TOYOTA AVENSIS 2005 Service Repair Manual

D30566
D30541
C80352
C80351
C80394
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±29
C250 M/T REPAIR MANUAL (RM1020E)
(c) Install the shift detent ball, shift detent ball compression
spring and shift detent ball spring seat No.1 to the front
transaxle case.
(d) Coat the shift detent ball plug with sealant, install it with
using a hexagon wrench.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
85. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP
RING
(a) Using a snap ring expander, install the input shaft rear
bearing hole snap ring to the input shaft.
86. INSTALL OUTPUT SHAFT REAR BEARING HOLE
SNAP RING
(a) Using a snap ring expander, install the output shaft rear
bearing hole snap ring to the output shaft.
87. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using a brass bar and hammer, install the shift fork shaft
snap ring to the shift fork shaft No.2.

D30539
D30568
SST
D30537
C80396
C80397
Key Position 41±30
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
88. INSTALL BEARING RETAINER REAR (MTM)
(a) Coat the 5 bolts with sealant, install them and bearing re-
tainer rear to the manual transmission case.
Torque: 27 N
m (280 kgf
cm, 20 ft
lbf)
89. INSTALL 5TH DRIVEN GEAR
(a) Using SST, install the 5th driven gear to the output shaft.
SST 09950±30012 (09951±03010, 09953±03010,
09954±03010, 09955±03011, 09956±03020)
90. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 5th gear needle roller bearing and spacer with
gear oil, install them to the input shaft.
91. INSTALL 5TH GEAR
(a) Coat the 5th gear with gear oil, install it to the input shaft.
92. INSTALL SYNCHRONIZER RING NO.3
(a) Coat the synchronizer ring No.3 with gear oil, install it to
the 5th gear.

D30550
Engine
Side
D30551
Key Position
C80400
C80344
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±31
C250 M/T REPAIR MANUAL (RM1020E)
93. INSTALL TRANSMISSION CLUTCH HUB NO.3
(a) Install the 3 synchromesh shifting keys and 2 synchro-
mesh shifting key springs to the transmission clutch hub
No.3.
HINT:
Do not set both openings of the shifting key springs in the same
position.
(b) Using SST and a hammer, install the transmission clutch
hub No.3 to the input shaft.
SST 09636±20010
NOTICE:

Make sure the direction of the transmission clutch
hub No.3.

Attach the transmission clutch hub No.3 with check-
ing position of the spline on synchronizer ring and
synchromesh fitting key No.3.

Check that the 5th gear is rotating.
HINT:
Place the suitable sized wooden block to supports the transaxle
assy.
(c) Select a snap ring that will allow minimum axial play.
Clearance: 0.1 mm or less
MarkThickness mm (in.)MarkThickness mm (in.)
A2.25 (0.0886)E2.49 (0.0980)
B2.31 (0.0909)F2.55 (0.1004)
C2.37 (0.0933)G2.61 (0.1028)
D2.43 (0.0957)
(d) Using a brass bar and hammer, install the snap ring to the
input shaft.
94. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, inspect the 5th gear thrust clear-
ance.
Standard clearance:
0.1 ± 0.57 mm (0.0039 ± 0.02244 in.)
Maximum clearance:
0.57 mm (0.02244 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.

C80345
C80401
C80402
C80403
C80404
41±32
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
95. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, inspect the 5th gear radial clear-
ance.
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.
96. INSTALL GEAR SHIFT FORK NO.3
(a) Coat the transmission clutch hub sleeve No.3 with gear
oil, install it and gear shift fork No.3 to the transmission
clutch hub No.3.
HINT:
Do not set the transmission clutch hub No.3 in incorrect orienta-
tion.
(b) Coat the gear shift fork lock bolt with sealant, install it to
the gear shift fork No.3.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 16 N
m (160 kgf
cm, 12 ft
lbf)
97. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT
REAR SET NUT
(a) Engage the gear double meshing.
(b) Install the new manual transmission output shaft rear set
nut.
Torque: 118 N
m (1200 kgf
cm, 87 ft
lbf)
(c) Using a chisel and hammer, stake the manual transmis-
sion output shaft rear set nut.
(d) Disengage the gear double meshing.

C80556
FIPG
C80554
D30534
D30533
D30531
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±33
C250 M/T REPAIR MANUAL (RM1020E)
98. INSTALL MANUAL TRANSMISSION CASE COVER
SUB±ASSY
(a) Apply FIPG to the transaxle case, cover as shown to the
illustration.
FIPG:
Part No. 08826±00090, THREE BOND 1281
NOTICE:
Parts must be assembled within 10 minutes of application.
Otherwise, the packing (FIPG) material must be removed
and reapplied.
(b) Install the 9 bolts with manual transmission case cover to
the manual transmission case.
Torque: 18 N
m (185 kgf
cm, 14 ft
lbf)
99. INSTALL SHIFT & SELECT LEVER SHAFT ASSY
(a) Coat the sift & select lever shaft assy with gear oil, install
it to the manual transmission case.
100. INSTALL CONTROL SHAFT COVER
(a) Coat the 4 bolts with sealant, install the new gasket, con-
trol shaft cover with the bolt.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N
m (200 kgf
cm, 14 ft
lbf)
101. INSTALL CONTROL SHIFT LEVER
(a) Install the control shift lever with shift outer lever lever lock
pin to the shift & select lever shaft assy.
(b) Install the spring washer with nut.
Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)

D30530
D30528
D30527
D30526
SST
41±34
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
102. INSTALL LOCK BALL ASSY NO.1
(a) Coat the lock ball assy No.1 with sealant, install it to the
manual transmission case.
Torque: 29 N
m (300 kgf
cm, 22 ft
lbf)
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
103. INSTALL SELECTING BELL CRANK ASSY
(a) Install the 2 bolts with selecting bell crank assy to the
manual transmission case.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
104. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING
SUPPORT BRACKET
(a) Install the 3 bolts with floor shift control lever housing sup-
port bracket to the front transaxle case.
Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
105. INSTALL BACK UP LAMP SWITCH ASSY
(a) Using SST, install the back up lamp switch assy with new
gasket to the manual transmission case.
SST 09817±16011
Torque: 40 N
m (410 kgf
cm, 30 ft
lbf)
106. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB±ASSY
(a) Install a new O±ring to the speedometer driven hole cover sub±assy.
(b) Install the bolt with speedometer driven hole cover sub±assy to the manual transaxle case.
Torque: 11 N
m (115 kgf
cm, 8.3 ft
lbf)

C67604
D30525
C67602
C68381
D30524
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±35
C250 M/T REPAIR MANUAL (RM1020E)
107. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the front transaxle case.
Torque: 37 N
m (375 kgf
cm, 25 ft
lbf)
108. INSTALL CLUTCH RELEASE FORK BOOT
(a) Install the clutch release fork boot to the front transaxle
case.
109. INSTALL CLUTCH RELEASE BEARING ASSY
(a) Coat the clutch release bearing assy with release hub
grease, install it to the clutch release fork sub±assy.
Sealant:
Part No. 08887±01806, RELEASE HUB GREASE or
equivalent
110. INSTALL CLUTCH RELEASE FORK SUB±ASSY
(a) Install the clutch release fork sub±assy to the input shaft.
Sealant:
Part No. 08887±01806, CLUTCH SPLINE GREASE or
equivalent
(b) Apply clutch spline grease to the input shaft spline.
111. INSTALL MANUAL TRANSMISSION FILLER PLUG
(a) Install the manual transmission filler plug with new gasket
to the manual transmission case.
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)

C80550
41±36
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
112. INSTALL DRAIN (MTM) PLUG SUB±ASSY
(a) Install the drain plug with new gasket to the manual trans-
mission case.
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)

4101E±02
C67982
C80408
Match
marks
C67984
C67989
41±66
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR
(a) Remove the speedometer drive gear from the front differ-
ential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place match marks on the from the front differential ring
gear and from the front differential case.
(b) Remove the 8 bolts. Using a hammer, remove the front
differential ring gear from the front differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Fixing the front differential pinion to the from the front dif-
ferential case side. Using a dial indicator, measure the
front differential side gear back lash.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)

C67985
C67986
C67987
C67988
C68517
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
41±67
C250 M/T REPAIR MANUAL (RM1020E)
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a chisel and hammer, loosen the staked part of the
front differential case.
(b) Using a pin punch (3 mm) and a hammer, remove the
front differential pinion shaft straight pin from the front dif-
ferential case.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 from the
front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions , front differential
pinion thrust washers and front differential side gear
thrust washers No.1 from the front differential case.
HINT:
Revolving the front differential pinion, remove the 2 pinions, pin-
ion thrust washers and side gear thrust washers.
7. INSPECT FRONT DIFFERENTIAL PINION THRUST
WASHER
(a) Using a micrometer, measure the thickness of the front
differential pinion thrust washer.
Minimum thickness: 0.94 mm (0.03701 in.)
If the thickness exceed the minimum, replace the front differen-
tial pinion thrust washer.