

Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must

be removed and reapplied.

AVENSIS/CORONA SUP (RM781E)

MX–19

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

MX038–04

COMPONENTS

Spacer

NeedleRoller Bearing

4th Gear

Rear Bearing

Snap Ring

Synchronizer Ring

Shifting Key

Input Shaft

Snap Ring

3rd Gear

NeedleRoller Bearing

No.2 Hub Sleeve

ShiftingKeySpring

Q02560

AVENSIS/CORONA SUP (RM781E)

MX–20

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

MX039–04

DISASSEMBLY

1.

INSPECT 3RD AND 4TH GEARS THRUST CLEAR-

ANCES

Using a feeler gauge, measure each thrust clearance.

Maximum clearance:

3rd Gear

3rd gear: 0.35 mm (0.0138 in.)

4th gear: 0.45 mm (0.0177 in.)

Minimum clearance:

3rd gear: 0.10 mm (0.0039 in.)

4th gear: 0.10 mm (0.0039 in.)

4th Gear

Q05793

Z00417

Q05201

2.

INSPECT 3RD AND 4TH GEARS RADIAL CLEAR-

ANCES

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Maximum clearance:

0.051 mm (0.0020 in.)

Minimum clearance:

0.009 mm (0.0004 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

REMOVE SNAP RING

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

3.

4.

REMOVE REAR BEARING, 4TH GEAR, NEEDLE

ROLLER BEARING, SPACER AND SYNCHRONIZER

RING FROM INPUT SHAFT

SST

(a) Using SST and a press, remove the 4th gear and rear

bearing.

SST 09950–00020

(b) Remove the needle roller bearings, spacer and synchro-

nizer ring.

5.

REMOVE SNAP RING

Using a snap ring expander, remove the snap ring.

AVENSIS/CORONA SUP (RM781E)

MX–21

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

6.

REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR

SYNCHRONIZER RING AND NEEDLE ROLLER BEAR-

ING

SST

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

synchronizer ring and needle roller bearings.

SST 09950–00020

NOTICE:

Be careful not to mistake the 3rd gear synchronizer ring for

the 4th gear synchronizer ring.

CM0064

7.

REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND

SPRING FROM NO.2 CLUTCH HUB

Using a screwdriver, remove the 3 shifting keys and 2 springs

from the No.2 clutch hub.

SM0269

AVENSIS/CORONA SUP (RM781E)

MX–22

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

MX03A–04

INSPECTION

1.

INSPECT SYNCHRONIZER RING

(a) Check 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.

WM0064

WM0065

WM0066

(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:

3rd gear: 0.65 mm (0.0256 in.)

4th gear: 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.

2.

INSPECT NO.2 SHIFT FORK AND HUB SLEEVE

CLEARANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.4 mm (0.0157 in.)

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

hub sleeve.

AVENSIS/CORONA SUP (RM781E)

MX–23

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

3.

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.

A

B

C

D

Minimum outer diameter:

Part A: 26.987 mm (1.0625 in.)

Part B: 32.484 mm (1.2789 in.)

Part C: 33.100 mm (1.3031 in.)

Part D: 29.987 mm (1.1806 in.)

If the outer diameter is less than the minimum, replace the input

shaft.

SM0182

(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 input shaft.

CM0013

AVENSIS/CORONA SUP (RM781E)

MX–24

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

MX03B–04

REASSEMBLY

HINT:

Engine

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

reassembly.

Side

1.

INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE

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

(b) Install the shifting key springs under the shifting keys.

NOTICE:

Install the key springs positioned so that their end gaps are

not in line.

SM0282

2.

INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,

SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-

SEMBLY TO INPUT SHAFT

(a) Apply gear oil to the needle roller bearings.

(b) Place the synchronizer ring (for the 3rd gear) on the gear

and align the ring slots with the shifting keys.

NOTICE:

Do not install the synchronizer ring for 4th gear.

SM0193

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

Z00419

AVENSIS/CORONA SUP (RM781E)

MX–25

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

3.

INSTALL SNAP RING

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

Mark

Thickness mm (in.)

1

2

3

4

5

6

1.95–2.00 (0.0768–0.0787)

2.00–2.05 (0.0787–0.0807)

2.05–2.10 (0.0807–0.0827)

2.10–2.15 (0.0827–0.0846)

2.15–2.20 (0.0846–0.0866)

2.20–2.25 (0.0866–0.0886)

Z00604

(b) Using a snap ring expander, install the snap ring.

4.

INSPECT 3RD GEAR THRUST CLEARANCE

(See page MX–20)

5.

INSTALL SYNCHRONIZER RING, NEEDLE ROLLER

BEARING, SPACER, 4TH GEAR AND REAR BALL

BEARING

(a) Apply gear oil to the needle roller bearings.

(b) Install the spacer and needle roller bearings.

(c) Place the synchronizer ring on the gear.

SM0189

SM0190

SM0049

HINT:

Align the ring slots with the shifting keys and the ring projections

with the hub slots.

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

SST 09608–00071

SST

AVENSIS/CORONA SUP (RM781E)

MX–26

MANUALTRANSAXLE (S54, S55)

–

INPUT SHAFT

6.

INSTALL SNAP RING

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

Mark

A

Thickness mm (in.)

2.15–2.20(0.0846–0.0866)

2.20–2.25(0.0866–0.0886)

2.25–2.30(0.0886–0.0906)

2.30–2.35(0.0906–0.0925)

2.35–2.40(0.0925–0.0945)

B

C

D

E

SM0050

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

7.

INSPECT 4TH GEAR THRUST CLEARANCE

(See page MX–20)

AVENSIS/CORONA SUP (RM781E)

MX–27

MANUALTRANSAXLE (S54, S55)

–

OUTPUT SHAFT

MX03C–04

COMPONENTS

Output Shaft

Spacer

1st Gear

Needle Roller Bearing

Synchronizer Ring

No.1 Hub Sleeve

Shifting Key

Shifting Key Spring

No.1 Clutch Hub

Needle Roller Bearing

Ball

Spacer

Rear Bearing

Synchronizer Ring

2nd Gear

2nd Gear Bushing

3rd Driven Gear

4th Driven Gear

Q02544

AVENSIS/CORONA SUP (RM781E)

MX–28

MANUALTRANSAXLE (S54, S55)

–

OUTPUT SHAFT

MX03D–03

DISASSEMBLY

1.

INSPECT 1ST AND 2ND GEARS THRUST CLEAR-

ANCES

Using a feeler gauge, measure each thrust clearance.

Maximum clearance:

2nd Gear

1st Gear

1st gear: 0.29 mm (0.0114 in.)

2nd gear: 0.34 mm (0.0134 in.)

Minimum clearance:

1st gear: 0.10 mm (0.0039 in.)

2nd gear: 0.10 mm (0.0039 in.)

Q05794

2.

INSPECT 1ST AND 2ND GEARS RADIAL CLEAR-

ANCES

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Maximum clearance:

0.051 mm (0.0020 in.)

Minimum clearance:

0.009 mm (0.0004 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

SM0137

CM0065

MT0063

3.

REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR

AND OUTPUT GEAR SPACER

SST

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

4th driven gear.

SST 09950–00020

(b) Remove the output gear spacer and ball.

4.

REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE

ROLLER BEARING AND SYNCHRONIZER RING

SST

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

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

2nd gear.

SST 09950–00020

(c) Remove the needle roller bearing and synchronizer rings.

AVENSIS/CORONA SUP (RM781E)

MX–29

MANUALTRANSAXLE (S54, S55)

–

OUTPUT SHAFT

5.

REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR,

SYNCHRONIZER RING, NEEDLE ROLLER BEARING,

THRUST WASHER AND LOCKING BALL

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

synchronizer ring.

(b) Remove the needle roller bearing and locking ball.

(c) Using a screwdriver and hammer, drive out the thrust

washer.

Z00427

6.

REMOVE NO.1 HUB SLEEVE, 3 SHIFTING KEYS AND

SPRINGS FROM NO.1 CLUTCH HUB

Q02948

AVENSIS/CORONA SUP (RM781E)

MX–30

MANUALTRANSAXLE (S54, S55)

–

OUTPUT SHAFT

MX03E–04

INSPECTION

1.

INSPECT 1ST GEAR SYNCHRONIZER RING

(a) Check 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 the gear 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

MT0780

MT0787

2.

INSPECT 2ND GEAR SYNCHRONIZER RING

(a) Check 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: 0.7 mm (0.028 in.)

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

nizer ring.

AVENSIS/CORONA SUP (RM781E)

MX–31

MANUALTRANSAXLE (S54, S55)

–

OUTPUT SHAFT

3.

INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-

ANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.4 mm (0.016 in.)

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

hub sleeve.

WM0066

CM0014

CM0015

4.

INSPECT OUTPUT SHAFT

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

output shaft journal surface.

A

B

C

Minimum outer diameter:

Part A: 31.984 mm (1.2592 in.)

Part B: 37.984 mm (1.4954 in.)

Part C: 32.002 mm (1.2599 in.)

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

put shaft.

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

Maximum runout: 0.05 mm (0.0020 in.)

If the runout exceeds the maximum, replace the output shaft.

AVENSIS/CORONA SUP (RM781E)

MX–32

MANUALTRANSAXLE (S54, S55)

–

OUTPUT SHAFT

MX03F–04

REASSEMBLY

HINT:

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

reassembly.

1.

INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE

Front

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

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

HINT:

Position the identification groove of the hub sleeve to the front

of the transmission.

Q02949

2.

INSTALL THRUST WASHER, 1ST GEAR, NEEDLE

ROLLER BEARING, SYNCHRONIZER RING AND NO.1

HUB SLEEVE TO OUTPUT SHAFT

(a) Using SST and a press, install the thrust washer.

SST 09316–60011 (09316–00041)

SST

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

SM0199

Z00428

Z00429

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

slots with the shifting keys.

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

3.

INSPECT 1ST GEAR THRUST CLEARANCE

(See page MX–28)

AVENSIS/CORONA SUP (RM781E)

MX–33

MANUALTRANSAXLE (S54, S55)

–

OUTPUT SHAFT

4.

INSTALL SYNCHRONIZER RING, 2ND GEAR,

NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR

(a) Install the ball.

(b) Fit the 2nd gear bushing groove securely over the ball

when installing the 2nd gear bushing on the shaft.

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

(d) Apply gear oil to the needle roller bearing and install it.

(e) Install the 2nd gear.

NOTICE:

MT0792

Align the clutch hub grooves with the projections on the

synchronizer ring.

(f)

Using SST and a press, install the 3rd driven gear.

SST 09316–60011 (09316–00011)

INSPECT 2ND GEAR THRUST CLEARANCE

(See page MX–28)

5.

SST

SM0201

Z00431

SM0202

6.

INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN

GEAR AND RADIAL BALL BEARING

(a) Install the outer gear spacer.

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

7.

INSTALL REAR BEARING

Using SST and a press, install the rear bearing.

SST 09612–22011

SST

AVENSIS/CORONA SUP (RM781E)

MX–34

MANUALTRANSAXLE (S54, S55)

–

SHIFTAND SELECT LEVER SHAFT

SHIFT AND SELECT LEVER SHAFT

MX03G–04

COMPONENTS

Shift and Select Lever Shaft

E–ring

Select Spring Seat

Compression Spring

Shift Interlock Plate

6.4 (85, 56 in.·lbf)

Compression Spring

E–ring

Dust Boot

Washer

Slotted Spring Pin

Shift Inner Lever No.1

Shift Inner Lever No.2

Select Spring Seat No.2

Lever Lock Pin

Oil Seal

z

Control Shaft Lever

37 (375, 27)

Control Shaft Cover

: Specified torque

N·m(kgf·cm, ft·lbf)

z

zO–ring

Non–reusable part

MP Grease

Q10277

AVENSIS/CORONA SUP (RM781E)

MX–35

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

DIFFERENTIAL CASE

MX03H–04

COMPONENTS

Shim

z Outer Race and Side Bearing

Pinion Thrust Washer

Ring Gear

Pinion Gear

Pinion Shaft

83 (850, 61)

x 8

z

Side Bearing and Outer Race

Shim

Side Gear

Side Gear Thrust Washer

Differential Case

Straight Pin

Speed Sensor Drive Gear

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

Z19302

AVENSIS/CORONA SUP (RM781E)

MX–36

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

MX03I–04

DISASSEMBLY

SST

1.

Speed Sensor Drive Gear Side:

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

(a) Using SST, remove the bearing from the drive gear side

of the case.

SST 09950–00020, 09950–00030

(b) Remove the speed sensor drive gear.

Q08148

2.

REMOVE RING GEAR

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

(b) Remove the 8 bolts.

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

it from the case.

3.

Ring Gear Side:

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

Using SST, remove the bearing from the ring gear side of the

case.

SST 09950–00020, 09950–00030

SST

Q04969

4.

INSPECT SIDE GEAR BACKLASH

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

while holding one pinion toward the 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.

5.

DISASSEMBLE DIFFERENTIAL CASE

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

(b) Remove the pinion shaft from the case.

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

washers from each gear.

AT2799

AVENSIS/CORONA SUP (RM781E)

MX–37

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

6.

Transmission Case Side:

IF NECESSARY, REPLACE DIFFERENTIAL SIDE

BEARING RETAINER OIL SEAL

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

retainer.

SST 09950–60020 (09951–00680), 09950–70010

(09951–07150)

SST

Q08145

SM0286

SM0155

Z00442

MT0634

(b) Using SST and a hammer, drive in a new oil seal until its

surface is flush with the case surface.

SST 09350–32014 (09351–32130, 09351–32150)

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

SST

7.

Transaxle Case Side:

IF NECESSARY, REPLACE SIDE OIL SEAL

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

(b) Using SST and a hammer, drive in a new oil seal until its

surface is flush with the case surface.

SST 09350–32014 (09351–32130, 09351–32150)

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

SST

8.

Transmission Case Side:

IF NECESSARY, REPLACE SIDE BEARING OUTER

RACE

(a) Using a brass bar and hammer, drive out the bearing out-

er race.

(b) Install the bearing retainer without an O–ring.

(c) Install and torque the 6 bolts.

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

(d) Place the thinnest shim into the case.

(e) Using SST and a press, install a new bearing outer race.

SST 09950–60020 (09951–00680), 09950–70010

(09951–07150)

SST

(f)

Remove the 6 bolts.

(g) Remove the bearing retainer and shim.

AVENSIS/CORONA SUP (RM781E)

MX–38

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

9.

Transaxle Case Side:

IF NECESSARY, REPLACE SIDE BEARING OUTER

RACE

(a) Using a brass bar and hammer, drive out the bearing out-

er race and shim.

(b) Place the shim into the case.

SST

(c) Using SST and a press, install a new bearing outer race.

SST 09950–60020 (09951–00680), 09950–70010

(09951–07150)

Q08184

AVENSIS/CORONA SUP (RM781E)

MX–39

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

MX03J–04

REASSEMBLY

1.

ASSEMBLE DIFFERENTIAL CASE

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

the table below, select thrust washers which will allow 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.)

0.95(0.0374)

Thickness mm (in.)

1.10(0.0433)

1.00(0.0394)

1.15(0.0453)

1.05(0.0413)

1.20(0.0472)

Install the thrust washers and side gears in the differential

case.

(b) Install the pinion shaft.

(c) Inspect the side gear backlash.

Using a dial indicator, measure the side gear backlash

while holding one pinion gear toward the 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.

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

through the case and hole in the pinion shaft.

(e) Stake the differential case.

AT2981

2.

INSTALL RING GEAR ON DIFFERENTIAL CASE

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

threads of the ring gear and differential case.

(b) Heat the ring gear in boiling water.

(c) Carefully remove the ring gear from the water.

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

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

HINT:

Align the matchmark on the differential case with the one on the

ring gear.

(e) Temporarily install the 8 bolts.

NOTICE:

The ring gear set bolts should not be torqued until the ring

gear has cooled sufficiently.

(f)

After the ring gear has cooled sufficiently, torque the ring

gear set bolts.

Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

Q08147

AVENSIS/CORONA SUP (RM781E)

MX–40

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

3.

INSTALL SIDE BEARING TO DIFFERENTIAL CASE

(a) Using SST and a press, install a new side bearing to the

transmission case side.

SST 09316–60011 (09316–00011), 09350–32014

(09351–32120)

SST

SM0287

(b) Install the speed sensor drive gear to the transaxle case

side.

Case Side

Q08649

(c) Using SST and a press, install a new side bearing to the

transaxle case side.

SST 09316–60011 (09316–00011), 09350–32014

(09351–32120)

SST

NOTICE:

Install the black cage bearing on the speed sensor drive

gear side.

4.

ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-

LOAD

SM0289

(a) Install the differential to the transaxle case.

(b) Install the transmission case.

(c) Install and torque the case bolts.

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

(d) Install the shim into the transmission case.

(e) Install the bearing retainer without an O–ring.

(f)

Install and torque the 6 bolts.

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

AVENSIS/CORONA SUP (RM781E)

MX–41

MANUALTRANSAXLE (S54, S55)

–

DIFFERENTIALCASE

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

SST 09564–32011

Preload (at starting):

1.0–1.6 N·m (10–16 kgf·cm, 8.7–13.9 in.·lbf)

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

mission case side bearing retainer. Select another shim.

HINT:

SST

The preload will change by approx. 0.3–0.4 N·m (3–4 kgf·cm,

2.6–3.5 in.·lbf) corresponding to a change of 0.05 mm in shim

thickness.

Z00620

Mark

1

Thickness mm (in.)

1.90(0.0748)

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)

Mark

11

Thickness mm (in.)

2.40(0.0945)

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

12

13

14

15

16

17

18

19

–

3

4

5

6

7

8

9

10

(h) Remove the 6 bolts.

(i)

(j)

Remove the bearing retainer and shim.

Remove the 17 bolts.

(k) Remove the transmission case.

AVENSIS/CORONA SUP (RM781E)

MX–42

MANUALTRANSAXLE (S54, S55)

–

SHIFT LEVER AND CONTROL CABLE

MX03K–03

COMPONENTS

Console Box Assembly

Shift Lever Knob

Parking Brake Cover

Front Ash Receptacle

Cap

Shift Lever Assembly

12(120, 9)

Clip

Cap

4.9(50,43in.·lbf)

Air Duct

Clip

Washer

Transmission Control Cable Bracket

Select Control Cable

Shift Cable Grommet

Shift Control Cable

Clip

Shift Cable Grommet

Retainer

Washer

Clip

4.9(50,43in.·lbf)

Washer

z

Gasket

43(430,32)

Heat Insulator

zRivet

z

Spring

Exhaust Pipe

62(630,46)

LH Engine Under Cover

N·m (kgf·cm, ft·lbf)

: Specifiedtorque

RH Engine Under Cover

zNon–reusable part

D09356

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (S54, S55) for Your Toyota Avensis 4 Door First Generation (1997-2003)

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