Input Shaft Reassembly

Drivetrain. Corolla. Zre142 Aze141
E351 Manual Transmission Transaxle. Corolla. Zre142 Aze141

  1. INSTALL INPUT SHAFT FRONT BEARING

  2. INSTALL NO. 2 TRANSMISSION HUB SLEEVE

  3. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

  4. INSTALL 3RD GEAR

  5. INSTALL NO. 3 SYNCHRONIZER RING

  6. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

  7. INSTALL 4TH GEAR BEARING SPACER

  8. INSTALL NO. 4 SYNCHRONIZER RING

  9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

  10. INSTALL 4TH GEAR

  11. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

Input Shaft -- Reassembly



1. INSTALL INPUT SHAFT FRONT BEARING


    Corolla. Zre142 Aze141.E351 Manual Transmission Transaxle.Manual Transaxle System.Input Shaft Reassembly

  1. Using SST and a press, install the input shaft front bearing (inner race).

    SST
    09608-00071


2. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    Corolla. Zre142 Aze141.E351 Manual Transmission Transaxle.Manual Transaxle System.Input Shaft Reassembly

  1. Coat the No. 2 transmission hub sleeve with gear oil.

  1. Install the 3 synchromesh key springs with the No. 2 transmission hub sleeve.

    NOTICE:
    Install the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct direction.

  1. Using a screwdriver, install the synchromesh shifting key to the input shaft.



3. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    Corolla. Zre142 Aze141

  1. Coat the 3rd gear bearing with gear oil and install it to the input shaft.



4. INSTALL 3RD GEAR


    Corolla. Zre142 Aze141

  1. Coat the 3rd gear with gear oil and install it to the input shaft.



5. INSTALL NO. 3 SYNCHRONIZER RING


    Corolla. Zre142 Aze141

  1. Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.



6. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    Corolla. Zre142 Aze141.E351 Manual Transmission Transaxle.Manual Transaxle System.Input Shaft Reassembly

  1. Using SST and a press, install the No. 2 transmission clutch hub to the input shaft.

    SST
    09316-60011(09316-00041)
    NOTICE:
    1. Align the claw of the clutch hub No. 2 with the notch of the No. 3 synchronizer ring.
    2. Make sure that the 3rd gear can rotate.


    Corolla. Zre142 Aze141

  1. Select a snap ring so that clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub shaft snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.

    Standard clearance:
    0.1 mm (0.00394 in.) or less
    Snap Ring Thickness:
    Part No.
    		Thickness: mm (in.)
    		Mark
    90520-34003
    		2.30 to 2.35
    (0.0906 to 0.0925)
    		H
    90520-34004
    		2.35 to 2.40
    (0.0925 to 0.0945)
    		J
    90520-34005
    		2.40 to 2.45
    (0.0945 to 0.0965)
    		K
    90520-34006
    		2.45 to 2.50
    (0.0965 to 0.0984)
    		L
    90520-34007
    		2.50 to 2.55
    (0.0984 to 0.1004)
    		M
    90520-34008
    		2.55 to 2.60
    (0.1004 to 0.1024)
    		N
    90520-34009
    		2.60 to 2.65
    (0.1024 to 0.1043)
    		P


7. INSTALL 4TH GEAR BEARING SPACER


    Corolla. Zre142 Aze141

  1. Coat the 4th gear bearing spacer with gear oil and install it to the input shaft.



8. INSTALL NO. 4 SYNCHRONIZER RING


    Corolla. Zre142 Aze141

  1. Coat the No. 4 synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.

    NOTICE:
    Align the claw of the No. 2 clutch hub with the notch of the No. 4 synchronizer ring.


9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    Corolla. Zre142 Aze141

  1. Coat the 4th gear needle roller bearing with gear oil and install it to the input shaft.



10. INSTALL 4TH GEAR


    Corolla. Zre142 Aze141

  1. Coat the 4th gear with gear oil and install it to the input shaft.



11. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING


    Corolla. Zre142 Aze141.E351 Manual Transmission Transaxle.Manual Transaxle System.Input Shaft Reassembly

  1. Using SST and a press, install the input shaft rear radial ball bearing to the input shaft.

    SST
    09608-06041
    NOTICE:
    1. Install the bearing with its groove facing rearward.
    2. Make sure that the 3rd gear can rotate.


    Corolla. Zre142 Aze141

  1. 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 within the specified range. Using a brass bar and a hammer, install the snap ring.

    Standard clearance:
    0.1 mm (0.00394 in.) or less
    Snap Ring Thickness:
    Part No.
    		Thickness: mm (in.)
    		Mark
    90520-30008
    		2.35 to 2.40
    (0.0925 to 0.0945)
    		1
    90520-30009
    		2.40 to 2.45
    (0.0945 to 0.0965)
    		2
    90520-30010
    		2.45 to 2.50
    (0.0965 to 0.0984)
    		3
    90520-30011
    		2.50 to 2.55
    (0.0984 to 0.1004)
    		4
    90520-30012
    		2.55 to 2.60
    (0.1004 to 0.1024)
    		5
    90520-30013
    		2.60 to 2.65
    (0.1024 to 0.1043)
    		6
    90520-30021
    		2.65 to 2.70
    (0.1043 to 0.1063)
    		7
    90520-30022
    		2.70 to 2.75
    (0.1063 to 0.1083)
    		8