manual transmission TOYOTA CAMRY V20 1986 Service Information

DISASSEMBLY OF SHIFT AND SELECT LEVER
SHAFT ASSEMBLY
1. REMOVE N0.2 SHIFT INNER LEVER
(a) Using a pin punch and a hammer, drive out the slatted spring pin
and remove the transmission oil baffle.
(b) Using two screwdrivers and a hammer, remove
the snap ring.
(c) Remove No.2 select spring seat, No.2 compres-
sor spring and No.2 shift inner lever.
Shift and Select Lever Shaft
± MANUAL TRANSAXLEComponent Parts (Shift and Select Lever ShaftMT±150

6. INSTALL NO.2 SHIFT INNER LEVER
(a) Install the No.2 shift inner lever, No.2 compression
spring, transmission oil baffle and No.2 select spring
seat, as shown.
(c) Using a pin punch and hammer, drive in the
slotted spring pin. (b) Install the snap ring.
± MANUAL TRANSAXLEComponent Parts (Shift and Select Lever Shaft)MT±154

INSPECTION OF DIFFERENTIAL CASE
1. MEASURE DIFFERENTIAL NO.1 AND NO.2 CASE
Using a cylinder gauge, measure the inner diameter of
the differential No.1 and No.2 case.
Standard diameter:
No±1 case 104.000 ± 104.035 mm
(4.0945 ± 4.0959 in.)
No.2 case 97.000 ± 97.035 mm
(3.8189 ± 3.8203 in.)
Maximum diameter:
No.1 case 104.060 mm (4.0968 in.)
No.2 case 97.060 mm (3.8213 in.)
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of front
differential case.
Standard diameter: A 103.929 ± 103.964 mm
(4.0917 ± 4.0931 in.)
B 96.929 ± 96.964 mm
(3.8161 ± 3.8175 in.)
Minimum diameter: A 103.850 mm (4.0886 in.)
B 96.850 mm (3.8130 in.)
3. MEASURE CONICAL SPRING WASHER
Using a caliper, measure the height of the conical spring
washer.
Standard height:
No.1 case conical spring washer
1.85 ± 2.05 mm (0.073 ± 0.081 in.)
No.2 case conical spring washer
2.60 ± 2.80 mm (0.102 ± 0.110 in.)
Minimum height:
No±1 case conical spring washer
1.75 mm (0.069 in.)
No.2 case conical spring washer
2.50 mm (0.098 in.)
4. (TRANSMISSION CASE SIDE)
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver, remove the oil seal. (b) Using a pin punch and hammer, drive out the side bear-
ing evenly through two holes in the differential
No±2 case.
± MANUAL TRANSAXLEComponent Parts (Differential Case Assembly E5SF5)MT±159

(e) Install the new transmission oil baffle.
HINT:
wInstall the transmission oil baffle projection into
the case side cutout.
wDo not install the oil baffle when adjusting the dif-
ferential side bearing preload.
(f) Install the adjusting shim.
(See page MT± 168)
HINT: First select and install a shirr of lesser thick-
ness than before. (c) Using a brass bar and hammer, drive out the bearing
outer race lightly and evenly.
(d) Remove the adjusting shim.
Using SST and a press, install the taper roller bear-
ing outer race.
SST 09316±60010 (09316±00010,09316±00040) (b) Using a screw driver and hammer, drive out the
transmission oil baffle.
± MANUAL TRANSAXLEComponents Parts (Differential Case Assembly)MT±160

12. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT: If necessary, tap on the case with a plastic ham-
mer.
(b) Install and torque the seventeen bolts.
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
10. INSTALL DIFFERENTIAL NO.2 CASE
(a) Install the conical spring washer and No.2 side gear
thrust washer (Previously selected).
HINT: Be careful not to mistake the direction of conical
spring washer.
(a) Install the differential No.2 case to the No. 1
case.
HINT: Align the matchmarks on the differential No.1
case and connect the N.2 case.
11. INSTALL DIFFERENTIAL CASE ASSEMBLY
Install the differential case assembly ±to the transaxle
case.(c) Install and torque the sixteen bolts.
Torque: 1,260 kg±cm (91 ft±ib, 124 N±m)
± MANUAL TRANSAXLEComponent Parts (Differential Case Assembly E5SF5)MT±167

13. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Turn the differential case assembly counterclockwise and clock-
wise several time.
(b) Using a spring tension gauge, measure the differential case as-
sembly preload.
Preload (at starting)
New bearing
3.2 ± 6.3 kg
(7.1 ±13.9 lb,31.4±61.8N)
Reused bearing
2.0 ± 4.0 kg
(4.4±8.81b,19.6±39.2N)
If the preload is not within specification, select the thrust
washers.
HINT: The preload will change about 2.4 kg (5.3 Ib, 23.5 N) with
each shim thinness.
14. REMOVE TRANSMISSION CASE
Remove the seventeen bolts and tap off the case with a
plastic hammer.
15. REMOVE DIFFERENTIAL CASE ASSEMBLY
Thickness mm (in.) Thickness mm (in.)
Mark Mark
± MANUAL TRANSAXLEComponent Parts (Differential Case Assembly E5SF5)MT±168

INSTALLATION OF COMPONENT
PARTS
(See pages MT±118 to MT±120)
HINT: Coat all of the sliding and rotating surface with
gear oil before assembly.
1. ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle
case.
(b) Install the transmission case to the transaxle case.
If necessary, tap on the case with a plastic hammer.
(e) Install and torque the seventeen bolts.
Torque: 300 kg±cm (22 ft±lb, 29 N±m)
(e) Install the adjusting shim.
HINT: When re±using the output shaft rear bearing,
first install a shim of the same thickness as before.
If installing a new bearing, first select and install a
shim of lesser thickness than before.
(f) Using a torx wrench, install and torque the
seven torx screws.
Torx wrench T45 09042±00050
Torque: 430 kg±cm (31 ft±Ib, 42 N±m)
(d) Install the output shaft rear bearing outer race.
± MANUAL TRANSAXLEInstallation of Component PartsMT±190

16. INSTALL TRANSMISSION CASE
(a) Remove any packing material and be careful not to drop oil on
the contacting surfaces of the transaxle case.
(b) Apply seal packing to the transmission case as shown in the fig-
ure.
Seal packing: Part No.08826±00080, THREE BOND
1281 or equivalent
HINT: Install the transmission case as soon as the seal packing
is applied.
(c) Install and torque the seventeen bolts.
Transmission case side: Fourteen bolts
Transaxle case side: Three bolts
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
(d) Torque the two oil pipe bolts and reverse shift arm
bracket bolt.
Torque: 175 kg±cm (13 ft±lb, 17 N±m)
17. INSTALL AND TORQUE REVERSE IDLER GEAR
RETAINING BOLT WITH GASKET
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
(e) Install a new gasket to the oil pipe.
± MANUAL TRANSAXLEInstallation of Component PartsMT±197

25. INSTALL TRANSMISSION CASE COVER
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transmis-
sion case cover.
(b) Apply seal packing to the transmission case as shown
in the figure.
Seal packing: Part No.08826±00090, THREE
BOND
1281 or equivalent
HINT: Install the transmission case cover as soon as the
seal packing is applied.
Install and torque the ten bolts.
Torque: 300 kg±cm (22 ft±Ib, 29 N±m)
24. INSTALL LOCK NUT
(a) Engage the gear double meshing.
(b) install and torque a new lock nut.
Torque: 1,250 kg±cm (90 ft±Ib, 123 N±m)
(e) Stake the lock nut.
(d) Disengage the gear double meshing.
± MANUAL TRANSAXLEInstallation of Component PartsMT±201

Transmission case x Transaxle case
Transmission case x Case cover
Transmission case protector
Rear bearing retainer
Output shaft front bearing lock plate
Input shaft oil receiver
5th driven gear lock nut
Reverse idler shaft lock bolt
Control shaft cover
Reverse shift arm bracket
No.3 shift fork x Shift fork shaft Side bearing preioad (at starting)
Side bearing adjusting shim thickness
Shift lever preload
Shift lever seat shim thickness
Specifications (Cont'd)
Torque Specifications
Part tightened
± SERVICE SPECIFICATIONSManual Transaxle (S51)A±4