TOYOTA CAMRY V20 1986 Service Information

ASSEMBLY OF INPUT SHAFT ASSEMBLY
(See page MT±134)
HINT: Coat all the sliding and rotating surface with gear oil b¿¿ore
assembly.
1. INSERT NO.2 CLUTCH 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: install the key springs positioned so that their end gaps are
not in line.
2. INSTALL NEEDLE ROLLER BEARING. THIRD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE
ASSEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearings.
(b) Install the 3rd gear.
(e) Place the synchronizer ring 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
Select a snap ring that will allow minimum axial play and
install it on the shaft.
Snap ring thickness:
4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clear-
ance.
Standard clearance: 0.10 ± 0.35 mm
(0.0039 ± 0.0138 in.)(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.060 mm (0.0024 in.)
Thicknessmm (in.)Mark
± MANUAL TRANSAXLEComponent Parts (Input Shaft AssemblyMT±137

5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARINGS, FOURTH GEAR AND RADIAL
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
the ring slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the radial ball bearing.
SST 09506±35010
6. INSTALL ±SNAP RING
Select a snap ring that will allow minimum axial play and
install it on the shaft.
Snap ring thickness:
7. MEASURE FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 4th gear thrust
clearance.
Standard clearance: 0.10 ± 0.55 mm
(0.0039 ± 0.0217 in.)
8. INSTALL INPUT SHAFT FRONT BEARING INNER
RACE
Using SST and a press, install the input shaft front
bearing inner race.
SST 09316±60010 (09316±00020)
Thicknessmm (in.)Mark
± MANUAL TRANSAXLEComponent Parts (Input. Shaft Assembly)MT±138

DISASSEMBLY OF OUTPUT SHAFT
ASSEMBLY
1. MEASURE FIRST AND SECOND GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1 st gear 0.10 ± 0.35 mm
(0.0039 ± 0.0138 in.)2nd gear 0.10 ± 0.45 mm
(0.0038 ± 0.0177 in.)
Maximum clearance:
1 st gear 0.40 mm (0.0157 in.)
2nd gear 0.50 mm (0.0197 in.)
Output Shaft Assembly
± MANUAL TRANSAXLEComponent Parts (Output Shaft Assembly)MT±139

2. CHECK OIL CLEARANCE OF FIRST AND SECOND
GEAR
Using dial indicator, measure the oil 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 ± 0.0020 in.)
Maximum clearance: 0.080 mm (0.0031 in.)
If the clearance exceeds the limit, replace the gear,
needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, FOURTH
DRIVEN GEAR AND SPACER
(a) Using a press, remove the bearing and 4th driven
gear.
(b) Remove the spacer.
7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND FIRST
GEAR
Using a press, remove No. 1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE
ROLLER BEARING 4. REMOVE THIRD DRIVEN GEAR AND SECOND GEAR
Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 09950±00020
5. REMOVE NEEDLE ROLLER BEARING. SECOND GEAR
BUSHING AND BALL
6. REMOVE SYNCHRONIZER RING
± MANUAL TRANSAXLEComponent Parts (Output Shaft AssemblyMT±140

3. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
second gear bushing and output shaft journal sur-
face.
Minimum outer diameter:
Part A: 44.950 mm (1.7697 in.)
Part B: 43.950 mm (1.7303 in.)
INSPECTION OF OUTPUT SHAFT
COMPONENT PARTS
1. INSPECT SYNCHRONIZER RINGS
(a) Check for wear or damage.
(b) Turn the ring and push it in to check the braking action.
2. MEASURE CLEARANCE OF NO.1 SHIFT FORK AND
HUB SLEEVE
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 limit, replace the shift fork
or hub sleeve.(e) Measure the clearance between the synchronizer
ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the limit, replace the
synchronizer ring.
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.060 mm (0.0024 in.)
± MANUAL TRANSAXLEComponent Parts (Output Shaft AssemblyMT±141

ASSEMBLY OF OUTPUT SHAFT ASSEMBLY
(See page MT±139)
HINT: Coat all the sliding and rotating surface with gear oil before
assembly.
1. INSERT 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: Install the key springs positioned so that their end gaps are
not in line.
2. INSTALL NEEDLE ROLLER BEARINGS, FIRST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearings.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for 1st gear) on the gear
and align the ring slots with the shifting keys.
NOTICE: Do not install the synchronizer ring for 2nd gear.
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING
(a) Using SST and a press, remove the bearing.
SST 09307±12010, 09950±00020
(b) Using SST and a press, install a new bearing.
SST 09316±60010 (09316±00070)
± MANUAL TRANSAXLEComponent Parts (Output Shaft Assembly)MT±142

3. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.10 ± 0.35 mm
(0.0039 ± 0.0138 in.)
5. SYNCHRONIZER RING, SECOND GEAR AND THIRD
DRIVEN GEAR
(a) Place the synchronizer ring (for 2nd gear) on the gear
and align the ring slots with the shifting keys.
NOTICE: Do not install the synchronizer ring for 1 st gear.
4. INSTALL BALL, SECOND GEAR BUSHING, NEEDLE
ROLLER BEARING
(a) Install the ball and bushing.
(b) Apply MP grease to the needle roller bearing.
(e) Install the needle roller bearing.(d) Using SST and a press, install the 1 st gear and
No. 1
hub sleeve.
SST 09316±60010¿09316±000401
(b) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
± MANUAL TRANSAXLEComponent Parts (Output Shaft Assembly)MT±143

6. MEASURE SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust
clearance.
Standard clearance: 0.10 ± 0.45 mm
(0.0039 ± 0.0177 in.)
8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the output shaft rear ta-
per roller bearing.
SST 09506±30012 7. INSTALL SPACER AND FOURTH DRIVEN GEAR
(a) Install the spacer.
(b) Using a press, install the 4th driven gear.
± MANUAL TRANSAXLEComponent Parts (Output Shaft Assembly)MT±144

REMOVAL OF COMPONENT PARTS
COMPONENTS
± MANUAL TRANSAXLERemoval of Component PartsMT±118

COMPONENTS (Cont'd)
± MANUAL TRANSAXLERemoval of Component PartsMT±119