TOYOTA AVENSIS 1999 Supplement

Q06190
Q01615
Q00056
Q05815
FIPG MX–14
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
16. REMOVE SNAP RING
(a) Using a snap ring expander, remove the input shaft rear
bearing snap ring.
(b) Using 2 screwdrivers and a hammer, remove the 2 snap
rings.
17. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND LOCKING BALL
(a) Using a hexagon wrench (6 mm), remove the plug.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the seat, spring and
locking ball.
18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
19. REMOVE TRANSMISSION CASE
Remove the 17 bolts and tap the case with a plastic hammer.
FIPG:
Part No. 08826–00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

MT0669
MT0693
SST
Q06375
Z17557
Matchmarks
Q01614
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–15
20. REMOVE SHIM
HINT:
At the time of reassembly, please refer to the following item.
Install the previously selected shim by adjusting output shaft
preload.
(See page MX–21)
21. REMOVE OUTPUT SHAFT REAR TAPER ROLLER
BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 09316–60011 (09316–00011)
22. REMOVE TRANSMISSION OIL PIPE
(a) Remove the gasket from the oil pipe.
(b) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
23. REMOVE REVERSE SHIFT ARM BRACKET AS-
SEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
24. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
HINT:
At the time of reassembly, please refer to the following item.
Align the matchmarks, as shown.
25. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.

Q08124
Q08125
Q08126
Z00182
MX–16
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
26. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
27. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.
28. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the re-
verse shift fork.
29. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD
AND NO.1 SHIFT FORK
(a) Pull out the No.2 shift fork shaft.
(b) Remove the shift head and No.1 shift fork.
30. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE
SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with the reverse shift fork.
(b) Remove the No.2 shift fork.
31. REMOVE SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the snap
ring and reverse shift fork from the No.3 shift fork shaft.
(b) Using 2 screwdrivers and a hammer, remove the 3 snap
rings from the No.1, No.2 and No.3 shift fork shafts.
32. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
(a) Leaning the output shaft to the differential side, remove
the input shaft assembly.
(b) Lift up the differential case assembly, remove the output
shaft assembly.
33. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the oil pump drive gear.
(b) Remove the differential case assembly.
34. REMOVE MAGNET FROM TRANSAXLE CASE
35. REMOVE TRANSMISSION OIL PUMP ASSEMBLY
AND OIL PIPE

MT0781
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–17
(a) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
(b) Remove the 2 bolts and the oil pump assembly.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
36. REMOVE NO.5 SYNCHRONIZER RING WITH KEY
SPRING FROM NO.3 CLUTCH HUB
(a) Remove the No.5 synchronizer ring with the key spring
from the No.3 clutch hub.
(b) Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.

MX05W–02
MT0782
WM0066
Z00192
SST
Z00194
SST
Q08014
SST MX–18
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
middle No.5 synchronizer ring in one direction while push-
ing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If it does not lock, replace the synchronizer ring.
2. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. IF NECESSARY, REPLACE INPUT SHAFT BEARING
AND OIL SEAL
(a) Remove the 3 bolts and transaxle case receiver.
(b) Using SST, pull out the bearing.
SST 09612–65014
(c) Using a screwdriver, remove the oil seal.
(d) Using SST, drive in a new oil seal.
SST 09608–00081, 09950–70010 (09951–07150)
(e) Coat the lip of seal with MP grease.
(f) Using SST, drive in a new bearing.
SST 09950–60010 (09951–00580), 09950–70010
(09951–07150)
(g) Install the transaxle case receiver.
(h) Install and torque the 3 bolts.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)

Q05164
SST
Q00141
SST
Q00338
SST
Z00197
Q06368
SST
SST
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–19
(i) Using SST and a press, remove the inner race.
SST 09950–00020
(j) Using SST and a press, install a new input shaft front
bearing inner race.
SST 09316–60011 (09316–00021)
4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT
BEARING OUTER RACE AND OUTPUT SHAFT
FRONT COVER
(a) Using SST, pull out the output shaft front bearing outer
race.
SST 09308–00010
(b) Remove the output shaft cover.
(c) Install a new output shaft cover.
HINT:
Install the output shaft cover projection into the case side
groove.
(d) Using SST and a hammer, drive in a new output shaft front
bearing outer race.
SST 09316–60011 (09316–00011, 09316–00021)

Q00245
SSTSocket Wrench
Z00199SST
Q01611
Z00201
MX–20
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
(e) Using SST and a socket wrench, remove the output shaft
front bearing.
SST 09950–00020, 09950–00030
(f) Using SST and a press, install a new output shaft front
bearing.
SST 09316–60011 (09316–00071)
5. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench (6 mm), remove the screw plug.
(b) Using a pin punch and hammer, drive out the slotted
spring pin.
(c) Replace the reverse restrict pin.
(d) Using a pin punch and hammer, drive in the slotted spring
pin.
(e) Apply sealant to the screw plug threads.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench (6 mm), install and torque the
screw plug.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

MX05X–02
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–21
REASSEMBLY
Reassembly is in the reverse order of disassembly.
(See page MX–12)
NOTICE:
When working with FIPG material, you must observe the follow-
ing items.
Using a razor blade and gasket scraper, remove all the old
FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose
material.
Clean both sealing surfaces with a non–residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along
the sealing surface.
Parts must be assembled within 10 minutes of application.
Otherwise, the FIPG material must be removed and reap-
plied.
HINT:
Before reassembly, select a shim by adjusting output
shaft preload.
Coat all of the sliding and rotating surfaces with gear oil
before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle case.
(b) Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
(c) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(d) Install the output shaft rear taper roller bearing outer race.
(e) Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the
same thickness as before. If installing a new taper roller bear-
ing, first select and install a shim of lesser thickness than be-
fore.
(f) Install the rear bearing retainer.
(g) Using a torx wrench (T45), install and torque the 7 torx
screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
(h) Install a new lock nut to the output shaft.
(i) Turn the output shaft right and left 2 or 3 times to allow the
bearing to settle.

Z12593
MX–22
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
(j) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing
0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)
Reused bearing
0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
The preload will change about 0.4 – 0.5 N·m (4 – 5 kgf·cm, 3.5
– 4.3 in.·lbf) for every 0.05 mm change in adjusting shim thick-
ness.
MarkThickness mm (in.)MarkThickness mm (in.)
01.30 (0.0512)D1.95 (0.0768)
11.35 (0.0531)E2.00 (0.0787)
21.40 (0.0551)F2.05 (0.0807)
31.45 (0.0571)G2.10 (0.0827)
41.50 (0.0591)H2.15 (0.0846)
51.55 (0.0610)J2.20 (0.0866)
61.60 (0.0630)K2.25 (0.0886)
71.65 (0.0650)L2.30 (0.0906)
81.70 (0.0669)M2.35 (0.0925)
91.75 (0.0689)N2.40 (0.0945)
A1.80 (0.0709)P2.45 (0.0965)
B1.85 (0.0728)Q2.50 (0.0984)
C1.90 (0.0748)––
(k) Remove the lock nut.
(l) Remove these parts. Removal is in the reverse order of
installation.
Rear bearing retainer
Shim
Transmission case
Output shaft assembly
Output shaft rear bearing outer race

MX028–03
MT0791
Rear Bearing4th GearSpacer
Synchronizer Ring
Snap Ring
Needle Roller Bearing3rd GearNeedle Roller Bearing

Input Shaft Front Bearing Inner Race
Input Shaft Synchronizer Ring
No.2 Hub Sleeve
No.2 Clutch Hub
Shifting KeySpring
Snap Ring

Non–reusable part
– MANUAL TRANSAXLE (E251)INPUT SHAFT
MX–23
INPUT SHAFT
COMPONENTS