TOYOTA AVENSIS 2005 Service Repair Manual

C67831
C67843
C67842
C67833
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±43
C250 M/T REPAIR MANUAL (RM1020E)
(c) Using a feeler gauge, measure the clearance between
the synchronizer ring No.2 back and 3rd gear spline end.
Standard clearance:
0.75 ± 1.65 mm (0.0295 ± 0.0649 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring No.2 and apply a small amount of the fine lapping
compound on the 3rd gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
17. INSPECT TRANSMISSION HUB SLEEVE NO.2
(a) Check the sliding condition between the transmission hub
sleeve No.2 and transmission clutch hub No.2.
(b) Check that the spline gear's edges of the transmission
hub sleeve No.2 is not worn down.
(c) Using a vernier calipers, inspect the transmission hub
sleeve No.2 and gear shift fork No.2 as shown in the il-
lustration.
Standard clearance:
0.15 ± 0.35 mm (0.0059 ± 0.0137 in.)
If the clearance exceeds the standard clearance, replace the
transmission hub sleeve No.2 and gear shift fork No.2.
18. INSTALL TRANSMISSION HUB SLEEVE NO.2
(a) Coat the transmission hub sleeve No.2 with gear oil,
install it to the transmission clutch hub No.2.
NOTICE:
Do not set the transmission hub sleeve No.2 and the trans-
mission clutch hub in incorrect orientation.
(b) Install the 2 synchromesh key springs with 3 synchro-
mesh shifting keys No.2 to the transmission clutch hub
No.2.

C67823
C67834
C82010
Key Position
For 3rd gear
C80563
SST
C67837
41±44
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
19. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear needle roller bearing with gear oil,
install it to the input shaft.
20. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, install it to the input shaft.
21. INSTALL SYNCHRONIZER RING NO.2 (FOR THIRD
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.2 with gear oil, install it to
the 3rd gear.
HINT:
The synchronizer ring No.2 (for 3rd) is a gray color.
22. INSTALL TRANSMISSION CLUTCH HUB NO.2
(a) Using SST and a press, install the transmission clutch
hub No.2 to the input shaft.
SST 09316±60011 (09316±00021)
NOTICE:
Paying attention to the proper position, fit the synchro-
mesh shifting key into the groove of the synchronizer ring.
(b) Select a snap ring that will allow the minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less.
MarkThickness mm (in)MarkThickness mm (in)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)

D30573
Key Position
For 4th gear
C80560
C80564
C80565
SST
C80566
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±45
C250 M/T REPAIR MANUAL (RM1020E)
23. INSTALL SYNCHRONIZER RING NO.2 (FOR FOURTH
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.2 with gear oil, install it to
the transmission clutch hub No.2.
HINT:
The synchronizer ring No.2 (for 4th) is a yellow copper color.
24. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing and 4th gear bear-
ing spacer with gear oil, install it to the transmission clutch
hub No.2.
25. INSTALL 4TH GEAR
(a) Coat the 4th gear with gear oil, install it to the input shaft.
26. INSTALL INPUT SHAFT REAR RADIAL BALL
BEARING
(a) Using SST and a press, install the input shaft rear radial
ball bearing to the input shaft.
(b) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less
MarkThickness mm (in)MarkThickness mm (in)
A2.29 (0.0901)D2.47 (0.0972)
B2.35 (0.0925)E2.53 (0.0996)
C2.41 (0.0948)F2.59 (0.1019)
If the clearance is less than the limit, replace the input shaft rear
radial ball bearing.

C67815
C80558
C67816
C80557
41±46
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
27. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance be-
tween the 3rd gear.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
If the clearance is less than the limit, replace the 3rd gear.
28. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance be-
tween the 4th gear.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
If the clearance is less than the limit, replace the 4th gear.
29. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 3rd thrust clearance.
Standard clearance:
0.1 ± 0.35 mm (0.0039 ± 0.0138 in.)
30. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 4th thrust clearance.
Standard clearance:
0.1 ± 0.55 mm (0.0039 ± 0.0217 in.)
If the clearance is less than the limit, replace the 4th gear.

410DE±01
D30519
Input Shaft
Syncronizer Ring No.2 (For 3rd)
Syncromesh Shifting Key No.2
Syncromesh Shifting Key Spring No.2
Syncronizer Ring No.2 (For 4th)
3rd Gear Needle Roller Bearing
3rd Gear
Transmission Hub Sleeve No.2
Clutch Hub No.2 Setting Shaft Snap Ring
4th Gear Bearing Spacer
4th Gear Needle Roller Bearing
4th Gear
Input Shaft Rear Redial Ball Bearing
Input Shaft Rear Bearing
Shaft Snap Ring
Transmission Clutch Hub No.2
x3
x3
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±37
C250 M/T REPAIR MANUAL (RM1020E)
INPUT SHAFT ASSY (C250)
COMPONENTS

410DD±01
D30524
C80550
C67601
C67602
41±4
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the manual transmission filler plug and gasket
from the manual transmission case.
2. REMOVE DRAIN (MTM) PLUG SUB±ASSY
(a) Remove the drain plug and gasket from the manual trans-
mission case.
3. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB±ASSY
(a) Remove the bolt and speedometer driven hole cover sub±assy.
(b) Remove the O±ring from the speedometer driven hole cover sub±assy.
4. REMOVE CLUTCH RELEASE FORK SUB±ASSY
(a) Remove the clutch release fork sub±assy with clutch re-
lease bearing assy from the front transaxle case.
5. REMOVE CLUTCH RELEASE BEARING ASSY
(a) Remove the clutch release bearing clip and clutch release
bearing assy from the clutch release fork sub±assy.

C67604
D30525
D30526
SST
D30527
D30528
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±5
C250 M/T REPAIR MANUAL (RM1020E)
6. REMOVE RELEASE FORK SUPPORT
(a) Remove the clutch release fork support from the front
transaxle case.
7. REMOVE CLUTCH RELEASE FORK BOOT
(a) Remove the clutch release fork boot from the front trans-
axle case.
8. REMOVE BACK UP LAMP SWITCH ASSY
(a) Using SST, remove the back±up lamp switch assy and
gasket from the manual transmission case.
SST 09817±16011
9. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING
SUPPORT BRACKET
(a) Remove the 3 bolts and control cable bracket from the
front transaxle case.
10. REMOVE SELECTING BELL CRANK ASSY
(a) Remove the 2 bolts and selecting bell crank assy from the
manual transmission case.

D30530
D30531
D30532
D30533
D30534
41±6
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
11. REMOVE LOCK BALL ASSY NO.1
(a) Remove the lock ball assy No.1 from the manual trans-
mission case.
12. REMOVE CONTROL SHIFT LEVER
(a) Remove the nut and spring washer.
(b) Using a brass bar and a hammer, remove the shift outer
lever lever lock pin.
(c) Remove the control shift lever.
13. REMOVE CONTROL SHAFT COVER
(a) Remove the 4 bolts, control shaft cover and gasket from
the manual transmission case.
14. REMOVE SHIFT & SELECT LEVER SHAFT ASSY
(a) Remove the shift & select lever shaft assy from the manu-
al transmission case.

D30529
C80554
C80555
C80341
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±7
C250 M/T REPAIR MANUAL (RM1020E)
15. FIX MANUAL TRANSAXLE ASSY
(a) Using 2 wooden blocks, fixing the manual transaxle assy.
16. REMOVE MANUAL TRANSMISSION CASE COVER
SUB±ASSY
(a) Remove the 9 bolts.
(b) Carefully tap the projection of the manual transmission
case cover sub±assy with a hammer and remove it.
NOTICE:
Do not damage the manual transmission case sub±assy.
17. REMOVE MANUAL TRANSMISSION OUTPUT SHAFT
REAR SET NUT
(a) Using a chisel and a hammer, loosen the staked part of
the manual transmission output shaft rear set nut.

Q06512
D30535
C80343
C80344
C80345
41±8
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
(b) Engage the gear to the double meshing.
(c) Remove the manual transmission output shaft rear set
nut.
(d) Disengage the double meshing of the gear.
18. REMOVE GEAR SHIFT FORK NO.3
(a) Remove the shift fork set bolt from the gear shift fork
No.3.
(b) Remove the No.3 hub sleeve and gear shift fork No.3 from
the transmission clutch hub No.3.
19. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 ± 0.57 mm (0.0039 ± 0.0224 in.)
Maximum clearance:
0.57 mm (0.0224 in.)
20. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the gear needle
roller bearing or shaft.