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

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)

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

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