differential TOYOTA AVENSIS 1999 Supplement

MX098–01
D06620
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Lever Housing
Support Bracket
Boot
Clutch Release
Line Bracket
Transaxle Case
Transmission
Oil Cooler
Sub–AssemblyElbow

O–Ring Vehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
PipeMagnet
Transmission
Oil Pipe

Output Shaft Cover
Tapered Roller Bearing
Outer Race

Front Oil Seal
Input Shaft Front
BearingTransmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
17 (175, 13)
47 (480, 35)
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
Gasket



17 (175, 13)
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–9
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

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

MX060–02
D06656
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer

Tapered Roller Bearing
and Outer Race
Differential Right Case Vehicle Speed Sensor Drive Gear
Differential Left Case

Tapered Roller Bearing
and Outer Race Ring Gear
Oil Baffle

Oil Seal x16
Shim
Oil Seal
63 (640, 46)
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable partx16
124 (1,260, 91)
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–41
DIFFERENTIAL CASE
COMPONENTS

MX09A–01
Q05166
SST
D06654
Matchmarks
MX–42
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
DISASSEMBLY
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.
1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950–40011
2. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
FROM DIFFERENTIAL RIGHT CASE
3. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap the ring gear and remove it.
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the differential right and left cases.
(b) Using a torx wrench (T50), remove the 16 torx screws.
(c) Using a plastic hammer, tap the differential left case.

Z00284
Z00286
Z00288
SST
Z00289
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–43
(d) Remove the 2 differential side gears, side gear thrust
washers, 4 differential pinions and pinion thrust washers
from the differential left case.
5. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the shim.
(e) Install the shim.
(See page MX–41)
HINT:
First select and install a shim of lesser thickness than before.
(f) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316–60011 (09316–00011, 09316–00041)
(g) Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.

Q06288
SST
N00100
SST
Z00292
SST
Z00293
SST MX–44
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
(h) Using SST and a hammer, drive in a new oil seal.
SST 09223–15020, 09950–70010 (09951–07150)
(i) Coat the lip of oil seal with MP grease.
6. Transaxle Case Side:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver and hammer, drive out the oil seal
from the transaxle case.
(b) Using SST, pull out the tapered roller bearing outer race.
SST 09612–65014
(c) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316–60011 (09316–00011, 09316–00041)
(d) Using SST and a hammer, drive in a new oil seal.
SST 09316–60011 (09316–00011)
(e) Coat the oil seal lip with MP grease.

Z00295
MX09B–01
Z00296
Z00297
D06655
Matchmarks
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–45
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washer to the side gear.
(b) Install the 4 pinions and thrust washers to the spider.
(c) Install the side gear and spider with the 4 pinions to the
differential left case.
(d) Using a dial indicator, measure the backlash of the pinion
gear while holding the differential left case.
Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079
in.)
HINT:
Push the pinion gear and spider with the 4 pinions to the differ-
ential left case.
(e) Install the side gear and spider with the 4 pinions to the
right side of the differential case. Check the side gear
backlash.
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)–
(g) Align the matchmarks on the differential cases.
(h) Using a plastic hammer, carefully tap the differential case
to install it.
(i) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.

Z00303
Driven Gear
Side
Q06410
SST
SST MX–46
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
(b) Heat the ring gear to about 100
C (212
F  



(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the differential left case and contact
the ring gear.
(f) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(g) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
3. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
4. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316–20011, 09316–60011 (09316–00011)
HINT:
Press the bearing on the ring side first.
5. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See page MX–21)
6. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
7. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
8. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm 22 ft·lbf)
9. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
10. INSTALL SHIM (See page MX–21)
HINT:
Install the previously selected shim.
11. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

Q00036
Z00309
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–47
12. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 – 0.3 N·m (1.8 – 3.5 kgf·cm, 1.6 – 3.0 in.·lbf)
Reused bearing (Output shaft preload plus)
0.1 – 0.2 N·m (1.1 – 2.2 kgf·cm, 1.0 – 1.9 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
HINT:
The total preload will change by about 0.1 – 0.2 N·m (1 – 2
kgf·cm, 0.9 – 1.7 in.·lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
13. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
14. REMOVE SHIM
15. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
16. REMOVE OUTPUT SHAFT ASSEMBLY
17. REMOVE DIFFERENTIAL CASE ASSEMBLY

SA02Z–03
SA–10
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
INSTALLATION
1. LH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Install a new snap ring to the inboard joint shaft.
(b) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(c) Set the snap ring with opening side facing downward.
(d) Using a brass bar and hammer, install the drive shaft.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
HINT:
Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feel-
ing when driving it in.
(e) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction.
(f) Check that the drive shaft cannot be removed by hand.
2. RH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(b) Install the drive shaft with the center bearing bracket.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
(c) Install the 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
3. CONNECT DRIVE SHAFT TO AXLE HUB
NOTICE:
Be careful not to damage the boot and ABS speed sensor rotor.
4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
5. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle.
(b) Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
6. INSTALL DRIVE SHAFT LOCK NUT
(a) While applying brakes, install the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
(b) Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
7. w/ABS:
INSTALL ABS SPEED SENSOR AND BOLT
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
8. FILL AND CHECK GEAR OIL (See page MX–4)
9. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
10. CHECK FRONT WHEEL ALIGNMENT (See Pub. No. RM599E on page SA–4)
11. CHECK ABS SPEED SENSOR SIGNAL (See Pub. No. RM599E on page DI–115)