41 Manual Transmission Transaxle

411
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM
MANUAL TRANSAXLE SYSTEM

4105201
PROBLEM SYMPTOMS TABLE

Use the table below to help you determine the cause of the problem. The numbers in the column of Suspect Area indicate the possibility of the problem in descending order. Therefore, check the areas in this order. If necessary, replace or exchange these parts.
Symptom 1. 2. 3. 4. 1. 2. 3. 4. Suspect Area Oil (Level low) Oil (Wrong) Gear (Worn or damaged) Bearing (Worn or damaged) Oil (Level too high) Gasket (Damaged) Oil seal (Worn or damaged) ORing (Worn or damaged) See page 412 412 4115 4115 412 4115 4115 4115 417 419 4115 4115 4115 4115 4115 4115
Noise
Oil leakage
1. Control cable (Faulty) Hard to shift or will not shift 2. Synchronizer ring (Worn or damaged) 3. Shift key spring (Damaged) 1. 2. 3. 4. Locking ball spring (Damaged) Shift fork (Worn) Gear (Worn or damaged) Bearing (Worn or damaged)
Jumps out of gear
2002 CAMRY REPAIR MANUAL (RM881U)
Author :
Date :
2131
412
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE OIL
MANUAL TRANSAXLE OIL

4105101
ONVEHICLE INSPECTION
1. (a) (b) (c) CHECK TRANSAXLE OIL Stop the vehicle on the level place. Remove the transmission filler plug and gasket. Check that the oil surface is within 5 mm (0.20 in.) from the lowest position of the inner surface of the transmission filler plug opening. NOTICE: S Excessively large or small amount of oil may cause troubles. S After exchanging oil, drive the vehicle and check the oil level. (d) Check for oil leakage when the oil level is low. (e) Install the transmission filler plug and new gasket. Torque: 49 Nm (500 kgfcm, 36 ftlbf)
0 5 mm (0 0.20 in.)
D25304
Author :
Date :
2132
413
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL
FRONT DIFFERENTIAL OIL SEAL

4104T02
REPLACEMENT
1. 2. 3. DRAIN MANUAL TRANSAXLE OIL Torque: 49 Nm (500 kgfcm, 36 ftlbf) REMOVE FRONT WHEEL REMOVE FRONT DRIVE SHAFT ASSY LH (See page 308) SST 0952001010, 0952024010 (0952032040) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 308)
4.
5.
REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL Using SST, remove the oil seal. SST 0930800010
(a)
SST
D26285
6. (a)
SST
REMOVE TRANSMISSION CASE OIL SEAL Using SST, remove the oil seal. SST 0930800010
D25305
7.
INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
SST
D25722
Coat a new oil seal lip with MP grease. Using SST and a hammer, install the oil seal. SST 0960810010, 0995070010 (0995107200) Drive in depth: 0 " 0.5 mm (0 " 0.020 in.) NOTICE: Be careful not to damage the oil seal lip.
(a) (b)
Author :
Date :
2133
414
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL
8. (a) (b)
INSTALL TRANSMISSION CASE OIL SEAL
SST
Coat a new oil seal lip with MP grease. Using SST and a hammer, install the oil seal. SST 0960832010, 0995070010 (0995107200) Drive in depth: 3.5 " 0.5 mm (0.138 " 0.020 in.) NOTICE: Be careful not to damage the oil seal lip.
D26133
9. 10. 11.
INSTALL FRONT DRIVE SHAFT ASSY LH (See page 308) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 308) INSTALL FRONT WHEEL Torque: 103 Nm (1,050 kgfcm, 76 ftlbf)
12.
ADD MANUAL TRANSAXLE OIL Oil grade: API GL4 or GL5 Viscosity: SAE 75W90 Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts) Torque: 49 Nm (500 kgfcm, 36 ftlbf)
0 5 mm (0 0.20 in.)
D25304
13. 14. 15.
INSPECT AND ADJUST MANUAL TRANSAXLE OIL(See page 412) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 265) CHECK ABS SPEED SENSOR SIGNAL(See page 05404)
Author :
Date :
2134
415
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY
FLOOR SHIFT SHIFT LEVER ASSY

4104U01
REPLACEMENT
1. 2. 3. 4. 5. 6. (a) (b) 7. (a) (b) 8. (a) 9. (a) REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUBASSY REMOVE RR CONSOLE BOX REMOVE CONSOLE BOX FRONT (See page 7112) REMOVE AIR DUCT REAR NO.1 (See page 5529) REMOVE AIR DUCT REAR NO.2 (See page 5529) DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT Remove the clip and separate the top of the select cable from the shift lever assy. Turn the lock and separate the select cable from the shift lever retainer. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT Separate the top of the shift cable from the shift lever assy. Turn the lock and separate the shift cable from the shift lever retainer. REMOVE FLOOR SHIFT SHIFT LEVER ASSY Remove the 4 bolts and shift lever assy. INSTALL FLOOR SHIFT SHIFT LEVER ASSY Install the shift lever assy with 4 the bolts. Torque: 12 Nm (122 kgfcm, 9 ftlbf)
Projecting Part
Lock
10.
CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT
D26289
(a) Connect the shift cable to the shift lever retainer. NOTICE: S The projecting part of the cable outer should face upward when the shift cable is installed. S Make sure that after installation the cable outer lock is projecting from A shown in the illustration. (b) Install the top of the shift cable to the shift lever assy. 11. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (a) Connect the select cable to the shift lever retainer. NOTICE: S The projecting part of the cable outer should face upward when the select cable is installed. S Make sure that after installation the cable outer lock is projecting from A shown in the illustration.
Projecting Part
Lock
D26290
Author :
Date :
2135
416
MANUAL TRANSMISSION/TRANSAXLE Serrate Part FLOOR SHIFT SHIFT LEVER ASSY
(b)
Connect the top of the select cable to the shift lever assy and install the clip. NOTICE: S The serrate part of the select cable point should face upward when the select cable point is connected. S the clip should be inserted to the direction shown in the illustration.
D26295
12. 13. 14. 15. 16.
INSTALL AIR DUCT REAR NO.2 (See page 5529) INSTALL AIR DUCT REAR NO.1 (See page 5529) REMOVE CONSOLE BOX FRONT (See page 7112) REMOVE RR CONSOLE BOX REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUBASSY
Author :
Date :
2136
MANUAL TRANSMISSION/TRANSAXLE
FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT
417

4104V01
REPLACEMENT
1. 2. 3. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSY (See page 7112) REMOVE AIR CONDITIONING RADIATOR ASSY (See page 5529) REMOVE AIR BAG SENSOR ASSY CENTER (See page 6056) 4. REMOVE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT Remove the clip and washer and separate the top of the shift cable from the transaxle. Remove the clip and shift cable from the control cable bracket. Turn the lock and separate the shift cable from the shift lever retainer. Separate the top of the shift cable from the shift lever assy.
(a) (b) (c) (d)
Select Cable Retainer
(e) (f) (g) (h)
Remove the 2 retainer set bolts from the floor. Separate the retainer from the grommet. Remove the select cable from the grommet. Remove the shift cable through the floor hole and retainer.
Grommet Shift Cable

D26291
5.
INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT
(a) Put the shift cable through the floor hole and retainer. (b) Install the select cable to the grommet. (c) Install the retainer to the grommet. NOTICE: Fit 3 projections of the grommet into 3 holes of the retainer. (d) Install the 2 retainer set bolts. Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
Grommet Shift Cable

D26291
Author :
Date :
2137
418
Projecting Part
6. 7. 8. 9.
(e) Connect the shift cable to the shift lever retainer. NOTICE: S The projecting part of the cable outer should face upward when the shift cable is installed. S Make sure that after installation the cable outer lock is projecting from A shown in the illustration. (f) Install the top of the shift cable to the shift lever assy. (g) Connect the shift cable to the control cable bracket and install a new clip. D26292 (h) Connect the shift cable to the transaxle and install the washer and clip. INSTALL AIR BAG SENSOR ASSY CENTER (See page 6056) INSTALL AIR CONDITIONING RADIATOR ASSY (See page 5529) INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSY (See page 7112) INSPECT SRS WARNING LIGHT(See page 05690)
Lock A
Author :
Date :
2138
FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT
419

4104W01
REPLACEMENT
1. 2. 3. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSY (See page 7112) REMOVE AIR CONDITIONING RADIATOR ASSY (See page 5529) REMOVE AIR BAG SENSOR ASSY CENTER (See page 6056) 4. REMOVE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT Remove the clip and washer and separate the top of the select cable from the transaxle. Remove the clip and select cable from the control cable bracket. Turn the lock and separate the select cable from the shift lever retainer. Remove the clip and separate the top of the select cable from the shift lever assy.
(a) (b) (c) (d)
(e) (f) (g) (h)
Remove the 2 retainer set bolts from the floor. Separate the retainer from the grommet. Remove the select cable from the grommet. Remove the select cable through the floor hole and retainer.
Grommet Shift Cable

D26291
5.
INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT
(a) Put the select cable through the floor hole and retainer. (b) Install the select cable to the grommet. (c) Install the retainer to the grommet. NOTICE: Fit 3 projections of the grommet into 3 holes of the retainer. (d) Install the 2 retainer set bolts. Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
Grommet Shift Cable

D26291
Author :
Date :
2139
4110
Projecting Part
Lock
(e) Connect the select cable to the shift lever retainer. NOTICE: S The projecting part of the cable outer should face upward when the select cable is installed. S Make sure that after installation the cable outer lock is projecting from A shown in the illustration.
D26290
6. 7. 8. 9.
Connect the top of the select cable to the shift lever assy and install the clip. NOTICE: S The serrate part of the select cable point should face upward when the select cable point is connected. S the clip should be inserted to the direction shown in the illustration. (g) Connect the top of the select cable to the shift lever assy and install the clip. D26295 (h) Connect the select cable to the control cable bracket and install a new clip. (i) Connect the select cable to the transaxle and install the washer and clip. INSTALL AIR BAG SENSOR ASSY CENTER (See page 6056) INSTALL AIR CONDITIONING RADIATOR ASSY (See page 5529) INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSY (See page 7112) INSPECT SRS WARNING LIGHT(See page 05690)
Serrate Part
(f)
Author :
Date :
2140
4111
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY
MANUAL TRANSAXLE ASSY

400FP01
REPLACEMENT
1. 2. 3. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE(See page 1422) REMOVE FRONT DRIVE SHAFT ASSY RH (See page 308) REMOVE FRONT DRIVE SHAFT ASSY LH (See page 308) 4. (a) (b) DISCONNECT WIRE HARNESS Disconnect the wire harness clamp. Disconnect the backup lamp switch connector and starter connector.
C92365
5. (a)
REMOVE ENGINE WIRE NO.3 Remove the bolt and engine wire No.3.
C92366
6. (a)
REMOVE WIRE HARNESS CLAMP Remove the 2 bolts and 2 wire harness clamps.
C90604
7. (a)
REMOVE STARTER ASSY Remove the 2 bolts and starter assy.
C90605
Author :
Date :
2141
4112
8.
REMOVE TRANSVERSE MOUNTING BRACKET
ENGINE
ENGINE
(a)
Remove the 3 bolts and engine mounting bracket.
C90606
9.
REMOVE MANUAL PROTECTOR
TRANSMISSION
CASE
(a)
Remove the 2 bolts and manual transmission case protector.
C90607
10. (a)
REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 Remove the 2 bolts and exhaust pipe support bracket No.1.
C90608
11.
REMOVE TRANSVERSE MOUNTING INSULATOR
ENGINE
ENGINE
(a)
Remove the 4 bolts and engine mounting insulator.
C92535
12. (a) (b) 13. (a)

D25747
REMOVE MANUAL TRANSAXLE ASSY Remove the 10 bolts. Separate and remove the transaxle from the engine. INSTALL MANUAL TRANSAXLE ASSY Align the input shaft with the clutch disc and install the transaxle to the engine.
Author :
Date :
2142
4113
A B
(b)
C B
Install the 10 bolts. Torque: Bolt A: 64 Nm (650 kgfcm, 47 ftlbf) Bolt B: 46 Nm (470 kgfcm, 34 ftlbf) Bolt C: 44 Nm (449 kgfcm, 32 ftlbf)
D25747
14.
B D A C
C92535
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Install the engine mounting insulator with the 4 bolts. Torque: 64 Nm (653 kgfcm, 47 ftlbf)
(a)
HINT: Tighten them in the order, A, B, C and D.
15. (a)
INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 Install the exhaust pipe support bracket No.1 with the 2 bolts. Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
C90608
16.
INSTALL MANUAL PROTECTOR
TRANSMISSION
CASE
(a)
Install the manual transmission case protector with the 2 bolts. Torque: 18 Nm (184 kgfcm, 13 ftlbf)
C90607
17.
INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket with the 3 bolts. Torque: 64 Nm (653 kgfcm, 47 ftlbf)
(a)
C90606
Author :
Date :
2143
4114
18. (a)
INSTALL STARTER ASSY Install the starter assy with the 2 bolts. Torque: 37 Nm (377 kgfcm, 27 ftlbf)
C90605
19. (a)
INSTALL WIRE HARNESS CLAMP Install the wire harness clamps with the 2 bolts. Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
C90604
20. (a)
INSTALL ENGINE WIRE NO.3 Install the engine wire No. 3 with the bolt. Torque: 25.5 Nm (260 kgfcm, 19 ftlbf)
C92366
21. (a) (b)
CONNECT WIRE HARNESS Connect the wire harness clamp. Connect the backup lamp switch connector and starter connector.
C92365
22. 23. 24.
INSTALL FRONT DRIVE SHAFT ASSY LH (See page 308) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 308) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE(See page 1422)
Author :
Date :
2144
4115
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (E351)
MANUAL TRANSAXLE ASSY (E351)

4105301
OVERHAUL
1. (a) REMOVE CLUTCH RELEASE FORK SUBASSY Remove the clutch release fork with clutch release bearing from the manual transaxle case.
C69774
2. (a)
REMOVE CLUTCH RELEASE BEARING ASSY Remove the clutch release bearing assy and clutch release bearing hub clip from the clutch release fork subassy. 3. (a) REMOVE RELEASE FORK SUPPORT Remove the release fork support from the manual transaxle case.
C83809
4. (a) 5. (a)
REMOVE CLUTCH RELEASE FORK BOOT Remove the clutch release fork boot from the manual transaxle case. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUBASSY Remove the bolt and speedometer driven hole cover.
6. (a)
REMOVE SELECTING BELL CRANK ASSY Remove the 2 bolts and selecting bell crank assy from manual transmission case.
C90198
C92831
Author :
Date :
2145
4116
7. (a)
REMOVE CONTROL SHIFT LEVER Remove the nut and spring washer.
C90199
C92832
(b) (c)
Using a brass bar and hammer, remove the shift outer lock pin. Remove the control shift lever.
C90200
C92833
8. (a)
REMOVE CONTROL SHAFT COVER Remove the 4 bolts and control shaft cover from the manual transmission case.
C90201
C92834
9. (a)
FIX MANUAL TRANSAXLE ASSY Using wooden blocks, fix the manual transaxle assy.
C87963
10. (a)
REMOVE LOCK BALL ASSY NO.1 Remove the lock ball assy No.1 from the manual transmission case.
C87964
Author :
Date :
2146
4117
11.
REMOVE MANUAL TRANSMISSION BREATHER PLUG Remove the manual transmission breather plug and gasket.
(a)
C87965
12. (a)
REMOVE SHIFT & SELECT LEVER SHAFT ASSY Remove the shift & select lever shaft assy from the manual transmission case.
C69776
13. (a)
REMOVE BACK UP LAMP SWITCH ASSY Remove the back up lamp switch assy and gasket from the manual transmission case.
C87966
14. (a)
REMOVE MANUAL TRANSMISSION FILLER PLUG Remove the manual transmission filler plug and gasket from the manual transmission case.
C70824
15. (a)
REMOVE DRAIN (MTM) PLUG SUBASSY Remove the drain (MTM) plug subassy and gasket from the manual transmission case.
C87967
Author :
Date :
2147
4118
16.
REMOVE MANUAL TRANSMISSION CASE COVER SUBASSY Remove the 10 bolts and manual transmission case cover from the manual transmission case.
(a)
C83219
17.
REMOVE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT Engage the gear to the double meshing.
(a)
C69266
(b)
SST
Using SST and a hammer, loosen the staked part of the manual transmission output shaft rear set nut. SST 0993000010
C87968
SST
(c)
(d)
Using SST, remove the manual transmission output shaft rear set nut from the output shaft. SST 0922955010 Disengage the double meshing of the gear.
C87969
18. (a)
INSPECT 5TH GEAR THRUST CLEARANCE Using a dial indicator, inspect the 5th gear thrust clearance. Standard clearance: 0.10 0.65 mm (0.0039 0.0256 in.)
C69517
Author :
Date :
2148
4119
19. (a)
INSPECT 5TH GEAR RADIAL CLEARANCE Using a dial indicator, inspect the 5th gear radial clearance. Standard clearance: 0.009 0.050 mm (0.0004 0.0020 in.)
HINT: If the clearance is out of the specification, replace 1st gear needle roller bearing.
C69516
20. (a)
REMOVE TRANSMISSION CLUTCH HUB NO.3 Using 2 screwdrivers and hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft.
HINT: Using a waste to prevent the snap ring from being scattered.
C69269
(b)
Remove the gear shift fork bolt from the gear shift fork No.3.
C69270
(c)
SST
Using SST, remove the transmission clutch hub No.3 and gear shift fork No.3 from the input shaft. SST 0995030012 (0995103010, 0995303010, 0995403010), 0995050013 (0995704010), 0995060010 (0995100280)
SST
C69777
21. (a)
REMOVE 5TH GEAR Remove the 5th gear from the input shaft.
C69454
Author :
Date :
2149
4120
22. (a)
REMOVE 5TH GEAR NEEDLE ROLLER BEARING Remove the 5th gear needle roller bearing from the input Shaft.
C69455
23. (a)
SST SST
REMOVE 5TH DRIVEN GEAR Using SST, remove the 5th driven gear from the output shaft. SST 0995030012 (0995103010, 0995303010, 0995403010, 0995704010), 0995060010 (0995100180, 0995503011), 0995050013
C69456
24. (a)
REMOVE BEARING RETAINER REAR (MTM) Using a torx socket wrench (T45), remove the 7 torx screws and bearing retainer rear (MTM) from the manual transmission case.
C69457
25. (a)
REMOVE OUTPUT SHAFT REAR BEARING SHIM Remove the output shaft rear bearing shim from the output shaft.
C69458
26.
REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft.
(a)
C87970
Author :
Date :
2150
4121
27. (a)
REMOVE SHIFT FORK SHAFT SHAFT SNAP RING Using 2 screwdrivers and a hammer, remove the shift fork shaft shaft snap ring from the gear shift fork shaft No.1.
C87971
(b)
Using 2 screw drivers and a hammer, remove the shift fork shaft shaft snap ring from the gear shift fork shaft No.2.
C69460
28. (a)
REMOVE REVERSE IDLER GEAR SHAFT BOLT Remove the reverse idler gear shaft bolt and gasket.
C83225
29. (a)
REMOVE CLUTCH TUBE BRACKET NO.1 Remove the 3 bolts and remove the clutch tube bracket.
30. (a)
REMOVE MANUAL TRANSMISSION CASE Remove the 3 bolts of the manual transaxle case side.
C83226
Author :
Date :
2151
4122
(b) (c)
Remove the 14 bolts of the manual transmission case side. Using a plastic hammer, remove the manual transmission case.
C83227
31. (a)
REMOVE OIL RECEIVER PIPE NO.2 (MTM)
Remove the bolt and oil receiver pipe No.2 (MTM) from the manual transmission case. NOTICE: Do not damage the pipe.
C69465
32. (a)
REMOVE OIL RECEIVER PIPE NO.1 (MTM)
Remove the bolt and oil receiver pipe No.1 (MTM) from the manual transmission case. NOTICE: Do not damage the pipe.
C69464
33. (a)
REMOVE REVERSE RESTRICT PIN ASSY Using a hexagon wrench (6 mm), remove the reverse restrict pin plug from the manual transmission case.
C70521
(b)
Using a pin punch ( 5 mm), remove the slotted pin and reverse restrict pin assy.
C69467
Author :
Date :
2152
4123
34. (a)
REMOVE TRANSMISSION MAGNET Remove the transmission magnet from the manual transaxle case.
C69468
35. (a)
REMOVE REVERSE IDLER GEAR SUBASSY Remove the reverse idler gear subassy from the manual transaxle case.
C69470
(b)
Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft.
C70512
36. (a)
REMOVE REVERSE SHIFT ARM BRACKET ASSY Remove the 2 bolts and reverse shift arm bracket from the manual transaxle case.
C83230
37. (a)
REMOVE GEAR SHIFT FORK SHAFT NO.1 Remove the shift fork bolt from the gear shift fork No.1.
C83231
Author :
Date :
2153
4124
(b)
Pull out the gear shift fork shaft No.1 while the gear fork shaft No.3 is pulled up.
C87975
(c)
Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the gear shift fork shaft No.1. NOTICE: Using a waste to prevent the snap ring from being scattered.
C69500
38. (a)
REMOVE REVERSE SHIFT FORK ROLLER Using a magnetic finger, remove the reverse shift fork roller from the reverse shift fork.
C83233
39. (a)
REMOVE GEAR SHIFT FORK SHAFT NO.2 Remove the 2 shift fork bolts from the gear shift fork No.2 and gear shift head No.1.
C83234
Shift Fork Shaft No.2 Shift Head No.1
(b)
Remove the gear shift fork shaft No.2 and gear shift head No.1 from the manual transaxle case.
C87976
Author :
Date :
2154
4125
40.
Shift Fork No.1
REMOVE GEAR SHIFT FORK NO.1
C87977
41.
Shift Fork Shaft No.3
REMOVE GEAR SHIFT FORK SHAFT NO.3 Remove the gear shift fork shaft No.3 from the manual transaxle case.
(a)
C87978
(b) (c)
Using 2 screwdriver and a hammer, remove the 2 shift fork shaft snap rings from the gear shift fork shaft No. 3. Remove the reverse shift fork from the gear shift fork shaft No.3.
C83238
42.
Shift Fork No.2
REMOVE GEAR SHIFT FORK NO.2 Remove the gear shift fork No.2 from the input shaft assy.
(a)
C87979
43. (a)
REMOVE INPUT SHAFT ASSY Incline the output shaft then remove the input shaft from the manual transaxle case.
C83240
Author :
Date :
2155
4126
44. (a)
REMOVE OUTPUT SHAFT ASSY Remove the output shaft from the manual transaxle case.
C83241
45. (a)
REMOVE DIFFERENTIAL CASE ASSY Remove the differential case assy from the manual transaxle case.
C83242
46. (a)
REMOVE MANUAL TRANSAXLE CASE RECEIVER Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case.
C83243
47. (a)
SST
REMOVE INPUT SHAFT FRONT BEARING Using SST, remove the input shaft front bearing (outer race) from the manual transaxle case. SST 0961265014 (0961201040, 0961201050)
C87980
48. (a)
SST
REMOVE FRONT TRANSAXLE CASE OIL SEAL Using SST, remove the manual transaxle case oil seal from the manual transaxle case. SST 0961265014 (0961201040, 0961201050)
C87981
Author :
Date :
2156
4127
49. (a)
SST
REMOVE OUTPUT SHAFT FRONT BEARING Using SST, remove the output shaft front bearing (outer race) from the manual transaxle case. SST 0938700041 (0938702020, 0938702010)
C87982
50. (a)
REMOVE OUTPUT SHAFT (MTM) COVER Remove the output shaft (MTM) cover from the manual transaxle case.
C69483
51.
SST
REMOVE OUTPUT SHAFT REAR BEARING Using SST, remove the output shaft rear bearing from the manual transmission case (outer race). SST 0995060010 (0995100680), 0995070010 (0995107100)
(a)
C87983
52.
SST
REMOVE TRANSMISSION CASE OIL SEAL Using SST, remove the transmission case oil seal from the manual transmission case. SST 0930800010
(a)
C87984
53.
REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL Using a screwdriver, remove the front transaxle case cover oil seal.
(a)
HINT: Tape the screwdriver tip before use.

C87985
Author :
Date :
2157
4128
54.
REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using a brass bar and a hammer, remove the FR differential case rear tapered roller bearing (outer race) from the manual transaxle case.
(a)
C69490
(b)
Using SST, remove the front differential case rear tapered roller bearing from the front differential case. SST 0995000020, 0995000030, 0995040011 (0995704010), 0995060010 (0995100560)
SST
C70822
55.
SST
REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST and hammer, remove the FR differential case front tapered roller bearing (outer race) and FR differential case rear shim from the manual transmission case. SST 0995060020 (0995100790), 0995070010 (0995107100)
(a)
C87986
(b)
Using SST, remove the FR differential case front tapered roller bearing (inner race) from front differential case. SST 0995000020, 0995000030, 0995040011 (0995704010), 0995060010 (0995100490)
SST
C90344
56.
REMOVE CONTROL SHAFT COVER BIMETAL FORMED BUSH Using SST, remove the shift & select lever shaft bimetal formed bush. SST 0931960020
(a)
C90202
C92835
Author :
Date :
2158
4129
57. (a)
INSPECT REVERSE IDLER GEAR SUBASSY
Using a callipers gauge, measure the inside diameter of the reverse idler gear. Inside diameter: mm (in.)
Standard inside diameter 20.056 20.074 (0.7896 0.7903)
C69503
Maximum inside diameter 20.074 (0.7903)
If the inside diameter is exceeds than the maximum, replace the reverse idler gear. (b) Using a micro meter, measure the outer diameter of the reverse idler gear shaft. Outer diameter: mm (in.)
Standard outer diameter 19.984 20.000 (0.7868 0.7874) Minimum outer diameter 19.984 (0.7868)
If the outer diameter is less than the minimum, replace the reverse idler gear shaft.
C69505
Hub Sleeve No.3
58. (a)
REMOVE TRANSMISSION HUB SLEEVE NO.3 Remove the transmission hub sleeve No.3 from the transmission clutch hub No.3.
C87988
59.
REMOVE SYNCHROMESH SHIFTING KEY SPRING NO.3 Push the synchromesh shifting key spring No.3 then remove the 2 synchromesh shifting key spring No.3 from the transmission clutch hub No.3.
(a)
C69507
60. (a) (b)
REMOVE SYNCHRONIZER PULL RING Using a screwdriver, remove the synchronizer pull ring snap ring. Remove the synchronizer pull ring, synchronizer outer ring No.5, synchronizer inner ring No.5 and synchronizer middle ring No.5 from the synchronizer ring No.5.
C69508
Author :
Date :
2159
4130
61. (a) (b)
INSPECT TRANSMISSION CLUTCH HUB NO.3 Inspect the sliding condition between transmission clutch hub No.3 and transmission hub sleeve No.3. Inspect tip of spline gear on the transmission hub sleeve No.3 for wear.
C69509
62. (a)
INSPECT TRANSMISSION HUB SLEEVE NO.3
Using vernier calipers, measure the transmission hub sleeve No.3 groove and the thickness of the claw part on gear shift fork No.3, and calculate the clearance. Standard clearance: 0.15 0.35 mm (0.0059 0.0138 in.) {A B} If the clearance is out of the specification, replace the transmission hub sleeve No.3 and gear shift fork No.3 with the new one.
B
C70509
63. (a)
INSPECT 5TH GEAR Using a calipers gauge, measure the inside diameter of the 5th gear. Inside diameter: mm (in.)
Standard inside diameter 34.981 34.997 (1.3772 1.3778) Maximum inside diameter 34.997 (1.3778)
C69768
If the inner diameter is exceeds than the maximum, replace the 5th gear. 64. INSTALL SYNCHRONIZER PULL RING (a) Install the synchronizer middle ring No.5, synchronizer ring outer No.5 and synchronizer pull ring to the synchronizer ring inner No.5. using a screwdriver, fix with snap ring.
C69514
Author :
Date :
2160
4131
65. (a)
INSPECT SYNCHRONIZER RING MIDDLE NO.5 Check that the synchronizer ring middle No.5 rotates smoothly.
C69510
(b)
Check that the synchronizer ring middle No.5 does not rotate while it is being pushed to the clutch hub No.3.
C69511
66.
INSTALL SYNCHROMESH SHIFTING KEY SPRING NO.3
(a)
C69515
Install the synchromesh shifting key spring No.3 to the transmission clutch hub No.3. NOTICE: Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install them. (b) Install the synchronizer ring set and synchromesh shifting key spring No.3 to the transmission clutch hub No.3. NOTICE: S Engage the shifting key spring claw to the center of the teeth of the synchronizer ring. S Align the projection of the shifting key spring with the hole of the clutch hub No.3 and install them.
67.
SST
INSTALL CONTROL SHAFT COVER BIMETAL FORMED BUSH Using SST, install the shift & select lever shaft bimetal formed bush. SST 0995060010 (0995100180), 0995070010 (0995107100) Clearance: 0.081 0.149 mm (0.0032 0.0059 in.)
(a)
C90203
C92836
Author :
Date :
2161
4132
68.
INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL Using SST and a hammer, install the front transaxle case cover oil seal. SST 0931620011, 0995060020 (0995100910), 0995070010 (0995107150) Oil seal driven in depth: 0 " 0.5 mm (0 " 0.020 in.) Coat the lip of front transaxle case cover oil seal with MP grease.
SST
(a)
C87990
(b)
69.
SST
INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST and a hammer, install the FR differential case rear tapered roller bearing (outer race) to the front transaxle case. SST 0995060020 (0995100910), 0995070010 (0995107100)
(a)
C87991
(b)
SST
Using SST and press, install the FR differential case rear tapered roller bearing (inner race) to the front differential case. SST 0995070010 (0995107100, 0995107150), 0960810010
C70823
70.
SST
INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING
(a) (b)
C87992
Install the front differential case shim rear. Using SST and a hammer, install FR differential case front tapered roller bearing (outer race). SST 0995060020 (0995100890), 0995070010 (0995107100) NOTICE: Install the case shim as thick as the removed one.
Author :
Date :
2162
4133
(c)
SST
Using SST, remove the FR differential case front tapered roller bearing (inner race) SST 0963112090, 0995060010 (0995100600), 0995070010 (0995107100)
C90204
71. (a)
INSTALL TRANSMISSION CASE OIL SEAL Using SST and a hammer, install the transmission case oil seal to the manual transmission case. SST 0960832010, 0995070010 (0995107150) Oil seal driven in depth: 3.5 " 0.5 mm (0.138 " 0.020 in.) Coat the lip of transmission case oil seal with MP grease.
SST
C87993
(b)
72.
SST
INSTALL OUTPUT SHAFT REAR BEARING Using SST and a hammer, install the output shaft rear bearing (outer race) to the manual transmission case. SST 0995060020 (0995100680), 0995070010 (0995107100) Clearance: 3.8 4.4 mm (0.150 0.173 in.)
(a)
C87994
73. (a)
INSTALL OUTPUT SHAFT (MTM) COVER
Coat the output shaft (MTM) cover with MP grease, install it to the manual transaxle case. NOTICE: Align the projection of the output shaft with the transmission grooves and install them.
C69709
74.
SST
INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a hammer, install the output shaft front bearing (outer race). SST 0995060020 (0995100730), 0995070010 (0995107100)
(a)
C87995
Author :
Date :
2163
4134
75. (a)
ADJUST OUTPUT SHAFT BEARING PRELOAD Install the output shaft to the manual transaxle case.
C83254
(b)
Install the transmission case with 14 bolts to the manual transaxle case. Torque: 29 Nm (296 kgfcm, 21 ftlbf)
C83227
(c)
Install the 3 bolts to the manual transaxle side. Torque: 30 Nm (306 kgfcm, 22 ftlbf)
C83226
(d)
Install the output shaft rear bearing shim to the output shaft.
HINT: Install the same thickness of case shim as the removed one.
C83255
(e)
(f)
Using a torx socket wrench (T45), install the bearing retainer RR with 7 screws to the manual transmission case. Torque: 42 Nm (428 kgfcm, 31 ftlbf) Install the new output rear set nut to the output shaft.
C83256
Author :
Date :
2164
4135
(g) (h)
Turn the output shaft in both directions to make it smooth. Using a socket wrench and torque wrench, inspect the preload. Preload: Nm (kgfcm, in.lbf)
Bearing New Used Torque 0.8 1.6 (8.16 16.32, 7.1 14.2) 0.5 1.0 (5.10 10.20, 4.4 8.9)
(i)
C69773
If the preload is out of the specification, select the output shaft rear bearing shim and adjust it.
HINT: The preload of the output shaft rear bearing shim varies in torque from about 0.04 to 0.06 Nm in one size. Shim: mm (in.)
Part No. 9056459001 9056459002 9056459003 9056459004 9056459005 9056459006 9056459007 9056459008 9056459009 9056459010 905645901 1 9056459012 9056459013 9056459014 9056459015 9056459016 9056459017 9056459018 9056459019 9056459020 9056459021 9056459022 9056459023 9056459024 9056459025 thickness: mm (in.) 1.30 (0.0512) 1.35 (0.0531) 1.40 (0.0551) 1.45 (0.0571) 1.50 (0.0591) 1.55 (0.0610) 1.60 (0.0630) 1.65 (0.0650) 1.70 (0.0669) 1.75 (0.0689) 1.80 (0.0709) 1.85 (0.0728) 1.90 (0.0748) 1.95 (0.0768) 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0846) 2.20 (0.0866) 2.25 (0.0886) 2.30 (0.0906) 2.35 (0.0925) 2.40 (0.0945) 2.45 (0.0965) 2.50 (0.0984) Make 0 1 2 3 4 5 6 7 8 9 A B C D E F G H J K L M N P Q
(j) (k)
Remove the output shaft rear set nut from the output shaft. Using a torx socket wrench (T45), remove the 7 screws and bearing retainer RR from the manual transmission case.
C83258
Author :
Date :
2165
4136
(l)
Remove the output shaft rear bearing shim from the output shaft.
C83255
(m)
Remove the 3 bolts.
C83226
(n)
Remove the 14 bolts and manual transmission case from the manual transaxle case.
C83227
(o)
Remove the output shaft assy from the front manual transaxle case.
C83254
76. (a)
ADJUST TAPERED POLLER BEARING PRELOAD Install differential case assy to the manual transaxle case.
C83242
Author :
Date :
2166
4137
(b)
Install the 14 bolts and manual transmission case to the manual transaxle case. Torque: 29 Nm (296 kgfcm, 21 ftlbf)
C83227
(c) (d)
Install the 3 bolts and front manual transaxle case side. Torque: 30 Nm (306 kgfcm, 22 ftlbf) Turn the differential case in both directions to make it smooth.
C83226
SST
(e)
Using SST and torque wrench, inspect preload. SST 0956432011 Preload: Nm ( kgfcm, in.lbf)
Bearing New Used Torque 0.8 1.6 (8.16 16.32, 7.1 14.2) 0.5 1.0 (5.10 10.2, 4.4 8.9)
C87996
If the preload is out of the specification, select the front differential case shim RR and adjust it. HINT: The preload of the front differential case shim RR varies in torque from about 0.04 to 0.06 Nm is one size. Shim: mm (in.)
Part No. 9056456055 9056456056 9056456057 9056456058 9056456059 9056456060 9056456061 9056456062 9056456063 9056456064 9056456065 9056456066 9056456067 9056456068 9056456069 9056456070 Thickness 2.00 (0.0787) 2.05 (0.0807) 2.10 (0.0827) 2.15 (0.0846) 2.20 (0.0866) 2.25 (0.0886) 2.30 (0.0906) 2.35 (0.0925) 2.40 (0.0945) 2.45 (0.0965) 2.50 (0.0984) 2.55 (0.1004) 2.60 (0.1024) 2.65 (0.1043) 2.70 (0.1063) 2.75 (0.1083) Mark 0 1 2 3 4 5 6 7 8 9 A B C D E F
Author :
Date :
2167
4138
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (E351) Thickness 2.80 (0.1102) 2.85 (0.1122) Mark G H
Part No. 9056456071 9056456072
(f)
Remove the 3 bolts.
C83226
(g)
Remove the 14 bolts and manual transmission case to the manual transaxle case.
C83227
(h)
Remove the differential case assy from the manual transaxle case.
C83242
77.
SST
INSTALL FRONT TRANSAXLE CASE OIL SEAL Using SST and a hammer, install the front transaxle case oil seal No.1 to the manual transaxle case. SST 0995060010 (0995100420), 0995070010 (0995107150) Coat the lip of front transaxle case oil seal No.1 with MP grease. Clearance: 1 2 mm (0.0394 0.0787 in.)
(a)
(b)
C87997
Author :
Date :
2168
4139
78.
SST
INSTALL INPUT SHAFT FRONT BEARING Coat the input shaft front bearing with gear oil, install it to the manual transaxle case. SST 0995060010 (0995100570), 0995070010 (0995107150) Clearance: 4.28 4.60 mm (0.1685 0.1811 in.)
(a)
C87998
79. (a)
INSTALL MANUAL TRANSAXLE CASE RECEIVER Install the 3 bolts and manual transaxle case receiver to the manual transaxle case. Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)
C83243
80. (a)
INSTALL DIFFERENTIAL CASE ASSY Coat the differential case taper roller bearing with gear oil, install the differential case assy to the manual transaxle case.
C83242
81. (a) (b)
INSTALL OUTPUT SHAFT ASSY Apply gear oil to each sliding part of the output shaft assy. Lift the differential case assy up with the output shaft assy leaned, and install it to the manual transaxle case.
C83241
82. (a) (b)
INSTALL INPUT SHAFT ASSY Apply gear oil to each sliding part of the input shaft assy. With the output shaft assy leaned, install the input shaft assy to the manual transaxle case.
C83240
Author :
Date :
2169
4140
83.
Shift Fork No.2
INSTALL GEAR SHIFT FORK NO.2 Coat the gear shift fork No.2 with gear oil, install it to the input shaft assy.
(a)
C87999
84. (a) (b)
INSTALL GEAR SHIFT FORK NO.3 Install the gear shift fork No.3 to the gear shift fork shaft No.3. Using a brass bar and hammer, install the 2 shift fork shaft snap rings to the gear shift fork shaft.
C83257
(c)
Apply gear oil to each sliding part of the gear shift fork shaft No.3, install it to the manual transaxle case.
C88000
85.
Shift Fork No.1
INSTALL GEAR SHIFT FORK NO.1 Apply gear oil to each sliding part of the gear shift fork No.1, install it to the output shaft assy.
(a)
C88001
Shift Fork Shaft No.2 Shift Head No.1
86. (a) (b)
INSTALL GEAR SHIFT FORK SHAFT NO.2 Install the gear shift head No.1 to the gear shift fork shaft No.2. Apply gear oil to each sliding part of the gear shift fork shaft No.2, install it to the manual transaxle case.
C88002
Author :
Date :
2170
4141
(c)
Install the 2 shift fork bolts to the gear shift head No.1. Torque: 24 Nm (245 kgfcm, 18 ftlbf)
C83234
87. (a)
INSTALL REVERSE SHIFT FORK ROLLER Using a magnetic finger, install the reverse shift fork roller to the reverse shift fork.
C83233
88. (a)
INSTALL GEAR SHIFT FORK SHAFT NO.1 Using a brass bar and hammer, install the shift fork shaft snap ring to the shift fork shaft No.1.
C69752
(b)
Install the gear shift fork shaft No.1 to the manual transaxle case.
C88003
(c)
Install the shift fork bolt to the gear shift fork No.1. Torque: 24 Nm (245 kgfcm, 18 ftlbf)
C83231
Author :
Date :
2171
4142
89. (a)
INSTALL REVERSE SHIFT ARM BRACKET ASSY Install the 2 bolts and reverse shift arm bracket assy to the manual transaxle case. Torque: 17 Nm (173 kgfcm, 13 ftlbf)
C83230
90. (a)
INSTALL REVERSE IDLER GEAR SUBASSY Coat the reverse idler gear and reverse idler thrust washer with MP grease, install them to the reverse idler gear shaft.
C70512
(b) Install the reverse idler gear to the manual transaxle case. HINT: Align the mark of the reverse idler gear shaft with the hole of the bolt.
Align the mark

C69753
91. (a)
INSTALL TRANSMISSION MAGNET Clean the transmission magnet, install it to the manual transaxle case.
C83229
92. (a)
INSTALL REVERSE RESTRICT PIN ASSY Using a pin punch ( 5mm), install the reverse restrict pin and reverse restrict pin assy. Clearance: 12.5 13.5 mm (0.492 0.531 in.)
C69759
Author :
Date :
2172
4143
(b)
Coat the reverse restrict pin plug with adhesive 1324, using hexagon wrench (6mm), install the manual transmission case. Torque: 13 Nm (133 kgfcm, 9.6 ftlbf)
C70521
93. (a)
INSTALL OIL RECEIVER PIPE NO.1 (MTM) Install the bolt and oil receiver pipe No.1 (MTM) to the manual transmission case. Torque: 17 Nm (173 kgfcm, 13 ftlbf)
HINT: Tighten the oil receiver pipe No.1 with the bolt.
C83815
94. (a)
INSTALL OIL RECEIVER PIPE NO.2 (MTM) Install the bolt and oil receiver pipe No.2 (MTM) to the manual transmission case. Torque: 17 Nm (173 kgfcm, 13 ftlbf)
HINT: Tighten the oil receiver pipe No.2 (MTM) with the bolt while manual transmission case is being put.
C69465
95. (a)
INSTALL MANUAL TRANSMISSION CASE Apply FIPG bead condition sequentially to the position shown in the diagram of the manual transmission case.
HINT: Install within 10 minutes after applying FIPG.
C69755
(b)
Install the manual transmission case and 14 bolts to the manual transaxle case. Torque: 29 Nm (296 kgfcm, 21 ftlbf)
C83227
Author :
Date :
2173
4144
(c)
Install the 3 bolts to the manual transaxle case side. Torque: 30 Nm (306 kgfcm, 22 ftlbf)
C83226
96. (a)
INSTALL CLUTCH TUBE BRACKET NO.1 Install the clutch tube with 3 bolt brackets. Torque: 17 Nm (173 kgfcm, 13 ftlbf) 97. (a) INSTALL REVERSE IDLER GEAR SHAFT BOLT Coat the bolt with sealant, install new gasket to the manual transmission case with the bolt. Torque: 30 Nm (306 kgfcm, 22 ftlbf) Sealant: Part No. 0883300080, THREE BOND 1344, LOCTITE 242 or equivalent
C83225
98. (a)
INSTALL SHIFT FORK SHAFT SHAFT SNAP RING Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No.1.
C69758
(b)
Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No.2.
C69757
Author :
Date :
2174
4145
99.
INSTALL INPUT SHAFT REAR BEARING SHAFT SNAP RING Using a snap ring expander, install the input shaft rear bearing hole snap ring.
(a)
C88004
100. INSTALL OUTPUT SHAFT REAR BEARING SHIM (a) Install the output shaft rear bearing shim to the output shaft.
HINT: Install the same thickness of the case shim as the remove one.
C69458
101. INSTALL BEARING RETAINER REAR (MTM) (a) Coat the bearing retainer rear (MTM) with sealant, install it with a torx wrench (T45). Torque: 42 Nm (428 kgfcm, 31 ftlbf)
C83259
102. INSTALL 5TH DRIVEN GEAR (a)

SST
Using SST, install the 5th driven gear to the output shaft. SST 0995030012 (0995103010, 0995303010, 0995403010, 0995603030, 0995503011)
C88005
103. INSTALL 5TH GEAR NEEDLE ROLLER BEARING (a) Coat the 5th gear needle roller bearing with gear oil, install it to the input shaft.
C69455
Author :
Date :
2175
4146
104. INSTALL 5TH GEAR (a) Coat the 5th gear with gear oil, install it to the input shaft.
C69454
105. INSTALL TRANSMISSION CLUTCH HUB NO.3 (a)

SST
C88006
Using SST, install the transmission clutch hub No.3 to the input shaft. SST 0995030012 (0995103010, 0995303010, 0995403010) NOTICE: Align the projection of the synchronizer ring with the hole of the 5th gear and install them. (b) Install the transmission hub sleeve No.3 and gear shift fork No.3 to the transmission clutch hub No.3.
C69764
(c)
Coat the shift fork bolt with sealant, install the gear shift fork No. 3. Sealant: Part No. 0883300080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 24 Nm (245 kgfcm, 18 ftlbf)
C83260
(d)
Select a snap ring that will allow minimum axial play. Using a brass bar and a hammer, install the shaft snap ring. Clearance: 0.1 mm or less Snap ring: mm (in.)
Part No. 9052027061 9052027062
C69763
Thickness 1.75 1.80 (0.0689 0.0709) 1.80 1.85 (0.0709 0.0728)
Mark a b
Author :
Date :
2176
4147
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (E351) Thickness 1.85 1.90 (0.0728 0.0748) 1.90 1.95 (0.0748 0.0768) 1.95 2.00 (0.0768 0.0787) 2.00 2.05 (0.0787 0.0807) 2.05 2.10 (0.0807 0.0827) 2.10 2.15 (0.0827 0.0846) 2.15 2.20 (0.0846 0.0866) Mark c d e f g h j
Part No. 9052027063 9052027064 9052027065 9052027066 9052027067 9052027068 9052027069
106. INSPECT 5TH GEAR RADIAL CLEARANCE (a) Using a dial indicator, inspect the 5th gear radial clearance. Standard clearance: 0.009 0.050 mm (0.0004 0.0020 in.) If the clearance is out of the specification, replace 1st gear needle roller bearing.
C69516
107. INSPECT 5TH GEAR THRUST CLEARANCE (a) Using a dial indicator, inspect the 5th gear thrust clearance. Standard clearance: 0.10 0.65 mm (0.0039 0.0260 in.)
C69517
108. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT (a) Engage the gear double meshing.
C69266
Author :
Date :
2177
4148
(b)
Install the new manual transmission output shaft rear set nut. Torque: 123 Nm (1,254 kgfcm, 91 ftlbf)
C90287
(c)
Using a chisel and a hammer, stake the manual transmission output shaft rear set nut.
C69766
109. INSTALL MANUAL TRANSMISSION CASE COVER SUBASSY (a) Apply FIPG to the transaxle case cover subassy, as shown in the installation. FIPG: Part No. 0882600090, THREE BOND 1281 NOTICE: Install the parts within 10 minutes after applying the packing material (FIPG). (b) Install the transmission case cover subassy with 10 bolts to the manual transaxle case.
C69756
C83219
110. INSTALL DRAIN (MTM) PLUG SUBASSY (a) Install the drain plug subassy with new gasket to the manual transmission case. Torque: 49 Nm (500 kgfcm, 36 ftlbf)
C87967
Author :
Date :
2178
4149
111. INSTALL MANUAL TRANSMISSION FILLER PLUG (a) Install the manual transmission filler plug with new gasket to the oil seal. Torque: 49 Nm (500 kgfcm, 36 ftlbf)
C70824
112. INSTALL SHIFT & SELECT LEVER SHAFT ASSY (a) Coat the shift & select lever shaft assy with gear oil, install it to the manual transmission case.
C69776
113. INSTALL BACK UP LAMP SWITCH ASSY (a) Install back up lamp switch assy to the manual transmission case. Torque: 40 Nm (408 kgfcm, 30 ftlbf)
C87966
114. INSTALL MANUAL TRANSMISSION BREATHER PLUG (a) Install the new gasket with manual transmission breather plug to the manual transmission case. Torque: 49 Nm (500 kgfcm, 36 ftlbf)
C87965
115. INSTALL LOCK BALL ASSY NO.1 (a) Install the lock ball assy No.1 to the manual transmission case. Torque: 29 Nm (296 kgfcm, 21 ftlbf)
C87964
Author :
Date :
2179
4150
116. INSTALL CONTROL SHAFT COVER (a) Coat the 4 bolts with sealant, install new gasket with control shaft cover with the bolt. Sealant: Part No. 0883300080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 Nm (204 kgfcm, 15 ftlbf)
C90201
C92834
117. INSTALL CONTROL SHIFT LEVER (a) (b) Install the control shift lever with shift outer lock pin to the shift & select lever shaft. Install the spring washer with nat. Torque: 6.4 Nm (65 kgfcm, 57 in.lbf)
C90199
C92832
118. INSTALL SELECTING BELL CRANK ASSY (a) Coat the 2 bolts with sealant, install it with selecting bell crank assy to the manual transmission case. Sealant: Part No. 0883300080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 Nm (204 kgfcm, 15 ftlbf)
C90198 C92831
119. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUBASSY (a) Install the bolt and speedometer driven hole cover subassy to the transmission case. 120. INSTALL CLUTCH RELEASE FORK BOOT (a) Install the clutch release fork bolt to the manual transaxle case.
121. INSTALL RELEASE FORK SUPPORT (a) Using a deep socket wrench, install the release fork support to the manual transaxle case. Torque: 47.1 Nm (480 kgfcm, 35 ftlbf)
C83809
Author :
Date :
2180
4151
122. INSTALL CLUTCH RELEASE BEARING ASSY (a) Coat the clutch release bearing assy with release hub grease, install it to the clutch release fork sub assy. Sealant: Part No. 0888701806, RELEASE HUB GREASE or equivalent Apply clutch spline grease to the input shaft spline.
(b)
123. INSTALL CLUTCH RELEASE FORK SUBASSY (a) Install the clutch release fork sub assy to the input shaft.
C69774
Author :
Date :
2181
4152
MANUAL TRANSMISSION/TRANSAXLE INPUT SHAFT ASSY (E351)
INPUT SHAFT ASSY (E351)

4104Z01
OVERHAUL
1. (a) INSPECT 4TH GEAR THRUST CLEARANCE Using a feeler gauge, measure the 4th gear thrust clearance. Standard clearance: 0.10 0.57 mm (0.0039 0.0224 in.)
C69546
2. (a)
INSPECT 3RD GEAR THRUST CLEARANCE Using a dial indicator, measure the 3rd gear thrust clearance. Standard clearance: 0.10 0.35 mm (0.0039 0.0138 in.)
C69637
3. (a)
INSPECT 4TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the 4th gear radial clearance. Standard clearance: mm (in.)
Bearing KOYO made NSK made Standard clearance 0.009 0.053 (0.0004 0.0021) 0.009 0.051 (0.0004 0.0020)
C69548
If the clearance exceeds the maximum, replace the 4th gear needle roller bearing.
Author :
Date :
2182
4153
4. (a)
INSPECT 3RD GEAR RADIAL CLEARANCE Using a dial indicator, measure the 3rd gear radial clearance. Standard clearance: mm (in.)
C69549
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing.
5. (a) (b)
REMOVE 4TH GEAR
Hold the input shaft assy and soft jaws with a vise. Using a 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft. NOTICE: Using a waste to prevent the snap ring from being scattered.
C70515
(c)
SST
Using SST and a press, remove the input shaft rear bearing and 4th gear. SST 0995000020 NOTICE: Do not tighten SST excessively.
C92867
6. (a)
REMOVE 4TH GEAR NEEDLE ROLLER BEARING Remove the 4th gear needle roller bearing from the input shaft.
C69551
Author :
Date :
2183
4154
7. (a)
REMOVE 2ND SYNCHRONIZER OUTER RING Remove the 2nd synchronizer outer ring from the transmission clutch hub No.2.
C69552
8. (a)
REMOVE 4TH GEAR BEARING SPACER Remove the 4th gear bearing spacer from the transmission clutch hub No.2.
C69553
9. (a)
REMOVE 3RD GEAR
Using 2 screwdrivers and a hammer, remove the clutch hub No.2 setting shaft snap ring from the input shaft. NOTICE: Using a waste to prevent the snap ring from being scattered.
C69615
(b)
SST
Using SST and a press, remove the transmission clutch hub No.2 and 3rd gear from the input shaft. SST 0995000020 NOTICE: Do not tighten SST excessively.
C92868
10. (a)
REMOVE 3RD GEAR NEEDLE ROLLER BEARING Remove the 3rd gear needle roller bearing from the input shaft.
C69617
Author :
Date :
2184
4155
11. (a)
REMOVE SYNCHRONIZER RING NO.3 Remove the synchronizer ring No.3 from the 3rd gear.
C69618
12. (a)
REMOVE TRANSMISSION HUB SLEEVE NO.2
Remove the transmission hub sleeve No.2, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from the transmission clutch hub No.2. NOTICE: Using a waste to prevent the shifting key and shifting key spring from being scattered.
C69619
SST
13. (a)
REMOVE INPUT SHAFT FRONT BEARING
Using SST and a press, remove the input shaft bearing front (inner race) from the input shaft. SST 0995000020 NOTICE: Do not tighten SST excessively.
C92869
14. (a)
INSPECT INPUT SHAFT
Using Vblock and dial indicator, measure the shaft run out. Maximum run out: 0.03 mm (0.0012 in.) If the run out exceeds the maximum, replace the input shaft.
C69620
Author :
Date :
2185
4156
(b)
A B C
Using a micrometer, measure the outer diameter of the input shaft journal surface. Outer diameter: mm (in.)
Standard outer diameter A B 35.984 36.000 (1.4167 1.4173) 35.984 36.000 (1.4167 1.4173) 27.957 27.972 (1.1007 1.1013) Minimum outer diameter 35.984 (1.4167) 35.984 (1.4167) 27.957 (1.1007)
C92870
If the outer diameter is less than the minimum, replace the input shaft.
15. (a)
INSPECT 4TH GEAR Using a cylinder gauge, measure the inside diameter of the 4th gear. Inside diameter: mm (in.)
C69622
16. (a)
INSPECT 3RD GEAR Using a cylinder gauge, measure the inside diameter of the 3rd gear. Inside diameter: mm (in.)
C69622
17. (a)
INSPECT 2ND SYNCHRONIZER OUTER RING Coat the 4th gear cone with gear oil. Turn the synchronizer ring No.3 in one direction while pushing it to the 4th gear cone. Check that the ring locks.
C69623
Author :
Date :
2186
4157
(b)
Using a feeler gauge, measure the clearance between the synchronizer outer ring back and 4th gear spline end. Standard clearance: 0.75 1.65 mm (0.0295 0.0650 in.) If the standard clearance is out of specification, replace the synchronizer ring.
C69624
18. (a)
INSPECT SYNCHRONIZER RING NO.3 Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it to the 3rd gear cone. Check that the ring locks.
C69625
(b)
Using a feeler gauge, measure the clearance between the synchronizer ring No.3 back and 3rd gear spline end. Standard clearance: 0.65 1.75 mm (0.0256 0.0689 in.) If the standard clearance is out of specification, replace the synchronizer ring No.3.
C69626
19. (a) (b)
INSPECT TRANSMISSION HUB SLEEVE NO.2 Inspect the sliding condition between transmission hub sleeve No.2 and transmission clutch hub No.2. Inspect tip of spline gear on the transmission hub sleeve No.2 for wear.
C67843
Author :
Date :
2187
4158
(c)
Using a vernier calipers, measure the transmission hub sleeve No.3 groove and the thickness of the claw part on gear shift fork No.1, and calculate the clearance. Standard clearance: 0.15 0.35 mm (0.0059 0.0138 in.) {A B} If the clearance is out of the specification, replace the transmission hub sleeve No.2 and gear shift fork No.2 with the new one.
A
B
C70506
20.
SST
INSTALL INPUT SHAFT FRONT BEARING Using SST and a press, install the input shaft front bearing (inner race). SST 0960800071
(a)
C92871
21. (a) (b)
INSTALL TRANSMISSION HUB SLEEVE NO.2
C69660
Coat the transmission hub sleeve No.2 with gear oil. Install the 3 synchromesh key springs with transmission hub sleeve No.2. NOTICE: Do not install the transmission clutch hub sleeve No.2 and the transmission clutch hub No.2 incorrect orientation. (c) Using a screwdriver, install the synchromesh shifting key to the input shaft. 22. INSTALL 3RD GEAR NEEDLE ROLLER BEARING (a) Coat the 3rd gear bearing with gear oil, install it to the input shaft.
C69617
Author :
Date :
2188
4159
23. (a)
INSTALL 3RD GEAR Coat the 3rd gear with gear oil, install it to the input shaft.
C69629
24. (a)
INSTALL SYNCHRONIZER RING NO.3 Coat the synchronizer ring No.3 with gear oil, install it to the 3rd gear.
C69630
25. (a)
INSTALL TRANSMISSION CLUTCH HUB NO.2
SST
C92872
Using SST and a press, install the transmission clutch hub No.2 to the input shaft. SST 0931660011 (0931600041) NOTICE: S Align the claw of clutch hub No.2 with notch of synchronizer ring No.3 and install them. S Make sure that the 3rd gear should rotate. (b) Select a snap ring so that clearance between the transmission clutch hub No.2 and the clutch hub No.2 shaft snap ring will be the standard clearance. Using a brass bar and a hammer, install the snap ring. Standard clearance: 0.1 mm or less (0.0039 or less) Snap ring thickness
Part No. 9052034003 Thickness: mm (in.) 2.30 2.35 (0.0906 0.0925) 2.35 2.40 (0.0925 0.0945) 2.40 2.45 (0.0945 0.0965) 2.45 2.50 (0.0965 0.0984) 2.50 2.55 (0.0984 0.1004) 2.55 2.60 (0.1004 0.1024) 2.60 2.65 (0.1024 0.1043) Mark H J K L M N P
C69632
9052034004 9052034005 9052034006 9052034007 9052034008 9052034009 2002 CAMRY REPAIR MANUAL (RM881U)
Author :
Date :
2189
4160
26. (a)
INSTALL 4TH GEAR BEARING SPACER Coat the 4th gear bearing spacer with gear oil, install it to the input shaft.
C69553
27. (a)
INSTALL 2ND SYNCHRONIZER OUTER RING
Coat the 2nd synchronizer outer ring with gear oil, install it to the transmission clutch hub No.2. NOTICE: Align the claw of the clutch hub No.2 with the notch of the 2nd synchronizer outer ring and assemble.
C69552
28. (a)
INSTALL 4TH GEAR NEEDLE ROLLER BEARING Coat the 4th gear needle roller bearing with gear oil, install it to the input shaft.
C69551
29. (a)
INSTALL 4TH GEAR Coat the 4th gear with gear oil, install it to the input shaft.
C69633
SST
30.
INSTALL INPUT SHAFT REAR RADIAL BALL BEARING
(a)
C92857
Using SST and a press, install the input shaft rear radial ball bearing to the input shaft. NOTICE: S Make the groove on the bearing face to the rear and install. S Make sure that the 3rd gear rotates. SST 0960806041
Author : Date : 2190
4161
(b)
Select a snap ring so that the clearance between the Input shaft radial ball rear bearing and the input shaft rear bearing snap ring will be the standard clearance. Using a brass bar and a hammer, install the snap ring. Standard clearance: 0.1 mm or less Snap ring
Part No. 9052030008 thickness: mm (in.) 2.35 2.40 (0.0925 0.0945) 2.40 2.45 (0.0945 0.0965) 2.45 2.50 (0.0965 0.0984) 2.50 2.55 (0.0984 0.1004) 2.55 2.60 (0.1004 0.1024) 2.60 2.65 (0.1024 0.1043) 2.65 2.70 (0.1043 0.1063) 2.70 2.75 (0.1063 0.1083) Mark 1 2 3 4 5 6 7 8
C69635
9052030009 9052030010 905203001 1 9052030012 9052030013 9052030021 9052030022
31. (a)
INSPECT 3RD GEAR RADIAL CLEARANCE Using a dial indicator, measure the 3rd gear radial clearance. Standard clearance: mm (in.)
C69549
If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing.
Author :
Date :
2191
4162
32. (a)
INSPECT 4TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the 4th gear radial clearance. Standard clearance: mm (in.)
C69548
If the clearance exceeds the maximum, replace the 4th gear needle roller bearing.
33. (a)
INSPECT 3RD GEAR THRUST CLEARANCE Using a dial indicator, measure the 3rd gear thrust clearance. Standard clearance: 0.10 0.35 mm (0.0039 0.0138 in.)
C69547
34. (a)
INSPECT 4TH GEAR THRUST CLEARANCE Using a feeler gauge, measure the 4th gear thrust clearance. Standard clearance: 0.10 0.57 mm (0.0039 0.0224 in.)
C69546
Author :
Date :
2192
4163
MANUAL TRANSMISSION/TRANSAXLE OUTPUT SHAFT ASSY (E351)
OUTPUT SHAFT ASSY (E351)

4105001
OVERHAUL
1. (a) INSPECT 1ST GEAR THRUST CLEARANCE Using a feeler gauge, measure the 1st gear thrust clearance. Standard clearance: 0.25 0.40 mm (0.0098 0.0157 in.)
C69636
2. (a)
INSPECT 2ND GEAR THRUST CLEARANCE Using a dial indicator, measure the 2nd gear thrust clearance. Standard clearance: 0.10 0.35 mm (0.0039 0.0138 in.)
C69637
3. (a)
INSPECT 1ST GEAR RADIAL CLEARANCE Using a dial indicator, measure the 1st gear radial clearance. Standard clearance: mm (in.)
C69638
If the clearance is out of the specification, replace the 1st gear needle roller bearing.
Author :
Date :
2193
4164
4. (a)
INSPECT 2ND GEAR RADIAL CLEARANCE Using a dial indicator, measure the 2nd gear radial clearance. Standard clearance: mm (in.)
C69639
If the clearance is out of the specification, replace the 2nd gear needle roller bearing.
5.
SST
REMOVE 4TH DRIVEN GEAR Using SST and a press, remove the output shaft bearing rear (inner race) and 4th driven gear. SST 0995000020
(a)
C92858
6. (a)
REMOVE OUTPUT GEAR SPACER Remove the output gear spacer from the output shaft.
C69641
7.
SST
REMOVE 2ND GEAR Using SST and a press, remove the 3rd driven gear and 2nd gear from the out put shaft. SST 0995000020
(a)
C92859
Author :
Date :
2194
4165
8. (a)
REMOVE SYNCHRONIZER RING SET NO.2 Remove the synchronizer ring set No.2 from the transmission clutch hub No.1.
C69643
9. (a)
REMOVE 2ND GEAR NEEDLE ROLLER BEARING Remove the 2nd gear needle roller bearing from the output shaft.
C69644
10. (a)
REMOVE 2ND GEAR BEARING SPACER Remove the 2nd gear bearing spacer from the output shaft.
C69645
11. (a)
REMOVE 2ND GEAR BUSH Remove the 2nd gear bush from the output shaft.
C69646
12. (a)
REMOVE 2ND GEAR BUSH BALL Using a magnetic finger, remove the 2nd gear bush ball from the output shaft.
C83814
Author :
Date :
2195
4166
13.
SST
REMOVE 1ST GEAR Using SST and a press, remove the transmission clutch hub No.1 and 1st gear from the output shaft. SST 0995000020
(a)
C92860
14. (a)
REMOVE SYNCHRONIZER RING SET NO.1 Remove the synchronizer ring set No.1 from the 1st gear.
C69649
15. (a)
REMOVE 1ST GEAR NEEDLE ROLLER BEARING Remove the 1st gear needle roller bearing from the output shaft.
C69650
SST
16. (a)
REMOVE OUTPUT SHAFT FRONT BEARING
Using SST and a press, remove the output shaft front bearing (inner race) from the output shaft. SST 0995000020, 0995060010 (0995100320), 0995070010 (0995107150) NOTICE: Do not tighten SST excessively.
C92861
17. (a)
REMOVE REVERSE GEAR Remove the reverse gear, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from the transmission clutch hub No.1.
C69652
Author :
Date :
2196
4167
18. (a)
INSPECT OUTPUT SHAFT
Using Vblock and a dial indicator, measure the shaft run out. Maximum run out: 0.03 mm (0.0012 in.) If the run out exceeds the maximum, replace the input shaft.
C69653
(b)
A A B
Using a micrometer, measure the outer diameter of the output shaft journal surface. Outer diameter: mm (in.)
Part A B Standard outer diameter 37.610 37.626 (1.4807 1.4813) 34.802 34.512 (1.3702 1.3587) minimum outer diameter 37.610 (1.4807) 34.802 (1.3702)
C91168
If the outer diameter is less than the minimum, replace the input shaft. 19. (a) INSPECT 2ND GEAR Using a cylinder gauge, measure the inside diameter of the 2nd gear. Inside diameter: mm (in.)
C69655
If the inside diameter exceeds the maximum, replace the 2nd gear. 20. INSPECT 1ST GEAR (a) Using a cylinder gauge, measure the inside diameter of the 1st gear. Inside diameter: mm (in.)
C69655
If the inside diameter exceeds the maximum, replace the 1st gear. 21. INSPECT SYNCHRONIZER RING SET NO.2 (a) Coat the cone of the 2nd gear with gear oil, check that it does not turn in the both circumference directions while pushing it to the synchronizer ring No.2.
C69657
Author :
Date :
2197
4168
(b)
Check the clearance between the synchronizer ring No.2 and 2nd gear while pushing it to the synchronizer ring No.2. Standard clearance: 0.70 1.45 mm (0.0276 0.0571 in.) If the standard clearance is out of the specification, replace the synchronizer ring set No.2 with a new one.
C69656
22. (a)
INSPECT SYNCHRONIZER RING SET NO.1 Coat the 1st gear cone with gear oil. Turn the synchronizer ring set No.1. in one direction while pushing it to the 1st gear cone. Check that the ring locks.
C69658
(b)
Check the clearance between the synchronizer ring set No.1 and 1st gear while pushing it to the cone of synchronizer ring set No.1. Standard clearance: 0.70 1.45 mm (0.0276 0.0571 in.) If the standard clearance is out of the specification, replace the synchronizer ring set No.1 with a new one.
C69659
23. (a)
INSPECT REVERSE GEAR
Using a vernier calipers, measure the reverse gear groove and thickness of the claw part on gear shift fork No.1, and calculate Standard clearance: 0.15 0.35 mm (0.0059 0.0138 in.) {A B} If the clearance is out of the specification, replace the reverse gear and gear shift fork No.1 with the new one.
B
C70507
Author :
Date :
2198
4169
24. (a) (b)
INSPECT TRANSMISSION CLUTCH HUB NO.1 Check the sliding condition between the transmission clutch hub No.1 and reverse gear. Check the tip of spline gear on the sleeve of reverse gear for wear.
C69671
25. (a) (b)
INSTALL REVERSE GEAR
C69672
Coat the reverse gear with gear oil. Install the 3 synchromesh shifting key spring No.1 and transmission clutch hub No.1 to the reverse gear. NOTICE: Do not set the reverse gear and the transmission clutch hub No.1 in the incorrect direction. (c) Using a screwdriver, install the synchromesh sifting key No.1 to the reverse gear. 26. INSTALL OUTPUT SHAFT FRONT BEARING (a) Using SST and a press, install the output shaft front bearing (inner race) to the output shaft. SST 0995060010 (0995100430), 0995070010 (0995107150)
SST
C92874
27. (a)
INSTALL SYNCHRONIZER RING SET NO.1
Coat the synchronizer ring set No.1 with gear oil, install it to the 1st gear. NOTICE: Align the synchronizer ring set No.1 with the hole of 1st gear and install.
C69649
28. (a)
INSTALL 1ST GEAR NEEDLE ROLLER BEARING Coat the 1st gear needle roller bearing with gear oil, install it to the output shaft.
C69650
Author :
Date :
2199
4170
29. (a)
INSTALL 1ST GEAR Coat the 1st gear with gear oil, install it to the output shaft.
C69673
30.
SST
INSTALL TRANSMISSION CLUTCH HUB NO.1
(a)
SST
C92862
Using SST and a press, install transmission clutch hub No.1 to the output shaft. SST 0931660011 (0931600031), 0995060010 (0995100320), 0995070010 (0995107100) NOTICE: S Align the synchronizer ring No.1 with synchromesh shifting key No.1 and install. S Make sure that the 1st gear rotates. 31. INSTALL 2ND GEAR BUSH BALL (a) Coat the gear bush with MP grease, install it to the output shaft.
C83814
32. (a)
INSTALL 2ND GEAR BUSH Coat the 2nd gear bush with gear oil, install it to the output shaft.
C69646
33. (a)
INSTALL 2ND GEAR BEARING SPACER Coat the 2nd gear bearing spacer with gear oil, install it to the output shaft.
C69645
Author :
Date :
2200
4171
34. (a)
INSTALL 2ND GEAR NEEDLE ROLLER BEARING Coat the 2nd gear needle roller bearing with gear oil, install it to the output shaft.
C69644
35. (a)
INSTALL SYNCHRONIZER RING SET NO.2
Coat the synchronizer ring set No.2 with gear oil, install it to the transmission clutch hub No.1 NOTICE: Align the key groove on the synchronizer ring set No.2 with the synchromesh shifting key No.1.
C69643
36. (a)
INSTALL 2ND GEAR Coat the 2nd gear with gear oil, install it to the output shaft.
C69679
37.
SST SST
INSTALL 3RD DRIVEN GEAR Using SST and a press, install the 3rd driven gear to the output shaft. SST 0960800071, 0995060010 (0995100320), 0995070010 (0995107100)
(a)
C92863
38. (a)
INSTALL OUTPUT GEAR SPACER Install the output gear spacer to the output shaft.
C69641
Author :
Date :
2201
4172
39.
SST SST
INSTALL 4TH DRIVEN GEAR Using SST and a press, install the 4th driven gear to the output shaft. SST 0960800071, 0995060010 (0995100320), 0995070010 (0995107100)
(a)
C92864
40.
SST SST
INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a press, install the output shaft front bearing (inner race) to the output shaft. SST 0950630012, 0995060010 (0995100320), 0995070010 (0995107100)
(a)
C92865
41. (a)
INSPECT 2ND GEAR RADIAL CLEARANCE Using a dial indicator, measure the 2nd gear radial clearance. Standard clearance: mm (in.)
C69639
If the clearance is out of the specification, replace the 2nd gear needle roller bearing.
42. (a)
INSPECT 1ST GEAR RADIAL CLEARANCE Using a dial indicator, measure the 1st gear radial clearance. Standard clearance: mm (in.)
C69638
If the clearance is out of the specification, replace the 1st gear needle roller bearing.
Author :
Date :
2202
4173
43. (a)
INSPECT 2ND GEAR THRUST CLEARANCE Using a dial indicator, measure the 2nd gear thrust clearance. Standard clearance: 0.10 0.35 mm (0.0039 0.0138 in.)
C69637
44. (a)
INSPECT 1ST GEAR THRUST CLEARANCE Using a feeler gauge, measure the 1st gear thrust clearance. Standard clearance: 0.25 0.40 mm (0.0098 in. 0.0157 in.)
C69636
Author :
Date :
2203
4174
MANUAL TRANSMISSION/TRANSAXLE SHIFT & SELECT LEVER SHAFT ASSY (E351)
SHIFT & SELECT LEVER SHAFT ASSY (E351)

4104Y01
OVERHAUL
1. (a) REMOVE CONTROL SHIFT LEVER BUSH Remove the control shift lever bush from the selecting bellcrank No.2.
C69529
2.
REMOVE SELECTING BELLCRANK DUST COVER NO.1 Remove the selecting bellcrank dust cover No.1 from the selecting bellcrank No.2.
(a)
C69530
3.
REMOVE SELECTING BELLCRANK SUPPORT SUBASSY Remove the nut, washer and selecting bellcrank No.2 plate washer from the selecting bellcrank No.2.
(a)
C69532
(b)
Remove the selecting bellcrank support subassy from the selecting bell crank No.2.
C69799
Author :
Date :
2204
4175
4.
REMOVE SELECTING BELLCRANK DUST COVER NO.2 Remove the selecting bell crank dust cover No.2 from the selecting bellcrank No.2.
(a)
C69531
5. (a)
REMOVE SELECTING BELLCRANK NO.2 BUSH Remove the selecting bellcrank bush from the selecting bellcrank No.2.
C69798
6. (a)
REMOVE SHIFT LEVER INNER NO.2
C69534
Hold the shift & select lever on the vise through the soft jaw. NOTICE: Do not damage the shift & select lever shaft. (b) Using a pin punch ( 5 mm), remove the shift & select lever inner slotted pin and oil baffle. NOTICE: Do not damage the shift & select lever shaft. (c) Apply the force to the select return spring No.1 and select return spring No.2 then hold it on the vise through the soft jaw.
(d)
Using 2 screwdrivers and a hammer, remove the select seat snap ring from the shift & select lever shaft. NOTICE: Do not damage the shift & select lever shaft.
C69535
Author :
Date :
2205
4176
7. (a)
REMOVE SELECT SPRING SEAT NO.1 Using a pin punch ( 5 mm), remove the shift inner lever slotted pin from the shift & select lever shaft.
C68317
(b)
Remove the shift lever assy select return spring No.1 and select spring seat from the shift & select lever shaft.
C69538
Shift inter lock plate cover
8. (a)
REMOVE SHIFT INTER LOCK PLATE COVER Remove the shift inter lock plate cover from the shift inter lock plate.
C91167
Shift lever inner No.1
9. (a)
REMOVE SHIFT LEVER INNER NO.1 Remove the shift lever inner No.1 from the shift inter lock plate.
C91169
10.
REMOVE SELECT SPRING NO.1 SEAT SHAFT SNAP RING
(a)
Using 2 screwdrivers and a hammer, remove the select spring No.1 seat shaft snap ring. NOTICE: Do not damage the shaft.
C69539
Author :
Date :
2206
4177
11. (a)
REMOVE CONTROL SHAFT COVER OIL SEAL Using a screwdriver, remove the control shaft cover oil seal from the control shaft cover.
C69667
12.
SST
REMOVE CONTROL SHAFT COVER BIMETAL FORMED BUSH Using SST, remove the control shaft cover bimetal formed bush from the control shift cover. SST 0931960020
(a)
C92884
13.
SST
INSTALL CONTROL SHAFT COVER BIMETAL FORMED BUSH Using SST and hammer, install a new control shaft cover bimetal formed bush to the control shaft cover. SST 0995060010 (0995100210), 0995070010 (0995107100) Oil seal drive in depth: 0 " 0.25 mm (0 " 0.010 in.) INSTALL CONTROL SHAFT COVER OIL SEAL Using SST and hammer, install a new control shaft cover oil seal to the control shaft cover. SST 0995060010 (0995100280), 0995070010 (0995107100) Oil seal drive in depth: 28.5 " 0.50 mm (1.122 " 0.020 in.)
(a)
C92885
14. (a)
C92886
15.
INSTALL SELECT SPRING NO.1 SEAT SHAFT SNAP RING Using a brass bar and a hammer, install the select spring No.1 seat shaft snap ring.
(a)
C69540
Author :
Date :
2207
4178
MANUAL TRANSMISSION/TRANSAXLE Shift lever inner No.1 SHIFT & SELECT LEVER SHAFT ASSY (E351)
16. (a)
INSTALL SHIFT LEVER INNER NO.1 Install the shift lever inner No.1 to the shift inter lock plate.
C91169
Shift inter lock plate cover
17. (a)
INSTALL SHIFT INTER LOCK PLATE COVER Install the shift inter lock plate cover to the shift inter lock plate.
C91167
18. (a)
INSTALL SELECT SPRING SEAT NO.1 Install the select spring seat No.1, select return spring No.1 and shift lever inner assy to the shift & select lever shaft.
C69538
(b) (c)
Hold the shift & select lever on the vise through the soft jaw. Using a pin punch ( 5 mm), install the shift lever slotted pin to the shift & select lever shaft. Clearance: 0.5 0.5 mm ( 0.0197 0.0197 in.)
C69541
19. (a)
INSTALL SHIFT LEVER INNER NO.2 Install shift lever inner No.2, select return spring No.2 and select return spring seat No.2 to the shift & select lever shaft. Using a brass bar and a hammer, install the select seat snap ring to the shift & select lever shaft.
(b)
C69536
Author :
Date :
2208
4179
(c)
Install the transmission oil baffle. Using a pin punch ( 5 mm) and a hammer, install the shift inner lever slotted pin to the shift & select lever shaft. Clearance: 5.8 6.8 mm (0.228 0.268 in.)
C69542
20. (a)
INSTALL SELECTING BELLCRANK NO.2 BUSH Coat the 2 selecting bellcrank No.2 bushes with MP grease, install it to the selecting bellcrank No.2.
C69798
21.
INSTALL SELECTING BELLCRANK DUST COVER NO.2 Coat the selecting bellcrank dust cover No.2 with MP grease, install it to the selecting bellcrank No.2.
(a)
C69531
22.
INSTALL SELECTING BELLCRANK SUPPORT SUBASSY Install the selecting bellcrank support subassy to the selecting bellcrank No.2.
(a)
C69799
(b)
Install the selecting bellcrank No.2 plate washer, washer and nut. Torque: 12 Nm (122 kgfcm, 9 ftlbf)
C69532
Author :
Date :
2209
4180
23.
INSTALL SELECTING BELLCRANK DUST COVER NO.1 Install the selecting bellcrank dust cover No.1 to the selecting bellcrank No.2.
(a)
C69530
24. (a)
INSTALL CONTROL SHIFT LEVER BUSH Install the control shift lever bush to the selecting bell crank No.2.
C69529
Author :
Date :
2210
4181
MANUAL TRANSMISSION/TRANSAXLE DIFFERENTIAL CASE ASSY (E351)
DIFFERENTIAL CASE ASSY (E351)

4104X01
OVERHAUL
1. (a) REMOVE SPEEDOMETER DRIVE (MTM) GEAR Remove the speedometer drive (MTM) gear from front differential case assy.
C83559
2.
Matchmarks
REMOVE FRONT DIFFERENTIAL RING GEAR Place machmarks on the front differential ring gear and from the front differential case.
(a)
C83560
(b)
Remove the 16 bolts. Using a plastic hammer, remove the front differential case.
C83561
3. (a)
INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH Fixing the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash. Standard backlash: 0.05 0.20 mm (0.0020 0.0079 in.)
C83562
Author :
Date :
2211
4182
SST
4.
REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using SST and a hammer, unstake the stacked part of the front differential case. SST 0993000010
(a)
C92887
(b)
Using a pin punch and a hammer, remove the front differential pinion shaft straight pin from the front differential case.
C83564
5.
REMOVE FRONT DIFFERENTIAL PINION SHAFT NO.1 Remove the front differential pinion shaft No.1 to the front differential case.
(a)
C83565
6. (a)
REMOVE FRONT DIFFERENTIAL SIDE GEAR Remove the 2 front differential pinions, 2 front differential pinion thrust washers, 2 front differential side gear and 2 front differential side gear thrust washers from the front differential case.
C83566
HINT: Revolving front differential pinion, remove the 2 pinion thrust washers and side gear thrust washers. 7. INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER
(a)
Using a micrometer, measure the thickness of the front differential pinion thrust washer. Minimum thickness: 0.9 mm (0.035 in.) If the thickness smaller than the minimum, replace the front differential pinion thrust washer.
C68517
Author :
Date :
2212
4183
8.
INSPECT FRONT DIFFERENTIAL PINION SHAFT NO.1 Using a micrometer, measure the outer diameter of the front differential pinion shaft No.1. Minimum thickness: 17.975 mm (0.70768 in.)
(a)
C68518
9. (a) (b)
INSTALL FRONT DIFFERENTIAL SIDE GEAR Coat the rotating surface of the front differential side gear with gear oil. Install the 2 front differential side gear thrust washers to the 2 front differential side gears.
C83566
HINT: Install the front differential side gear as thick as the removed one. (c) Install the 2 front differential side gears, 2 front differential pinions and 2 front differential side gear thrust washers to the front differential case. HINT: Revolving the front differential pinion, install the 2 front differential pinions with front differential washers. 10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1 (a) (b) Coat the rotating surface of the front differential pinion shaft No.1 with gear oil. Install the front differential pinion shaft No.1 to the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.
C83565
11.
INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a pin punch and a hammer, install the front differential pinion shaft straight pin to the front differential case.
(a)
C83567
Author :
Date :
2213
4184
(b)
Using a chisel and hammer, stake the front differential case hole.
C83568
12. (a)
(b)
C83562
ADJUST FRONT DIFFERENTIAL SIDE GEAR BACKLASH Hold the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash. Standard backlash: 0.05 0.2 mm (0.0020 0.0079 in.) If the backlash is out of the specification, select another front differential side gear thrust washer and adjust it. Thrust washer: mm (in.)
Part No. 4136128230 4136128240 4136128250 4136128260 Thickness 1.00 (0.0394) 1.10 (0.0433) 1.20 (0.0472) 1.30 (0.0512) Mark 1 2 3 4
90 100_C
13. (a) (b)
INSTALL FRONT DIFFERENTIAL RING GEAR Using a heater, heat the front differential ring gear to 90 100 _C (194.0 230.0 _F). Clean the contact surface differential case.
C92888
(c)
Matchmarks
Aligning the matchmarks, quickly install the front differential ring gear to the front differential case. Torque: 106 Nm (1,081 kgfcm, 78 ftlbf)
C70796
Author :
Date :
2214
4185
14. (a)
INSTALL SPEEDOMETER DRIVE (MTM) GEAR Install the speedometer drive (MTM) gear to the front differential case.
C70795
Author :
Date :
2215

41 Manual Transmission Transaxle

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411

MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM

MANUAL TRANSAXLE SYSTEM

PROBLEM SYMPTOMS TABLE

Jumps out of gear

2002 CAMRY REPAIR MANUAL (RM881U)

MANUAL TRANSAXLE OIL

2002 CAMRY REPAIR MANUAL (RM881U)

FRONT DIFFERENTIAL OIL SEAL

INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL

2002 CAMRY REPAIR MANUAL (RM881U)

INSTALL TRANSMISSION CASE OIL SEAL

13. 14. 15.

2002 CAMRY REPAIR MANUAL (RM881U)

FLOOR SHIFT SHIFT LEVER ASSY

CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT

2002 CAMRY REPAIR MANUAL (RM881U)

12. 13. 14. 15. 16.

2002 CAMRY REPAIR MANUAL (RM881U)

FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT

FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT

(a) (b) (c) (d)

Select Cable Retainer

(e) (f) (g) (h)

Grommet Shift Cable

INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT

Select Cable Retainer

Grommet Shift Cable

2002 CAMRY REPAIR MANUAL (RM881U)

FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT

2002 CAMRY REPAIR MANUAL (RM881U)

FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT

FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT

(a) (b) (c) (d)

Select Cable Retainer

(e) (f) (g) (h)

Grommet Shift Cable

INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT

Select Cable Retainer

Grommet Shift Cable

2002 CAMRY REPAIR MANUAL (RM881U)

FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT

2002 CAMRY REPAIR MANUAL (RM881U)

MANUAL TRANSAXLE ASSY

REMOVE STARTER ASSY Remove the 2 bolts and starter assy.

2002 CAMRY REPAIR MANUAL (RM881U)

REMOVE TRANSVERSE MOUNTING BRACKET

Remove the 3 bolts and engine mounting bracket.

REMOVE MANUAL PROTECTOR

Remove the 2 bolts and manual transmission case protector.

REMOVE TRANSVERSE MOUNTING INSULATOR

Remove the 4 bolts and engine mounting insulator.

12. (a) (b) 13. (a)

2002 CAMRY REPAIR MANUAL (RM881U)

HINT: Tighten them in the order, A, B, C and D.

INSTALL MANUAL PROTECTOR

2002 CAMRY REPAIR MANUAL (RM881U)

21. (a) (b)

22. 23. 24.

2002 CAMRY REPAIR MANUAL (RM881U)

MANUAL TRANSAXLE ASSY (E351)

2002 CAMRY REPAIR MANUAL (RM881U)

2002 CAMRY REPAIR MANUAL (RM881U)