TOYOTA CAMRY 1999 Service Repair Manual

MX04I±01
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
MX±19
1869 Author: Date:
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MX±11).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.

MX04J±01
Q02560
Synchronizer RingSpacer
Needle Roller Bearing
4th Gear
Snap Ring
Input Shaft
3rd Gear
No.2 Hub Sleeve
Key Spring Shifting Key Synchronizer Ring
Needle Roller BearingSnap Ring Rear Bearing
No.2 Clutch Hub
MX±20
± MANUAL TRANSAXLE (S51)INPUT SHAFT
1870 Author: Date:
INPUT SHAFT
COMPONENTS

MX04K±01
Q05793
3rd Gear
4th Gear
Z00417
Q05201
SST
± MANUAL TRANSAXLE (S51)INPUT SHAFT
MX±21
1871 Author: Date:
DISASSEMBLY
1. INSPECT 3RD AND 4TH GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the clearance.
Standard clearance:
3rd gear: 0.10 ± 0.25 mm (0.0039 ± 0.0098 in.)
4th gear: 0.20 ± 0.45 mm (0.0079 ± 0.0177 in.)
Maximum clearance:
3rd gear: 0.30 mm (0.0118 in.)
4th gear: 0.50 mm (0.0197 in.)
2. INSPECT 3RD AND 4TH GEARS RADIAL CLEAR-
ANCES
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
0.009 ± 0.053 mm (0.0004 ± 0.0021 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
4. REMOVE REAR BEARING, 4TH GEAR, NEEDLE
ROLLER BEARING, SPACER AND SYNCHRONIZER
RING FROM INPUT SHAFT
(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.

CM0064
SST
SM0269
MX±22
± MANUAL TRANSAXLE (S51)INPUT SHAFT
1872 Author: Date:
6. REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR
SYNCHRONIZER RING AND NEEDLE ROLLER BEAR-
ING
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.
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.

MX04L±01
WM0064
WM0065
WM0066
± MANUAL TRANSAXLE (S51)INPUT SHAFT
MX±23
1873 Author: Date:
INSPECTION
1. INSPECT SYNCHRONIZER RING
(a) Check for 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.
(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:
0.6 mm (0.024 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:
1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace shift fork or hub
sleeve.

SM0182
D C B A
CM0013
MX±24
± MANUAL TRANSAXLE (S51)INPUT SHAFT
1874 Author: Date:
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.
Minimum outer diameter:
Part A: 26.970 mm (1.0618 in.)
Part B: 32.470 mm (1.2783 in.)
Part C: 33.090 mm (1.3028 in.)
Part D: 29.970 mm (1.1799 in.)
If the outer diameter is less than the minimum, replace the input
shaft.
(c) Using a dial indicator, check the shaft runout.
Maximum runout:
0.05 mm (0.0020 in.)
If the runout exceeds the maximum, replace the input shaft.

MX04M±01
SM0282
Engine
Side
SM0193
Z00419
Z00604
± MANUAL TRANSAXLE (S51)INPUT SHAFT
MX±25
1875 Author: Date:
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
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:
Position the key springs so that their end gaps are not
aligned.
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.
(c) Using a press, install the 3rd gear and No.2 hub sleeve.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
11.95±2.00 (0.0768±0.0787)
22.00±2.05 (0.0787±0.0807)
32.05±2.10 (0.0807±0.0827)
42.10±2.15 (0.0827±0.0846)
52.15±2.20 (0.0846±0.0866)
62.20±2.25 (0.0866±0.0886)

SM0189
SM0190
SM0049
SST
SM0050
MX±26
± MANUAL TRANSAXLE (S51)INPUT SHAFT
1876 Author: Date:
(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.
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
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.15±2.20 (0.0846±0.0866)
B2.20±2.25 (0.0866±0.0886)
C2.25±2.30 (0.0886±0.0906)
D2.30±2.35 (0.0906±0.0925)
E2.35±2.40 (0.0925±0.0945)
(b) Using a screwdriver and hammer, tap in the snap ring.

± MANUAL TRANSAXLE (S51)INPUT SHAFT
MX±27
1877 Author: Date:
7. INSPECT 4TH GEAR THRUST CLEARANCE
(See page MX±20)

MX04N±01
Q02544
Output Shaft
Spacer
1st Gear
Needle Roller Bearing
Synchronizer Ring
No.1 Hub Sleeve
Shifting Key
Shifting Key Spring
No.1 Clutch Hub
Rear Bearing
4th Driven Gear 2nd Gear
2nd Gear Bushing
3rd Driven GearBall
Synchronizer RingSpacer
Needle Roller Bearing MX±28
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
1878 Author: Date:
OUTPUT SHAFT
COMPONENTS