boot TOYOTA AVENSIS 1999 Supplement

IN00U–34
N17080
Filler Cap
Float
Reservoir Tank

Grommet
Clip
Slotted Spring Pin
: Specified torque

Non–reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot

Gasket
Lock Nut
Clevis Pin
Clevis
N·m (kgf·cm, ft·lbf)
12 (120, 9)
15 (155, 11)
– INTRODUCTIONHOW TO USE THIS MANUAL
IN–1
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN–19.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

PP27U–01
PP–6
– PREPARATIONSUSPENSION AND AXLE
SUSPENSION AND AXLE
SST (Special Service Tools)
09240–00020Wire Gauge Set
09316–60011Transmission & Transfer Bearing
Replacer
(09316–00041)Replacer ”C”
09520–01010Drive Shaft Remover Attachment
09520–24010Differential Side Gear Shaft
Puller
(09520–32040)Shocker Set
09521–24010Drive Shaft Boot Clamping Tool
09608–16042Front Hub Bearing Adjusting Tool
(09608–02021)Bolt & Nut
(09608–02041)Retainer
09710–30021Suspension Bushing Tool Set
(09710–03121)Bushing Remover Base

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

MX02I–03
Q06217
Shift Interlock Plate
Transmission Oil Baffle Shift Interlock Plate
No.1 Compression SpringControl Shaft Cover
Oil Seal
Snap Ring
No.1 Select Spring Seat
Slotted Spring Pin
No.1 Shift Inner Lever
Shift and Select Lever Shaft Snap Ring
Non–reusable partNo.2 Select Spring SeatNo.2 Compression SpringNo.2 Shift Inner LeverSlotted Spring Pin
Apply MP grease

Dust Boot

MX–40
– MANUAL TRANSAXLE (E251)SHIFT AND SELECT LEVER SHAFT
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

F08949
Non–reusable part
Dynamic Damper

Dust Cover
Snap Ring Outboard Joint Shaft

Boot

Boot
Tripod
RH Inboard Joint Shaft
Snap Ring
Bearing CaseStraight Pin
Inboard Joint Shaft

Dust Cover LH
Boot ClampBearing

Snap Ring 1CD–FTV Engine

Dynamic Damper Clamp

Boot Clamp

Boot Clamp

Boot Clamp SA–2
– SUSPENSION AND AXLEFRONT DRIVE SHAFT

SA10A–02
FA1535
SST
F02688
F02721
F02724
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–3
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608–16042 (09608–02021, 09608–02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serration on the drive shaft.
1. REMOVE FRONT WHEEL
2. DRAIN OUT GEAR OIL
3. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
4. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See Pub. No. RM599E on page SA–11)
6. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See Pub. No. RM599E on page
SA–11)
7. DISCONNECT DRIVE SHAFT FROM AXLE HUB
(a) Using a plastic hammer, disconnect the drive shaft from
the axle hub.
NOTICE:
Cover the drive shaft boot and ABS speed sensor rotor with
cloth to protect it from being damaged.
(b) Push the front axle hub toward the outside of the vehicle
to separate the drive shaft from the axle hub.
8. REMOVE DRIVE SHAFTS
(a) RH drive shaft:
Remove the 2 bolts and pull out the drive shaft together
with the center bearing bracket.

SA10B–02
N00191
FA1615
Matchmarks
SA1443
Matchmarks
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–5
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no obvious play in the outboard
joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no obvious play in the radial
direction of the inboard joint.
(d) Check the boots for damage.
2. REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
Using a side cutter, cut the 4 boots clamps and remove them.
3. REMOVE INBOARD JOINT SHAFT
(a) Place matchmarks on the tripod, inboard and outboard
joint shafts.
NOTICE:
Do not punch the marks.
(b) Remove the inboard joint shaft from the outboard joint
shaft.
4. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the outboard joint shaft and tripod.
NOTICE:
Do not punch the marks.
(c) Using a brass bar and hammer, remove the tripod from
the drive shaft.
NOTICE:
Do not tap the roller.
5. REMOVE INBOARD JOINT BOOT
6. RH drive shaft:
REMOVE DYNAMIC DAMPER
(a) Using a side cutter, cut the dynamic damper clamp and re-
move it.
(b) Remove the dynamic damper.
7. REMOVE OUTBOARD JOINT BOOT
NOTICE:
Do not disassemble the outboard joint.

F02277
89.3 – 90.3 mm
(3.52 – 3.56 in.)
W01994
Vinyl Tape
SA–8
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
(b) RH drive shaft:
Using a steel plate and press, install a new dust cover until
the distance from the tip of center drive shaft to the dust
cover reaches the specification, as shown in the illustra-
tion.
3. TEMPORARILY INSTALL NEW OUTBOARD AND IN-
BOARD JOINT BOOTS WITH NEW BOOT CLAMPS
HINT:
Before installing the boots (and dynamic damper), wrap
the spline of the outboard joint shaft with vinyl tape to pre-
vent them from being damaged.
Before installing the boots (and dynamic damper), place
new clamps to each of them and then install boots to drive
shaft.
(a) Temporarily install a new outboard joint boot with 2
clamps to the drive shaft.
(b) Temporarily install the dynamic damper with clamp to the
drive shaft.
(c) Temporarily install a new inboard joint boot with 2 clamps
to the drive shaft.
4. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks placed before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint shaft and
boot with grease in the boot kit.
Grease capacity: (Color = Black)
85 – 105 g (3.00 – 3.70 oz.)
6. INSTALL INBOARD JOINT SHAFT TO OUTBOARD
JOINT SHAFT
(a) Pack the inboard joint shaft and boot with grease in the
boot kit.
Grease capacity: (Color = Yellow)
120 – 130 g (4.23 – 4.59 oz.)
(b) Align the matchmarks placed before removal.
(c) Install the inboard joint shaft to the outboard joint shaft.
(d) Temporarily install the boot to the inboard joint shaft.

F08950
RH Drive Shaft
LH Drive shaft
R10353
SST
F09070
F02727
SST
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–9
7. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Make sure that the 2 boots are on the shaft groove.
(b) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length:
RH852.15  2.0 mm (33.55  0.079 in.)
LH548.15  2.0 mm (21.58  0.079 in.)
(c) Secure the clamps onto the boot.
(d) Place SST onto the clamps.
SST 09521–24010
(e) Tighten the SST so that the clamps are pinched.
NOTICE:
Do not overtighten the SST.
(f) Using SST, adjust the clearance of the clamps.
SST 09240–00020
Clearance: 1.9 mm (0.075 in.) or less
8. RH drive shaft:
ASSEMBLE DAMPER CLAMP
(a) Make sure that the dynamic damper is on the shaft
groove.
(b) Set the distance, as described below.
Distance: 267
2.0 mm (10.512
0.079 in.)
(c) Secure the clamp onto the damper.
(d) Place SST onto the clamps.
SST 09521–24010
(e) Tighten the SST so that the clamps are pinched.
NOTICE:
Do not overtighten the SST.
(f) Using SST, adjust the clearance of the clamps.
SST 09240–00020
Clearance: 1.9 mm (0.075 in.) or less
9. CHECK DRIVE SHAFT (See page SA–5)

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)