TOYOTA CAMRY 1999 Service Repair Manual

MX04F±02
Z19123
Transmission Case Cover5th Driven GearRear Bearing Retainer
No.3 Shift Fork N0.3 Hub Sleeve No.3 Clutch Hub Assembly Needle Roller BearingRelease ForkTransmission
CaseDifferential Side
Bearing Retainer
Transmission
Case Protector Straight Screw Plug
Shift and Select Lever
Assembly
Selecting Bellcrank Back±UP
Light SwitchLock Ball
Assembly Release Bearing
Retainer
Vehicle
Speed Sensor
Release
BearingReverse
Restrict Pin

O±Ring Shim
x 6 Slotted
Spring Pin
Gasket
Clutch Release Fork
Support
x 17
Snap RingLock Nut Filler Plug
Lock Boltx 5
Spacer
5th Gear
x 8 Boot

Gasket 
Gasket Drain Plug
Snap Ring






Non±reusable part
Precoated part: Specified torque
N´m (kgf´cm, ft´lbf)
5.4 (55, 48 in.´lbf)
13 (130, 9)
123 (1,250, 90)
37 (375, 27)29 (300, 22)

44 (450, 33)
18 (185, 13)
18 (185, 13)
42 (430, 31)
29 (300, 22)
29 (300, 22)
49 (500, 36)
39 (400, 29)
18 (185, 13)
29 (300, 22)
7.4 (75, 65 in.´lbf)
37 (380, 27)
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
MX±9
1859 Author: Date:
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

Z18962Non±reusable part: Specified torque
N´m (kgf´cm, ft´lbf)Transaxle Case
No.2 Shift Fork ShaftReverse Shift Fork
Interlock Pin
No.1 Shift Fork
No.1 Shift Fork Shaft No.1 Shift Head
Differential Case Assembly
Input Shaft Front Bearing
Input Shaft Assembly
Output Shaft CoverOutput Shaft Front Bearing Reverse Idler Gear
and Shaft Reverse Shift ArmBearing Lock PlateTransaxle Case
Receiver Oil Seal
No.2 Shift Fork
Output Shaft Assembly 


7.4 (75, 65 in.´lbf)
18 (185, 13)
MX±10
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
1860 Author: Date:

MX04G±02
Z18142FIPG
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
MX±11
1861 Author: Date:
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK±UP LIGHT SWITCH
Torque: 44 N´m (450 kgf´cm, 33 ft´lbf)
3. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
4. REMOVE RELEASE BEARING RETAINER
Remove the 3 bolts and retainer.
Torque: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
5. REMOVE SELECTING BELLCRANK
Remove the 2 bolts and selecting bellcrank.
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
6. REMOVE TRANSMISSION CASE COVER
(a) Remove the 8 bolts.
Sealant:
Part No.08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Using a plastic hammer, tap the transmission case cover
and remove it.
FIPG:
Part No. 08826 ± 00090, THREE BOND 1281 or equiva-
lent
7. REMOVE LOCK BALL ASSEMBLY
Sealant:
Part No.08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
8. REMOVE SHIFT AND SELECT LEVER ASSEMBLY
HINT:
At the time of installation, please refer to the following item.
Apply FIPG to the underside of the flanged portion of the control
shaft cover.
FIPG:
Part No. 08826 ± 00090, THREE BOND 1281 or equiva-
lent
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)

Q02530
Q05696
Install
Remove
Q05200
SST
Z00455
SSTSST
Q02695
MX±12
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
1862 Author: Date:
9. REMOVE OUTPUT SHAFT LOCK NUT
(a) Unstake the nut.
(b) Engage the gear double meshing.
(c) Rotate the lock nut clockwise and remove it.
Torque: 123 N´m (1,250 kgf´cm, 90 ft´lbf)
HINT:
The lock nut has LH threads.
(d) Disengage the gear double meshing.
10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(b) Remove the No.3 hub sleeve and No.3 shift fork.
11. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950±40011
HINT:
At the time of installation, please refer to the following item.
Using SST, install the 5th driven gear.
SST 09309±12020
12. MEASURE 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.20 ± 0.40 mm (0.0079 ± 0.0157 in.)
Maximum clearance:
0.45 mm (0.0177 in.)

Q02696
Q02726
SST
Socket Wrench
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
MX±13
1863 Author: Date:
13. MEASURE 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009 ± 0.050 mm (0.0004 ± 0.0020 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or input shaft.
14. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of installation, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
132.20±2.25
(0.0866±0.0886)212.60±2.65
(0.1024±0.1043)
142.25±2.30
(0.0886±0.0906)222.65±2.70
(0.1043±0.1063)
152.30±2.35
(0.0906±0.0925)232.70±2.75
(0.1063±0.1083)
162.35±2.40
(0.0925±0.0945)242.75±2.80
(0.1083±0.1102)
172.40±2.45
(0.0945±0.0965)252.80±2.85
(0.1102±0.1122)
182.45±2.50
(0.0965±0.0984)262.85±2.90
(0.1122±0.1142)
192.50±2.55
(0.0984±0.1004)272.90±2.95
(0.1142±0.1161)
202.55±2.60
(0.1004±0.1024)±±
(b) Using SST and a socket wrench, remove the No.3 clutch
hub with the synchronizer ring.
SST 09950±30010

Q02682
SST
Q05785
x 5
Q05826
x 17
x 6
Q09474FIPG MX±14
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
1864 Author: Date:
HINT:
At the time of installation, please refer to the following item.
Using SST and a press, install the No.3 clutch hub assembly.
SST 09612±22011
(c) Remove the 5th gear.
15. REMOVE NEEDLE ROLLER BEARING
16. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Sealant:
Part No.08833 ± 00070, THREE BOND 1324 or equiva-
lent
Torque: 42 N´m (430 kgf´cm, 31 ft´lbf)
17. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT:
If it is difficult to remove and install the snap rings, pull up the
shafts.
18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
AND GASKET
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
AND SHIM
Remove the 6 bolts, retainer and shim.
Sealant:
Part No.08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
20. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Using a plastic hammer, tap the transmission case and re-
move it.
FIPG:
Part No. 08833 ± 00090, THREE BOND 1281 or equiva-
lent

Q05827
Q03065
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
MX±15
1865 Author: Date:
21. REMOVE REVERSE IDLER GEAR AND SHAFT
(a) Pull out the shaft.
(b) Remove the idler gear and thrust washer.
22. REMOVE REVERSE SHIFT ARM
(a) Shift the fork shaft into reverse.
(b) Remove the 2 bolts and pull off the reverse shift arm.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
23. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT
HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE
SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUT-
PUT SHAFTS ASSEMBLY
24. REMOVE DIFFERENTIAL CASE ASSEMBLY
25. REMOVE MAGNET FROM TRANSAXLE CASE
26. REMOVE NO.2 SHIFT FORK SHAFT
(a) Using a hexagon wrench, remove the straight screw plug.
Sealant:
Part No.08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Using a pin punch and hammer, drive out the slotted
spring pin.
(c) Pull out the shaft.
27. SEPARATE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT
HEAD, NO.1, NO.2 SHIFT FORKS AND REVERSE
SHIFT FORK
(a) Mount the shift forks to the vise.
(b) Using a pin punch and hammer, drive out the slotted
spring pin from the No.1 fork shaft.
(c) Using a pin punch and hammer, drive out the slotted
spring pin from the No.1 fork shaft, as shown.
(d) Separate the No.1 shift fork shaft, No.1 shift head, No.1
and No.2 shift forks and reverse shift fork.

MT0781
MX±16
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
1866 Author: Date:
28. 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.

MX05M±01
WM0066
Z00409
SSTSST
Z00410
SST
SST
Z00411
SSTSST
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
MX±17
1867 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
pushing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If the braking effect is insufficient, replace the synchronizer ring.
2. INSPECT NO.3 SHIFT FORK AND NO.3 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.
3. IF NECESSARY, REPLACE INPUT SHAFT FRONT
BEARING
(a) Remove the 2 bolts and transaxle case receiver.
(b) Using SST, pull out the bearing.
SST 09308±00010
(c) Using SST, press in a new bearing.
SST 09310±35010
(d) Install the transaxle case receiver and torque the 2 bolts.
Torque: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
4. 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

Z00593
SSTSST
Front
Z00413
SST0 ± 0.5mm
Z00596
13.5 ± 0.5mm MX±18
± MANUAL TRANSAXLE (S51)MANUAL TRANSAXLE ASSEMBLY
1868 Author: Date:
(c) Using SST, press in a new bearing.
SST 09310±35010
(d) Install the bearing lock plate and torque the bolt.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
5. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL
SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST, drive in a new oil seal.
SST 09608±00081, 09950±70010 (09951±07150)
Drive in depth:
0 ± 0.5 mm (0 ± 0.020 in.)
(c) Coat the lip of the oil seal with MP grease.
6. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench, remove the straight 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.
Drive in depth:
13.5 ± 0.5 mm (0.531 ± 0.020 in.)
(e) Apply sealant to the plug threads.
Sealant:
Part No.08833 ± 00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench, install and torque the straight
screw plug.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)