TOYOTA CAMRY V20 1986 Service Information

21. SEPARATE THE NO. 1 FORK SHAFT, NO. 1 SHIFT HEAD,
No. 1 AND NO. 2 SHIFT FORKS
(a) Mount the shift forks to the vise.
(b) Drive out the slotted spring pin from No. 1 fork shaft as
shown in the figure. 20. REMOVE NO. 1 SHIFT FORK SHAFT, NO. 1 SHIFT
HEAD, NO. 1 AND NO. 2 SHIFT FORKS, INPUT
SHAFT AND OUTPUT SHAFT.
(a) Drive out the slotted spring pin from No. 1 fork shaft.
(b) Remove the input shaft and output shaft together with
No. 1 fork shaft and shift head and shift forks from the
transaxle case.
22. REMOVE REVERSE SHIFT FORK AND INTERLOCK
PIN (c) Separate the No. 1 shift fork, shaft, No. 1 shift head,
No. 1 and No. 2 shift fork.
± MANUAL TRANSAXLES51 TransmissionMT±13

26. MEASURE THIRD AND FOURTH GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the thrust 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.)
27. REMOVE SNAP RING FROM INPUT SHAFT
Using two screwdrivers and a hammer, tap out the
snap ring.
28. REMOVE RADIAL BALL BEARING, FOURTH GEAR,
NEEDLE ROLLER BEARINGS, SYNCHRONIZER
RING AND SPACER FROM INPUT SHAFT
(a) Using a press, remove the radial ball bearing and 4th gear.
(b) Remove the needle roller bearings, synchronizer ring and
spacer. (b) Using a pin punch and hammer, drive out the slotted
spring pin.
(e) Pull out the shaft.
24. REMOVE DIFFERENTIAL ASSEMBLY
25. REMOVE MAGNET 23. REMOVE NO. 2 FORK SHAFT
(a) Using SST, remove the straight screw plug.
SST 09312±30021
± MANUAL TRANSAXLES51 TransmissionMT±14

31. MEASURE FIRST AND SECOND GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1 st gear 0.10 0.29 mm
(0.0039 ± 0.0114 in.)
2nd gear 0.20 0.44 mm
(0.0079 ± 0.0173 in.)
Maximum clearance:
1 st gear 0.35 mm (0.0138 in.)
2nd gear 0.50 mm (0.0197 in.)
32. REMOVE RADIAL BALL BEARING, FOURTH DRIVEN
GEAR AND OUTPUT GEAR SPACER FROM OUTPUT
SHAFT
(a) Using a press, remove the radial ball bearing and 4th
driven gear.
(b) Remove the spacer. 30. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, THIRD
GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER
BEARINGS
Using a press, remove No. 2 hub sleeve, 3rd gear, syn-
chronizer ring and needle roller bearings.
33. REMOVE THIRD DRIVEN GEAR, SECOND GEAR,
NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
(a) Shift No. 1 hub sleeve into the 1st gear. 29. REMOVE SNAP RING
Using snap ring pliers, remove the snap ring.
± MANUAL TRANSAXLES51 TransmissionMT±15

35. REMOVE NO. 1 HUB SLEEVE ASSEMBLY, FIRST
GEAR, SYNCHRONIZER RING, NEEDLE ROLLER
BEARING AND THRUST WASHER
(a) Using a press, remove No. 1 hub sleeve, 1 st gear and
synchronizer ring.
(b) Remove the needle roller bearing and thrust washer.
36. DISASSEMBLE SHIFT AND SELECT LEVER
ASSEMBLY
(a) Remove the lever lock pin and nut.
(b) Remove the control shift lever.
(c) Remove the dust boot.
(d) Remove the control shaft cover.(b) Using a press, remove the 3rd driven gear and
2nd gear.
(c) Remove the needle roller bearing, spacer and
synchronizer ring.
34. REMOVE SNAP RING
Using two screwdrivers and a hammer, tap out the snap
ring.
(e) Remove the E±ring.
± MANUAL TRANSAXLES51 TransmissionMT±16

(g) Using a pin punch and hammer, drive out the slotted
spring pin.
(h) Remove the shift fork lock plate, No. 1 shift inner
lever, spring and shift interlock plate. (f) Remove the reverse restrict pin holder, spring and
No. 2 shift inner lever.
(i) Remove the E±ring from the shaft.
± MANUAL TRANSAXLES51 TransmissionMT±17

3. CHECK OIL CLEARANCE OF EACH GEAR
Using a dial indicator, measure the oil clearance be-
tween the gear and input or output shaft with the needle
roller bearing installed.
Standard clearance:
1 st, 2nd, 3rd and 4th gears
0.009 ± 0.053 mm
(0.0004 ± 0.0021 in.)
5th gear 0.009 ± 0.050 mm
(0.0004 ± 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
if the clearance exceeds the limit, replace the gear,
needle roller bearing or shaft.
INSPECTION OF TRANSMISSION
COMPONENTS
1. INSPECT INPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the
input shaft journal surface.
Minimum outer diameter:
Part A 26.970 mm (1.0618 in.)
B 32.470 mm (1.2783 in.)
C 33.090 mm (7.3028 in.)
D 29.970 mm (1.1799 in.)
(b) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)
2. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A 31.970 mm (1.2587 in.)
6 37.970 mm (1.4949 in.)
C 31.970 mm (1.2587 in.)
(b) Using a dial indicator, check the shaft run-
out.
Maximum runout: 0.05 mm (0.0020 in.)
± MANUAL TRANSAXLES51 TransmissionMT±18

5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB
SLEEVES
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 limit, replace the shift fork or
hub sleeve.
(e) Using SST, press in a new bearing.
SST 09310±35010 .
(d) Install the transaxle case oil receiver and torque
the bolt.
Torque: 75 kg±cm (65 in.±Ib, 7.4 11f±m)
6. IF NECESSARY, REPLACE INPUT SHAFT FRONT
BEARING
(a) Remove the bolt and transaxle case oil receiver.
(b) Using SST, pull out the bearing.
SST 09308±00010 (b) Measure the clearance between the synchronizer ring
back and the gear spline end.
Minimum clearance: 0.6 mm 10.024 in.)
If the clearance is less than the limit, replace the synchro-
nizer ring. 4. INSPECT SYNCHRONIZER RINGS
(a) Turn the ring and push it in to check the braking action.
± MANUAL TRANSAXLES51 TransmissionMT±19

7. 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
(b) Using SST, drive in a new oil seal.
SST 09608±20012 (09608±00080, 09608±03020)
Drive in depth: 1.0 ± 2.0 mm (0.039 ± 0.079 in.)
(c) Coat the lip of the oil seal with MP grease. (c) Using SST, press in a new bearing.
SST 09310±35010
(d) Install the bearing lock plate and torque the
bolt.
Torque: 185 kg±cm (13 ft±Ib, 18 N±m)
9. IF NECESSARY, REPLACE LH SIDE OIL SEAL
(a) Using SST, press out the oil seal from the retainer.
SST 09608±20012 (09608±00030,09608±03020) 8. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL
SEAL
(a) Using a screwdriver, pry out the oil seal.
± MANUAL TRANSAXLES51 TransmissionMT±20

11. IF NECESSARY, REPLACE LH OUTER RACE OF
SIDE BEARING
(a) Using SST, press out the outer race.
SST 09608±20012 (09608±00060,09608±03020)
(b) Install the bearing retainer without an O±ring.
(e) Install and torque the retainer bolts.
Torque: 185 kg±cm(13 ft±Ib, 18 N±m)
(d) Place the thinnest shim into the case.
(See table on page MT±28)
(e) Using SST, press in a new outer race.
SST 09608±20012 (09608±03020,09608±03060) (b) Using SST, drive in a new oil seal until its surface
is flush with the case surface.
SST 09316±60010 (09316±00010)
(e) Coat the lip of the oil seal with MP grease.(b) Using SST, press in a new oil seal until its surface
is flush with the case surface.
SST 09316±60010 (09316±00010)
(c) Coat the lip of the oil seal with IMP grease.
10. IF NECESSARY, REPLACE RH SIDE OIL SEAL
(a) Drive out the oil seal with a screwdriver.
± MANUAL TRANSAXLES51 TransmissionMT±21

(b) Using SST, drive in a new oil seal until its surface is
flush with the cover surface.
SST 09608±200 12 (09608±00080, 09608±03020)
(c) Coat the lip of the oil seal with MP grease.
14. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN
GEAR OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09921±00010 12. IF NECESSARY, REPLACE RH OUTER RACE OF
SIDE BEARING
(a) Using SST, press out the outer race and shim.
SST 09608±20012 (09608±00030,09608±03020)
13. IF NECESSARY, REPLACE CONTROL SHAFT COVER
OIL SEAL
(a) Using a screwdriver, pry out the oil seal.(b) Place the shim into the case.
(c) Using SST, press in a new outer race.
SST 09608±20012 (09608±03020,09608±03060)
± MANUAL TRANSAXLES51 TransmissionMT±22