TOYOTA CAMRY 1999 Service Repair Manual

Q00036
Z00309
MX±48
± MANUAL TRANSAXLE (E153)DIFFERENTIAL CASE
1849 Author: Date:
8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
9. INSTALL SHIM (See pages MX±22)
HINT:
Install the previously selected shim.
10. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N´m (430 kgf´cm, 31 ft´lbf)
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 ± 0.3 N´m (1.8 ± 3.5 kgf´cm, 1.6 ± 3.0 in.´lbf)
Reused bearing (Output shaft preload plus)
0.1 ± 0.2 N´m (1.1 ± 2.2 kgf´cm, 1.0 ± 1.9 in.´lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
HINT:
The total preload will change by about 0.1 ± 0.2 N´m (1 ± 2
kgf´cm, 0.9 ± 1.7 in.´lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
12. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
13. REMOVE SHIM
14. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
15. REMOVE OUTPUT SHAFT ASSEMBLY
16. REMOVE DIFFERENTIAL CASE ASSEMBLY

MX05K±01
Q10281
Shift Lever Knob
Center Console Upper Panel
Heater Control Assembly
Center Cluster
Finish Panel
Front Console Box
12 (120, 9)
Shift Lever Assembly
Clip
Washer Shift Control Cable
Select Control Cable Clip
Clip ClipClip
Clip
Clip Shift Cable Grommet Retainer
4.9 (50, 43 in.´lbf)Shift Cable
Grommet
Grommet Shift Cable Grommet
Retainer
4.9 (50, 43 in.´lbf)
Washer
Clip
N´m (kgf´cm, ft´lbf): Specified torqueRear Console Box
Washer
± MANUAL TRANSAXLE (E153)SHIFT LEVER AND CONTROL CABLE
MX±49
1850 Author: Date:
SHIFT LEVER AND CONTROL CABLE
COMPONENTS

MX04A±01
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE SYSTEM
MX±1
1851 Author: Date:
MANUAL TRANSAXLE SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following items.

Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.

Thoroughly clean all components to remove all the loose material.

Clean both sealing surfaces with a non±residue solvent.

Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.

Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.

MX04B±04
MX±2
± MANUAL TRANSAXLE (S51)TROUBLESHOOTING
1852 Author: Date:
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
1. Oil (Level low)MX±4
Ni
1. Oil (Level low)
2. Oil (Wrong)
MX±4
MX±4Noise2. Oil (Wrong)
3. Gear (Worn or damaged)
MX±4
MX±93. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
MX 9
MX±9
1. Oil (Level too high)MX±4
Oil l k
1. Oil (Level too high)
2. Gasket (Damaged)
MX±4
MX±9Oil leakage2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
MX±9
MX±93. Oil seal (Worn or damaged)
4. O±ring (Worn or damaged)
MX 9
MX±9
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)MX±43
MX±9
Hard to shift or will not shift
yg( g)
3 Shift key s
pring (Damaged)
MX±20
MX±28
MX±93. Shift key spring (Damaged)MX±9
MX±20
MX±28
1. Locking ball spring (Damaged)MX±9
Jtf
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
MX±9
MX±9Jumps out of gear2. Shift fork (Worn)
3. Gear (Worn or damaged)
MX±9
MX±93. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
MX 9
MX±9

MX04C±01
Q09998
Hood
ClipCruise Control Actuator
Control Cable
Clutch Line
Bracket
Clutch Release CylinderWasher
RH Drive Shaft
Snap Ring
RH Stiffener
Plate
Ground Cable
Starter
Battery
Snap Ring
LH Drive Shaft

RH Fender Apron
Seal
LH Stiffener Plate
Manifold StayTransaxle Back±Up Light Switch
Connector
Rear End Plate with Oil Pan
InsulatorAir Cleaner
Case Assembly
with Air Hose
Vehicle Speed Sensor
Connector
No.1 Fuel Tube Protector Engine LH
Mounting Insulator
with Bracket
Rear RH Suspension Member Brace
PS Gear Assembly
Lock Cap
Rear LH Suspension Member Brace Manifold StayClip
LH Fender Apron
Seal
Suspension Member with
Lower Suspension Arm
Front RH Suspension
Member BraceStabilizer Bar Link
Front Exhaust PipeCotter Pin
RH Fender
Liner
LH Fender Liner
Exhaust Pipe BracketNo.1 Exhaust Pipe
Support Bracket
: Specified torque
Non±reusable partGasket w/ Cruise Control:






Cotter Pin


Hole
Plug




Engine Rear Side Shutter PlateHold±Down
Clamp
Hole
Plug
12 (120, 9)
13 (130, 9)
46 (470, 34)
39 (400, 29)
6.9 (70, 61 in.´lbf)
14 (145, 10)
12 (120, 9)
39 (400, 29)
39 (400, 29)
64 (650, 47)
56 (570, 41)
37 (380, 27)
9.3 (95, 82 in.´lbf)
42 (425, 31)
32 (330, 24)
Silver Bolt: 44 (450, 33)
Green Bolt: 66 (670, 48)
62 (630, 46)
64 (650, 47)
64 (650, 47)
37 (380, 27)
181 (1,850, 134)
181 (1,850, 134)
181 (1,850, 134)
36 (370, 27)
10 (100, 7)
32 (330, 24)19 (195, 14)
49 (500, 36)
294 (3,000, 217)
Silver Bolt: 44 (450, 33)
Green Bolt: 66 (670, 48)
36 (370, 27)66 (670, 48)
39 (400, 29)
127 (1,300, 94)
33 (330, 24)
33 (330, 24)
19 (195, 14)
80 (820, 59)
Gasket





Steering Return Pipe
Front LH
Suspension
Member Brace
N´m (kgf´cm, ft´lbf)
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE UNIT
MX±3
1853 Author: Date:
MANUAL TRANSAXLE UNIT
COMPONENTS

MX04D±01
Q09982
Q09999
BA
Q10000
Q10001
MX±4
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE UNIT
1854 Author: Date:
REMOVAL
1. REMOVE HOOD
HINT:
At the time of installation, please refer to the following item.
Adjust the hood.
(See page BO±10)
2. REMOVE BATTERY AND AIR CLEANER CASE AS-
SEMBLY WITH AIR HOSE
3. w/ Cruise Control:
REMOVE CRUISE CONTROL ACTUATOR
(a) Disconnect the cruise control actuator connector.
(b) Remove the 3 bolts and cruise control actuator with the
bracket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
4. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
5. DISCONNECT CLUTCH RELEASE CYLINDER
(a) Remove the 2 bolts and disconnect the release cylinder.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(b) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N´m (120 kgf´cm, 9 ft´lbf)
Bolt B: 6.9 N´m (70 kgf´cm, 61 in.´lbf)
6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
7. REMOVE MANIFOLD STAY
Remove the 2 bolts and stay.
Torque: 42 N´m (425 kgf´cm, 31 ft´lbf)
8. DISCONNECT VEHICLE SPEED SENSOR AND
BACK±UP LIGHT SWITCH CONNECTORS
9. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.

Q10002
14 mm Head
17 mm Head
Q10003
Oil Level
Filler Plug
Drain Plug0 ± 5 mm
Q10010
Q10004
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE UNIT
MX±5
1855 Author: Date:
10. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
17 mm head: 64 N´m (650 kgf´cm, 47 ft´lbf)
14 mm head: 46 N´m (470 kgf´cm, 34 ft´lbf)
11. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
12. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
13. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND
LH AND RH FENDER APRON SEALS
14. DRAIN TRANSAXLE OIL
Oil grade: API GL±4 or GL±5
Viscosity: SAE 75W±90
Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts)
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
15. REMOVE LH AND RH DRIVE SHAFTS
(See page SA±16)
16. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, nut and exhaust pipe bracket.
Torque:
Bolt: 19 N´m (195 kgf´cm, 14 ft´lbf)
Nut: 33 N´m (330 kgf´cm, 24 ft´lbf)
(b) Remove the 3 nuts and gasket from the exhaust manifold.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the 2 bolts, nuts and gasket.
Torque: 56 N´m (570 kgf´cm, 41 ft´lbf)
(d) Remove the 2 set bolts of the No.1 exhaust pipe support
bracket.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
(e) Remove the front exhaust pipe.

Q09989
Q09990
Q10005
Q10006
Q10007
MX±6
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE UNIT
1856 Author: Date:
17. DISCONNECT PS GEAR ASSEMBLY FROM FRONT
SUSPENSION MEMBER
(a) Remove the 2 nuts and disconnect the stabilizer bar link
from the stabilizer bar.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Remove the 4 set bolts of the stabilizer bar bracket.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(c) Remove the 2 bolts, nut and No.1 fuel tube protector.
(d) Tie the PS gear assembly to the proper position with a
code or an equivalent to suspend the assembly securely.
(e) Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 181 N´m (1,850 kgf´cm, 134 ft´lbf)
18. REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS
Torque:
Silver bolt: 44 N´m (450 kgf´cm, 33 ft´lbf)
Green bolt: 66 N´m (670 kgf´cm, 48 ft´lbf)
19. REMOVE LH ENGINE MOUNTING INSULATOR WITH
BRACKET
(a) Remove the 2 hole plugs, nuts and 3 bolts.
Torque:
Bolt: 64 N´m (650 kgf´cm, 47 ft´lbf)
Nut: 80 N´m (820 kgf´cm, 59 ft´lbf)
(b) Lift up the transaxle and remove the left engine mounting
insulator with the bracket.
20. REMOVE HOLE PLUG AND 3 ENGINE REAR SIDE
MOUNTING NUTS
Torque: 66 N´m (670 kgf´cm, 48 ft´lbf)
21. ATTACH ENGINE SLING DEVICE TO ENGINE HANG-
ER
(See page EM±69)
22. DISCONNECT STEERING RETURN PIPE FROM
FRONT SUSPENSION MEMBER
Remove the 2 bolts.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)

Q10008
C
C
A
CBA
ABC A
Q10011
Q10009
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE UNIT
MX±7
1857 Author: Date:
23. REMOVE FRONT SUSPENSION MEMBER WITH LOW-
ER SUSPENSION ARM
(a) Remove the LH and RH fender liner set screws.
(b) Remove the 6 bolts, 4 nuts, front LH and RH suspension
member braces, rear LH and RH suspension member
braces and front suspension member with the lower sus-
pension arm.
Torque:
Bolt A: 181 N´m (1,850 kgf´cm, 134 ft´lbf)
Bolt B: 32 N´m (330 kgf´cm, 24 ft´lbf)
Nut C: 36 N´m (370 kgf´cm, 27 ft´lbf)
24. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
25. REMOVE LH STIFFENER PLATE
Remove the 3 bolts and LH stiffener plate.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
26. REMOVE REAR END PLATE WITH OIL PAN INSULA-
TOR AND RH STIFFENER PLATE
(a) Remove the 2 bolts and rear end plate with the oil pan in-
sulator.
Torque: 9.3 N´m (95 kgf´cm, 82 in.´lbf)
(b) Remove the 2 bolts and manifold stay.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Remove the 4 bolts and RH stiffener plate.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
27. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:
At the time of installation, please refer to the following items.

Align the input shaft with the clutch disc and install the
transaxle to the engine.

Temporarily tighten the transaxle mounting bolts.

MX04E±01
MX±8
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE UNIT
1858 Author: Date:
INSTALLATION
Installation is in the reverse order of removal (See page MX±4).
HINT:

Front wheel alignment (See page SA±4).

Do the road test.