TOYOTA CAMRY 1999 Service Repair Manual

MX04O±01
Q05794
2nd Gear
1st Gear
SM0137
CM0065
SST
MT0063
SST
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
MX±29
1879 Author: Date:
DISASSEMBLY
1. INSPECT 1ST AND 2ND GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st 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:
1st gear: 0.35 mm (0.0138 in.)
2nd gear: 0.50 mm (0.0197 in.)
2. INSPECT 1ST AND 2ND GEARS RADIAL CLEAR-
ANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
0.009 ± 0.053 mm (0.0004 ± 0.0021 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR
AND OUTPUT GEAR SPACER
(a) Using SST and a press, remove the rear ball bearing and
4th driven gear.
SST 09950±00020
(b) Remove the output gear spacer and ball.
4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE
ROLLER BEARING AND SYNCHRONIZER RING
(a) Shift the No.1 hub sleeve into the 1st gear.
(b) Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 09950±00020
(c) Remove the needle roller bearing and synchronizer rings.

Z00427
Q02948
MX±30
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
1880 Author: Date:
5. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR,
SYNCHRONIZER RING, NEEDLE ROLLER BEARING,
THRUST WASHER AND LOCKING BALL
(a) Using a press, remove the No.1 hub sleeve, 1st gear and
synchronizer ring.
(b) Remove the needle roller bearing and locking ball.
(c) Using a screwdriver and hammer, drive out the thrust
washer.
6. REMOVE NO.1 HUB SLEEVE, 3 SHIFTING KEYS AND
SPRINGS FROM NO.1 CLUTCH HUB

MX04P±01
WM0064
WM0065
MT0780
MT0787
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
MX±31
1881 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 the gear spline end.
Minimum clearance:
0.6 mm (0.024 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 the braking effect is insufficient, 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
CM0014
ACB
CM0015
MX±32
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
1882 Author: Date:
3. INSPECT 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.
4. 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.)
Part B: 37.970 mm (1.4949 in.)
Part C: 31.990 mm (1.2594 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
(b) Using a dial indicator, check the shaft runout.
Maximum runout:
0.05 mm (0.0020 in.)
If the runout exceeds the maximum, replace the output shaft.

MX04Q±01
Q02949
Front
SM0199
SST
Z00428
Z00429
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
MX±33
1883 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 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Position the identification groove of the hub sleeve to the front
of the transmission.
2. INSTALL THRUST WASHER, 1ST GEAR, NEEDLE
ROLLER BEARING, SYNCHRONIZER RING AND NO.1
HUB SLEEVE TO OUTPUT SHAFT
(a) Using SST and a press, install the thrust washer.
SST 09316±60011 (09316±00041)
(b) Apply gear oil to the needle roller bearing.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Using a press, install the 1st gear and No.1 hub sleeve.
3. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MX±28)

MT0792
SM0201
SST
Z00431
SM0202
SST MX±34
± MANUAL TRANSAXLE (S51)OUTPUT SHAFT
1884 Author: Date:
4. INSTALL SYNCHRONIZER RING, 2ND GEAR,
NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
(a) Install the ball.
(b) Fit the 2nd gear bushing groove securely over the ball
when installing the 2nd gear bushing on the shaft.
(c) Place the synchronizer rings on the 2nd gear.
(d) Apply gear oil to the needle roller bearing and install it.
(e) Install the 2nd gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
(f) Using SST and a press, install the 3rd driven gear.
SST 09316±60011 (09316±00011)
5. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MX±28)
6. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN
GEAR AND RADIAL BALL BEARING
(a) Install the outer gear spacer.
(b) Using a press, install the 4th driven gear and bearing.
7. INSTALL REAR BEARING
Using SST and a press, install the rear bearing.
SST 09612±22011

MX04R±01
Q10277
Shift and Select Lever Shaft
Select Spring Seat
Shift Interlock Plate
Compression Spring
Select Spring Seat No.2Shift Inner Lever No.2Shift Inner Lever No.1Slotted Spring Pin
Control Shaft CoverControl Shaft Lever Lever Lock PinWasher Dust Boot
O±RingOil Seal


N´m (kgf´cm, ft´lbf)
: Specified torque
MP Grease Non±reusable partE±Ring
E±Ring

Compression Spring
6.4 (85, 56 in.´lbf)


± MANUAL TRANSAXLE (S51)SHIFT AND SELECT LEVER SHAFT
MX±35
1885 Author: Date:
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

MX04S±01
Z19302
Ring GearOuter Race and Side Bearing
Pinion Thrust Washer
Pinion Gear
Pinion Shaft
Side Gear
Side Gear Thrust Washer Side Bearing and Outer Race
Vehicle Speed Sensor Drive Gear Straight Pin Differential Case
Non±reusable partShim x 8

83 (850, 61)

Shim


N´m (kgf´cm, ft´lbf) : Specified torque MX±36
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
1886 Author: Date:
DIFFERENTIAL CASE
COMPONENTS

MX04T±01
Q08148
SST
Q04969
SST
AT2799
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
MX±37
1887 Author: Date:
DISASSEMBLY
1. Vehicle Speed Sensor Drive Gear Side:
REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
(a) Using SST, remove the bearing from the drive gear side
of the case.
SST 09950±00020, 09950±00030
(b) Remove the vehicle speed sensor drive gear.
2. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and case.
(b) Remove the 8 bolts.
(c) Using a copper hammer, tap on the ring gear to remove
it from the case.
3. Ring Gear Side:
REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
Using SST, remove the bearing from the ring gear side of the
case.
SST 09950±00020, 09950±00030
4. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear
while holding one pinion toward the case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washer to the side gears.
5. DISASSEMBLE DIFFERENTIAL CASE
(a) Using a pin punch and hammer, drive out the straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinions and side gears with the 4 thrust
washers from each gear.

Q08145
SST
SM0286
SST
SM0155
SST
Z00442
MT0634
SST MX±38
± MANUAL TRANSAXLE (S51)DIFFERENTIAL CASE
1888 Author: Date:
6. Transaxle Case Side:
IF NECESSARY, REPLACE DIFFERENTIAL SIDE
BEARING RETAINER OIL SEAL
(a) Using SST and a hammer, drive out the oil seal from the
retainer.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07150)
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case surface.
SST 09350±32014 (09351±32130, 09351±32150)
(c) Coat the lip of the oil seal with MP grease.
7. Transmission Case Side:
IF NECESSARY, REPLACE SIDE OIL SEAL
(a) Using a screwdriver and hammer, drive out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case surface.
SST 09350±32014 (09351±32130, 09351±32150)
(c) Coat the lip of the oil seal with MP grease.
8. Transaxle Case Side:
IF NECESSARY, REPLACE SIDE BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race.
(b) Install the bearing retainer without an O±ring.
(c) Install and torque the 6 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(d) Place the thinnest shim into the case.
(e) Using SST and a press, install a new bearing outer race.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07150)
(f) Remove the 6 bolts.
(g) Remove the bearing retainer and shim.