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

SS–15

SERVICE SPECIFICATIONS

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MANUALTRANSAXLE (S54, S55)

MANUAL TRANSAXLE (S54, S55)

SS09M–04

SERVICE DATA

Inputshaft roller bearing journal diameter

Input shaft 3rd gear journal diameter

Input shaft 4th gear journal diameter

Input shaft 5th gear journal diameter

Input shaft runout

Min. 29.987 mm (1.181 in.)

Min. 33.100 mm (1.3031 in.)

Min. 32.484 mm (1.2789 in.)

Min. 26.987 mm (1.0625 in.)

Max. 0.03 mm (0.0012 in.)

Min. 31.984 mm (1.2592 in.)

Min. 37.987 mm (1.4956 in.)

Min. 32.002 mm (1.2599 in.)

Max. 0.05 mm (0.0020 in.)

Output shaft roller bearing journal diameter

Output shaft 1st gear journal diameter

Output shaft 2nd gear journal diameter

Output shaft runout

Gear thrust clearance 1st

Max. 0.29 mm (0.0114 in.)

Min. 0.10 mm (0.0039 in.)

Gear thrust clearance 2nd

Gear thrust clearance 3rd

Max. 0.34 mm (0.0134 in.)

Min. 0.10 mm (0.0039 in.)

Max. 0.35 mm (0.0138 in.)

Min. 0.10 mm (0.0039 in.)

Gear thrust clearance 4th

Max. 0.45 mm (0.0177 in.)

Min. 0.10 mm (0.0039 in.)

Gear thrust clearance 5th

Max. 0.57 mm (0.0224 in.)

Min. 0.10 mm (0.0039 in.)

Gear radial clearance 1st, 2nd, 3rd and 4th

Gear radial clearance 5th

Max. 0.051 mm (0.0020 in.)

Min. 0.009 mm (0.0004 in.)

Max. 0.048 mm (0.0019 in.)

Min. 0.009 mm (0.0004 in.)

Shift fork to hub sleeve clearance

Max. 0.4 mm ( 0.016 in.)

Synchronizer ring to gear clearance 1st and 4th

Synchronizer ring to gear clearance 2nd

Min. 0.75 mm (0.030 in.)

Min. 0.7 mm (0.028 in.)

Synchronizer ring to gear clearance 3rd

Min. 0.65 mm (0.026 in.)

Differential case side bearing preload (at starting)(For use with SST)

Differential pinion to side gear backlash

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

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

Drive in depth

Input shaft front oil seal

0 – 0.5 mm (0 – 0.020 in.)

Slotted spring pin for reverse restrict pin

Shift and select lever shaft slotted spring pin

13.5 ± 0.5 mm (0.531 ± 0.020 in.)

23.5 ± 1.0 mm (0.925 ± 0.039 in.)

Differential side gear thrust washer thickness

0.95 mm (0.0374 in.)

1.00 mm (0.0394 in.)

1.05 mm (0.0413 in.)

1.10 mm (0.0433 in.)

1.15 mm (0.0453 in.)

1.20 mm (0.0472 in.)

AVENSIS/CORONA SUP (RM781E)

SS–16

SERVICE SPECIFICATIONS

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MANUALTRANSAXLE (S54, S55)

Input shaft snap ring thickness

No.2 clutch hub

Mark 1 1.95 – 2.00 mm (0.0768 – 0.0787 in.)

Mark 2 2.00 – 2.05 mm (0.0787 – 0.0807 in.)

Mark 3 2.05 – 2.10 mm (0.0807 – 0.0827 in.)

Mark 4 2.10 – 2.15 mm (0.0827 – 0.0846 in.)

Mark 5 2.15 – 2.20 mm (0.0846 – 0.0866 in.)

Mark 6 2.20 – 2.25 mm (0.0866 – 0.0886 in.)

Mark 13 2.20 – 2.25 mm (0.0866 – 0.0886 in.)

Mark 14 2.25 – 2.30 mm (0.0886 – 0.0906 in.)

Mark 15 2.30 – 2.35 mm (0.0906 – 0.0925 in.)

Mark 16 2.35 – 2.40 mm (0.0925 – 0.0945 in.)

Mark 17 2.40 – 2.45 mm (0.0945 – 0.0965 in.)

Mark 18 2.45 – 2.50 mm (0.0965 – 0.0984 in.)

Mark 19 2.50 – 2.55 mm (0.0984 – 0.01004 in.)

Mark 20 2.55 – 2.60 mm (0.1004 – 0.01024 in.)

Mark 21 2.60 – 2.65 mm (0.1024 – 0.01043 in.)

Mark 22 2.65 – 2.70 mm (0.1043 – 0.01063 in.)

Mark 23 2.70 – 2.75 mm (0.1063 – 0.01083 in.)

Mark 24 2.75 – 2.80 mm (0.1083 – 0.01102 in.)

Mark 25 2.80 – 2.85 mm (0.1102 – 0.01122 in.)

Mark 26 2.85 – 2.90 mm (0.1122 – 0.01142 in.)

Mark 27 2.90 – 2.95 mm (0.1142 – 0.01161 in.)

Mark A 2.15 – 2.20 mm (0.0846 – 0.0866 in.)

Mark B 2.20 – 2.25 mm (0.0866 – 0.0886 in.)

Mark C 2.25 – 2.30 mm (0.0886 – 0.0906 in.)

Mark D 2.30 – 2.35 mm (0.0906 – 0.0925 in.)

Mark E 2.35 – 2.40 mm (0.0925 – 0.0945 in.)

No.3 clutch hub

Rear bearing

Differential side bearing adjusting shim thickness

Mark 1 1.90 mm (0.0748 in.)

Mark 2 1.95 mm (0.0768 in.)

Mark 3 2.00 mm (0.0787 in.)

Mark 4 2.05 mm (0.0807 in.)

Mark 5 2.10 mm (0.0827 in.)

Mark 6 2.15 mm (0.0846 in.)

Mark 7 2.20 mm (0.0866 in.)

Mark 8 2.25 mm (0.0886 in.)

Mark 9 2.30 mm (0.0906 in.)

Mark 10 2.35 mm (0.0925 in.)

Mark 11 2.40 mm (0.0945 in.)

Mark 12 2.45 mm (0.0965 in.)

Mark 13 2.50 mm (0.0984 in.)

Mark 14 2.55 mm (0.1004 in.)

Mark 15 2.60 mm (0.1024 in.)

Mark 16 2.65 mm (0.1043 in.)

Mark 17 2.70 mm (0.1063 in.)

Mark 18 2.75 mm (0.1083 in.)

Mark 19 2.80 mm (0.1102 in.)

AVENSIS/CORONA SUP (RM781E)

SS–17

SERVICE SPECIFICATIONS

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MANUALTRANSAXLE (S54, S55)

SS09N–05

TORQUE SPECIFICATION

Parttightened

N·m

39

kgf·cm

ft·lbf

29

9

Starter x Transaxle

400

120

Clutch release cylinder x Transaxle

12

Clutch line bracket x Transaxle (See page MX–3)

Bolt A

Bolt B

12

120

50

9

4.9

43in.·lbf

Engine left mounting bracket x Transaxle

Engine left mounting bracket x Insulator

Transaxle x Engine (See page MX–3)

52

87

530

890

38

64

Upper bolt

64

25

650

250

47

18

Stiffener plate x Transaxle (See page MX–3)

Bolt A

Bolt B

43

21

440

210

32

15

Frontwheel

216

49

62

43

39

2,200

500

630

440

400

159

36

46

32

29

Filler and Drain plugs

Front exhaust pipe x Exhaust manifold

Front exhaust pipe x Center exhaust pipe

Front transport hook x Engine Mounting Center Member

Engine Mounting Center Member (See page MX–3)

Bolt A

Bolt B

73

72

740

730

54

53

Engine rear mounting bracket x Insulator

Engine rear mounting bracket x Transaxle

Intake manifold stay

87

64

44

12

4.9

29

18

42

18

7.4

123

18

29

37

6.4

83

37

18

29

44

18

7.4

13

890

650

450

120

50

64

47

33

Shift lever assembly x Body

Shift cable grommet retainer x Body

Transmission control cable bracket x Body

Transmission case x Transaxle case

Transmission case x Case cover

Transmission case protector

Rearbearingretainer

9

43in.·lbf

22

50

300

185

430

185

75

22

13

31

Output shaft front bearing lock plate

Transaxle case receiver set bolt

5th driven gear lock nut

13

65in.·lbf

90

1,250

185

300

375

65

No.3 shift fork x No.1 shift fork shaft

Reverse idler shaft lock bolt

Shift and select lever aseembly

Control shift lever x Lever shaft

Ring gear x Differentialcase

Selecting bellcrank x Transmission case

Reverse shift arm bracket

13

22

27

56in.·lbf

61

850

380

185

300

450

185

75

27

13

No.3 shift fork x Shift fork shaft

Lock ball assembly

13

22

Back–up light switch

33

Differentialsidebearingretainer

Releasebearingretainer

13

65in.·lbf

9

Straight screw plug

130

AVENSIS/CORONA SUP (RM781E)

SS–18

SERVICE SPECIFICATIONS

–

MANUALTRANSAXLE (S54, S55)

5.4

Speed sensor lock plate set bolt

Clutch release fork support

55

480

48in.·lbf

35

47

AVENSIS/CORONA SUP (RM781E)

SERVICE SPECIFICATIONS -> Manual Transaxle (S54, S55) for Your Toyota Avensis 4 Door First Generation (1997-2003)

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