transmission oil TOYOTA AVENSIS 1999 Supplement

PP27T–01
– PREPARATIONMANUAL TRANSAXLE (E251)
PP–1
MANUAL TRANSAXLE (E251)
SST (Special Service Tools)
09223–15020Oil Seal & Bearing ReplacerDifferential case oil seal
09308–00010Oil Seal PullerOutput shaft front bearing outer
race
09316–20011Transfer Bearing ReplacerDifferential case tapered roller
bearing
09316–60011Transmission & Transfer Bearing
Replacer
(09316–00011)Replacer Pipe
(09316–00021)Replacer ”A”
(09316–00041)Replacer ”C”1st gear
No.1 hub sleeve
Differential case tapered roller
bearing outer race
(09316–00071)Replacer ”F”Output shaft front bearing
09506–30012Differential Drive Pinion Rear
Bearing Cone ReplacerOutput shaft rear bearing
09506–35010Differential Drive Pinion Rear
Bearing ReplacerNo.2 hub sleeve
3rd gear
Input shaft rear bearing
1st gear bearing inner race
09608–00081Differential Side Bearing Cone
ReplacerInput shaft oil seal
09612–65014Steering Worm Bearing PullerInput shaft bearing
Differential case tapered roller
bearing outer race

SS–8
– SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E251)
Transmission case x Transaxle case
2930022
Transmission oil pipe x Transaxle case1717513
Reverse shift arm bracket assembly x Transaxle case1717513
Transmission oil pump assembly x Transaxle case1717513
Transaxle case receiver x Transaxle case7.47565 in.·lbf
Clutch release fork support4748035
Control lever housing support bracket x Transaxle case1717513
Vehicle speed sensor1717513
Clutch release line bracket x Transaxle case1717513
Back–up light switch4041030
Filler and drain plugs4950036
No.1 and No.2 oil receiver pipes x Transmission case1717513
Transmission oil cooler sub–assembly x Elbow3435025
Elbow x Transaxle case2727520
Transmission oil pump case x Oil pump cover101058
Differential left case x Differential right case6364046
Ring gear set bolt1241,26091
Shift lever assembly x Body121209
Retainer x Body4.95043 in.·lbf
Grommet retainer x Body4.95043 in.·lbf

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

D06621

N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
 Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse
Restrict Pin  Straight Screw PlugBack–Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Shift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted
Spring PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x 10 x 17


24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)29 (300, 22)
Breather Plug
Gasket

Gasket
Gasket
Gasket
Gasket
Snap Ring
MX–10
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY

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

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.

MX02B–03
Q00383
Front
MT0790
Q00183SST
Q00116
MX–28
– MANUAL TRANSAXLE (E251)INPUT SHAFT
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506–35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)––
(b) Using a screwdriver and hammer, tap in the snap ring.

MX02F–03
Q06204
Front
Q06205
SST Align the holes
Z00225
Q06206
SST
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
MX–35
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to the front of the
transmission.
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506–35010
HINT:
Align the hole of the output shaft and inner race.
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316–60011 (09316–00041)
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX–31)

MX02G–03
Z17558
GasketO–Ring
Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Gear Oil Pump Drive Rotor
Oil Pump Cover Spring Holder Spring Ball Relief Valve Transmission Oil Pump
Case
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
10 (105, 8)
10 (105, 8)



MX–38
– MANUAL TRANSAXLE (E251)OIL PUMP
OIL PUMP
COMPONENTS