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

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)

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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)

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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)

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

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