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

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)

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

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