TOYOTA AVENSIS 2003 Service Repair Manual

33±12
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
17.APPLY HIGH TEMPERATURE GREASE (See page 33±14)
18.INSTALL PARKING BRAKE SHOE LEVER LH (See page 33±14)
19.INSTALL PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
20.INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (See page 33±14)
21.INSTALL PARKING BRAKE ADJUSTER KIT (See page 33±14)
22. INSTALL REAR DISC
23.CONNECT REAR DISC BRAKE CALIPER ASSY LH(See page 30±31)
24.ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33±14)
25. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
26.SETTLING PARKING BRAKE SHOES AND DISC (See page 33±14)
27.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
28.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
29. CHECK EXHAUST LEAKAGE
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33068±03
F44809
Console Box Assy RR
Lock Nut Adjusting Nut
Parking BrakeLever Sub±assy
Parking Brake Switch Assy
Parking Brake Switch Connector
Parking BrakeCable No.1
N

m (kgf
cm, ft
lbf)
: Specified torque Screw
13 (127, 9)
A/T TRANSAXLE:
Floor Shift Shift
Lever Knob
Sub±Assy
Console Panel Sub±Assy Upper
Console Panel Sub±Assy Lower
A/T Transaxle
M/T Transaxle
M/T TRANSAXLE:
Console Panel
Sub±Assy Upper
5.0 (51, 44 in.

lbf)
M/T Transaxle
±
PARKING BRAKE PARKING BRAKE LEVER SUB±ASSY
33±3
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE LEVER SUB±ASSY
COMPONENTS
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330C6±01
F44810
F41838
F44811
F44812
33±4
±
PARKING BRAKE PARKING BRAKE LEVER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) (See page 41±11)
2.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY LOWER (See page 71±11)
4.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
5. REMOVE PARKING BRAKE LEVER SUB±ASSY
(a) Disconnect the parking brake switch connector from theparking brake switch.
(b) Remove the lock nut and adjusting nut from the parking brake cable assy No.1.
(c) Remove the 2 bolts.
(d) Using a screwdriver, raise the pick on the parking brake lever, and remove the parking brake cable assy No.1 from
the parking brake lever.
(e) Remove the parking brake lever from the body.
6. REMOVE PARKING BRAKE SWITCH ASSY
(a) Remove the screw and parking brake switch.
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F44812
F44813
F41838
F44810
±
PARKING BRAKE PARKING BRAKE LEVER SUB±ASSY
33±5
AVENSIS REPAIR MANUAL (RM1018E)
7. INSTALL PARKING BRAKE SWITCH ASSY
(a) Install the parking brake switch to the parking brake lever
with the screw.
8. INSTALL PARKING BRAKE LEVER SUB±ASSY
(a) Install the parking brake cable assy No.1 to the parking brake lever, temporally tighten the adjusting nut and lock
nut.
(b) Using a screwdriver, fix the parking brake cable No.1 to the pick.
(c) Install the parking brake lever with the 2 bolts. Torque: 13 N
m (127 kgf
cm, 9 ft
lbf)
(d) Install the parking brake switch connector to the parking brake switch.
9.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
10.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
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3300E±07
±
PARKING BRAKE PARKING BRAKE SYSTEM
33±1
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the likelihood of the
cause in the descending order. Check each parts in the order shown. Replace these parts as necessary.
SymptomSuspect AreaSee page
Brake drag
1. Parking brake lever travel (Out of adjustment)
2. Parking brake wire (Sticking)
3. Parking brake shoe clearance (Out of adjustment)
4. Parking brake shoe lining (Cracked or distorted)
5. Tension or return spring (Damaged)33±2
33±7
33±10
33±14
33±14
33±14
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3300F±07
F44808
Lock NutAdjusting Nut
33±2
±
PARKING BRAKE PARKING BRAKE SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. REMOVE REAR WHEEL
2.ADJUST PARKING BRAKE SHOE CLEARANCE (See page 33±14)
3. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
4. INSPECT PARKING BRAKE LEVER TRAVEL
(a) Pull the parking brake lever all the way up, and count the number of cli\
cks. Parking brake lever travel: 6 ± 9 clicks at 196 N (20 kgf, 44.1 lbf)\
5. ADJUST PARKING BRAKE LEVER TRAVEL
(a) Remove the console box assy RR.(See page71±11)
(b) Loosen the lock nut and turn the adjusting nut until the le- ver travel turns correct.
(c) Tighten the lock nut. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(d) Install the console box assy RR.
(See page 71±11)
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4105U±03
D30489
Gasoline Engine:Front Floor
Heat Insulator No.1
Console Box Carpet
Floor Shift Lever Knob
Sub±assy
Console Panel Sub±assy Upper
Console Panel Sub±assy Lower
Console Box Sub±assy Rear
Clip
Clip
Clip
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
ClipClip
12 (122, 9)
Floor Shift Shift Lever Assy
12 (122, 9)
N´m (kgf´cm, ft´lbf) : Specified torque
5.5 (56, 49 in.

lbf)
Transmission Control Cable Assy
41±10
±
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
FLOOR SHIFT SHIFT LEVER ASSY (MTM)
COMPONENTS
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410DR±01
D26893
D26895
D30474
D30474
±
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
41±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB±ASSY (See page 71±11)
2.REMOVE CONSOLE PANEL UPPER (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY LOWER (See page 71±11)
4.REMOVE CONSOLE BOX ASSY REAR (See page 71±11)
5. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the cable ends of the controlcable assy.
(b) Release the claws, separate the control cable assy.
6. REMOVE FLOOR SHIFT SHIFT LEVER ASSY
(a) Remove the 4 bolts and shift lever assy.
7. INSTALL FLOOR SHIFT SHIFT LEVER ASSY
(a) Install the shift lever assy with the 4 bolts. Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
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D26972
D26894
Serrate Part
41±12
±
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
8. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Connect the control cable assy to the shift lever assy.
NOTICE:
Make sure that the claws are firmly engaged.
(b) Connect the end of the select cable to the shift lever assy, install the clip.
NOTICE:

The serrate part of the select cable point should face
upward when the select cable point is connected.

The clip should be inserted to the direction as shown
in the illustration.
(c) Connect the end of the shift cable to the shift lever assy.
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41046±11
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
41±3
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (C50/C250)
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
6.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
7. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST(s), remove the oil seal.SST 09308±00010
8. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
9. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 1.9
0.3 mm (0.075
0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
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