TOYOTA CAMRY 1999 Service Repair Manual

MT0781
MX±18
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
1819 Author: Date:
32. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
(a) Leaning the output shaft to the differential side, remove
the input shaft assembly.
(b) Lift up the differential case assembly, remove the output
shaft assembly.
33. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the oil pump drive gear.
(b) Remove the differential case assembly.
34. REMOVE MAGNET FROM TRANSAXLE CASE
35. REMOVE TRANSMISSION OIL PUMP ASSEMBLY
AND OIL PIPE
(a) Remove the 2 bolts and oil pipe.
Torque: 17 N´m (175 kgf´cm, 13 ft´lbf)
(b) Remove the 2 bolts and oil pump assembly.
Torque: 17 N´m (175 kgf´cm, 13 ft´lbf)
36. 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.

MX054±01
MT0782
WM0066
Z00192
SST
Z00194
SST
Q08014
SST
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
MX±19
1820 Author: Date:
INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING
(a) Check for 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 it does not lock, replace the synchronizer ring.
2. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
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 the shift fork or
hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT BEARING
AND OIL SEAL
(a) Remove the 3 bolts and transaxle case receiver.
(b) Using SST, pull out the bearing.
SST 09612±65014
(c) Using a screwdriver, remove the oil seal.
(d) Using SST, drive in a new oil seal.
SST 09608±00081, 09950±70010 (09951±07150)
(e) Coat the lip of seal with MP grease.
(f) Using SST, drive in a new bearing.
SST 09950±60010 (09951±00580), 09950±70010
(09951±07150)
(g) Install the transaxle case receiver.
(h) Install and torque the 3 bolts.
Torque: 7.4 N´m (75 kgf´cm, 65 in.´lbf)

Q05164
SST
Q00141
SST
Q00338
SST
Z00197
Q06368
SST
SST MX±20
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
1821 Author: Date:
(i) Using SST and a press, remove the inner race.
SST 09950±00020
(j) Using SST and a press, install a new input shaft front
bearing inner race.
SST 09316±60011 (09316±00021)
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING OUTER RACE AND OUTPUT SHAFT
FRONT COVER
(a) Using SST, pull out the output shaft front bearing outer
race.
SST 09308±00010
(b) Remove the output shaft cover.
(c) Install a new output shaft cover.
HINT:
Install the output shaft cover projection into the case side
groove.
(d) Using SST and a hammer, drive in a new output shaft front
bearing outer race.
SST 09316±60011 (09316±00011, 09316±00021)

Q00245
SSTSocket Wrench
Z00199SST
Q01611
Z00201
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
MX±21
1822 Author: Date:
(e) Using SST and a socket wrench, remove the output shaft
front bearing.
SST 09950±00020, 09950±00030
(f) Using SST and a press, install a new output shaft front
bearing.
SST 09316±60011 (09316±00071)
5. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench (6 mm), remove the 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.
(e) Apply sealant to the screw plug threads.
Sealant:
Part No. 08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench (6 mm), install and torque the
screw plug.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

MX055±01
MX±22
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
1823 Author: Date:
REASSEMBLY
Reassembly is in the reverse order of disassembly.
HINT:

Before reassembly, select a shim by adjusting output
shaft preload.

Coat all of the sliding and rotating surfaces with gear oil
before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle case.
(b) Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
(c) Install and torque the 17 bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(d) Install the output shaft rear taper roller bearing outer race.
(e) Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the
same thickness as before. If installing a new taper roller bear-
ing, first select and install a shim of lesser thickness than be-
fore.
(f) Install the rear bearing retainer.
(g) Using a torx wrench (T45), install and torque the 7 torx
screws.
Torque: 42 N´m (430 kgf´cm, 31 ft´lbf)
(h) Install a new lock nut to the output shaft.
(i) Turn the output shaft right and left 2 or 3 times to allow the
bearing to settle.

Z12593
± MANUAL TRANSAXLE (E153)MANUAL TRANSAXLE ASSEMBLY
MX±23
1824 Author: Date:
(j) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing
0.8 ± 1.6 N´m (8 ± 16 kgf´cm, 6.9 ± 13.9 in.´lbf)
Reused bearing
0.5 ± 1.0 N´m (5 ± 10 kgf´cm, 4.3 ± 8.7 in.´lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
The preload will change approx. 0.4 ± 0.5 N´m (4 ± 5 kgf´cm, 3.5
± 4.3 in.´lbf) for every 0.05 mm change in adjusting shim thick-
ness.
MarkThickness mm (in.)MarkThickness mm (in.)
01.30 (0.0512)D1.95 (0.0768)
11.35 (0.0531)E2.00 (0.0787)
21.40 (0.0551)F2.05 (0.0807)
31.45 (0.0571)G2.10 (0.0827)
41.50 (0.0591)H2.15 (0.0846)
51.55 (0.0610)J2.20 (0.0866)
61.60 (0.0630)K2.25 (0.0886)
71.65 (0.0650)L2.30 (0.0906)
81.70 (0.0669)M2.35 (0.0925)
91.75 (0.0689)N2.40 (0.0945)
A1.80 (0.0709)P2.45 (0.0965)
B1.85 (0.0728)Q2.50 (0.0984)
C1.90 (0.0748)±±
(k) Remove the lock nut.
(l) Remove these parts. Removal is in the reverse order of
installation.

Rear bearing retainer

Shim

Transmission case

Output shaft assembly

Output shaft rear bearing outer race

MX056±01
MT0791
Synchronizer Ring Spacer
4th Gear
Snap Ring
Rear BearingNeedle Roller Bearing
Snap RingSpring
Shifting KeyNo.2 Clutch HubNo.2 Hub SleeveSynchronizer Ring3rd GearNeedle Roller Bearing

Input Shaft Front Bearing Inner Race
Input Shaft

Non±reusable part MX±24
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1825 Author: Date:
INPUT SHAFT
COMPONENTS

MX057±01
Q06369
3rd Gear
4th Gear
Q00111
Q05165
SST
± MANUAL TRANSAXLE (E153)INPUT SHAFT
MX±25
1826 Author: Date:
DISASSEMBLY
1. MEASURE 3RD AND 4TH GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
3rd gear: 0.10 ± 0.35 mm (0.0039 ± 0.0138 in.)
4th gear: 0.10 ± 0.55 mm (0.0039 ± 0.0217 in.)
Maximum clearance:
3rd gear: 0.40 mm (0.0157 in.)
4th gear: 0.60 mm (0.0236 in.)
2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
3rd gear: 0.009 ± 0.053 mm (0.0004 ± 0.0021 in.)
4th gear: 0.009 ± 0.051 mm (0.0004 ± 0.0020 in.)
Maximum clearance:
3rd and 4th gears: 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 BALL BEARING AND 4TH GEAR
Using SST and a press, remove the rear bearing.
SST 09950±00020
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.

Q00115
MX±26
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1827 Author: Date:
7. REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRO-
NIZER RING AND 3RD GEAR
Using a press, remove the No.2 hub sleeve, 3rd gear and syn-
chronizer rings.
8. REMOVE NEEDLE ROLLER BEARING

MX058±01
MT0780
MT0786
WM0064
WM0064
± MANUAL TRANSAXLE (E153)INPUT SHAFT
MX±27
1828 Author: Date:
INSPECTION
1. INSPECT 3RD GEAR 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 it does not lock, 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.
2. INSPECT 4TH GEAR 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 spline end.
Minimum clearance:
0.8 mm (0.031 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.