TOYOTA CAMRY 1999 Service Repair Manual

WM0066
Q00172
CBA
Q00173
MX±28
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1829 Author: Date:
3. MEASURE 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 the shift fork or
hub sleeve.
4. 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: 27.950 mm (1.1004 in.)
Part B and C: 35.950 mm (1.4154 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout:
0.05 mm (0.0020 in.)

MX059±02
Q00383
Front
MT0790
Q00183SST
Q00116
± MANUAL TRANSAXLE (E153)INPUT SHAFT
MX±29
1830 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 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506±35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)±±
(b) Using a screwdriver and hammer, tap in the snap ring.

N00494
SST
Q00116
MX±30
± MANUAL TRANSAXLE (E153)INPUT SHAFT
1831 Author: Date:
4. MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX±24)
5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the rear ball bearing.
SST 09506±35010
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
12.35 (0.0925)52.55 (0.1004)
22.40 (0.0945)62.60 (0.1024)
32.45 (0.0965)72.65 (0.1043)
42.50 (0.0984)82.70 (0.1063)
(b) Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX±24)

MX05A±01
N00785
Needle Roller Bearing
Spacer
2nd Gear 3rd Driven Gear
Spacer 4th Driven Gear

Output Shaft Rear Bearing
Spacer
Synchronizer RingNo.1 Clutch Hub Shifting Key Spring
S Shifting KeyNo.1 Hub Sleeve
Synchronizer Ring1st GearNeedle Roller Bearing
Output Shaft
Output Shaft Front Bearing

Non±reusable part
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
MX±31
1832 Author: Date:
OUTPUT SHAFT
COMPONENTS

MX05B±01
Q06370
1st Gear
2nd Gear
Z00218
Z00219
Z00220
MX±32
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
1833 Author: Date:
DISASSEMBLY
1. MEASURE 1ST AND 2ND GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 ± 0.35 mm (0.0039 ± 0.0138 in.)
2nd gear: 0.10 ± 0.45 mm (0.0039 ± 0.0177 in.)
Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.50 mm (0.0197 in.)
2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
1st gear: 0.009 ± 0.051 mm (0.0004 ± 0.0020 in.)
2nd gear: 0.009 ± 0.053 mm (0.0004 ± 0.0021 in.)
Maximum clearance:
1st and 2nd gears: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH
DRIVEN GEAR AND SPACER
(a) Using a press, remove the bearing and 4th driven gear.
(b) Remove the spacer.
4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6. REMOVE SNAP RING
Using a snap ring expander, remove the snap ring.

Z00222
Q00296
SST
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
MX±33
1834 Author: Date:
7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST
GEAR
Using a press, remove the No.1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE
ROLLER BEARING
9. REMOVE OUTPUT SHAFT FRONT BEARING
Using SST, remove the output shaft front bearing.
SST 09950±00020, 09950±00030

MX05C±02
WM0064
WM0065
MT0780
MT0787
MX±34
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
1835 Author: Date:
INSPECTION
1. INSPECT 1ST 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 gear 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.
2. INSPECT 2ND 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.

WM0066
Z00223
Z00224
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
MX±35
1836 Author: Date:
3. MEASURE NO.1 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 the shift fork or
hub sleeve.
4. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
38.950 mm (1.5335 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout:
0.06 mm (0.0024 in.)

MX05D±01
Q00384
Front
Z00225
Z00385
SST
Z00386
MX±36
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
1837 Author: Date:
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 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 NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316±60011 (09316±00041)
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.80 (0.1102)E3.00 (0.1181)
B2.85 (0.1122)F3.05 (0.1201)
C2.90 (0.1142)G3.10 (0.1220)
D2.95 (0.1161)±±
(b) Using a snap ring expander, install the snap ring.

MT0792
N00495
Z00390
Z00391
SST
± MANUAL TRANSAXLE (E153)OUTPUT SHAFT
MX±37
1838 Author: Date:
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX±31)
5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-
CHRONIZER RING, 2ND GEAR AND 3RD DRIVEN
GEAR
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearing.
(c) Place the synchronizer rings (for the 2nd gear) on the
gear.
NOTICE:
Do not install the synchronizer ring for the 1st gear.
(d) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
6. MEASURE 2ND GEAR THRUST CLEARANCE
(See page MX±31)
7. INSTALL SPACER AND 4TH DRIVEN GEAR
(a) Install the spacer.
(b) Using a press, install the 4th driven gear.
8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 09506±30012