TOYOTA AVENSIS 2005 Service Repair Manual

C69643
C69644
C69641
C69646
C83814
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±63
E355,E356 M/T REPAIR MANUAL (RM867E)
8. REMOVE SYNCHRONIZER RING SET NO.2
(a) Remove the synchronizer ring set No.2 from the transmis-
sion clutch hub No.1.
9. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing from the out-
put shaft.
10. REMOVE 2ND GEAR BEARING SPACER
(a) Remove the 2nd gear bearing spacer from the output
shaft.
11. REMOVE 2ND GEAR BUSH
(a) Remove the 2nd gear bush from the output shaft.
12. REMOVE 2ND GEAR BUSH BALL
(a) Using a magnetic finger, remove the 2nd gear bush ball
from the output shaft.

SST
C69648
C69649
C69650
SST
C69651
C69652
41±64
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
13. REMOVE 1ST GEAR
(a) Using SST and a press, remove the transmission clutch
hub No.1 and 1st gear from the output shaft.
SST 09950±00020
14. REMOVE SYNCHRONIZER RING SET NO.1
(a) Remove the synchronizer ring set No.1 from the 1st gear.
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
16. REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the output shaft front
bearing (inner race) from the output shaft.
SST 09950±00020, 09950±60010 (09951±00320),
09950±70010 (09951±07150)
NOTICE:
Do not tighten SST excessively.
17. REMOVE REVERSE GEAR
(a) Remove the reverse gear, 3 synchromesh shifting keys
and 3 synchromesh shifting key springs from the trans-
mission clutch hub No.1.

C69653
C91168
AA
B
C69655
C69655
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±65
E355,E356 M/T REPAIR MANUAL (RM867E)
18. INSPECT OUTPUT SHAFT
(a) Using V ± block and a dial indicator, measure the shaft run
out.
Maximum run out:0.03 mm (0.0012 in.)
If the run out exceeds the maximum, replace the input shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft jarnal surface.
Outer diameter: mm (in.)
PartStandard outer diameterminimum outer diameter
A37.610 ± 37.626
(1.4931 ± 1.4938)37.610
(1.4931)
B34.802 ± 34.512
(1.3816 ± 1.3701)34.802
(1.3816)
If the outer diameter is less than the minimum replace the input
shaft.
19. INSPECT 2ND GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 2 nd gear.
Inside diameter: mm (in.)
Standard inside diameterMaximum inside diameter
50.009±50.025
(1.9854 ± 1.9860)50.025
(1.9860)
If the inside diameter exceeds the maximum, replace the 2nd
gear.
20. INSPECT 1ST GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 1st gear.
Inside diameter: mm (in.)
Standard inside diameterMaximum inside diameter
51.009±51.025
(2.0250 ± 2.0257)51.025
(2.0257)
If the inside diameter exceeds the maximum, replace the 1st
gear.

C69657
C69656
C69658
C69659
41±66
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
21. INSPECT SYNCHRONIZER RING SET NO.2
(a) Coat the cone of the 2nd gear with gear oil, check that it
does not turn in the both circumference directions wile
pushing it to the synchronizer ring No.2.
(b) Check the clearance between the synchronizer ring No.2
and 2nd gear while pushing it to the synchronizer ring
No.2.
Standard clearance:
0.70 ± 1.45 mm (0.0278 ± 0.0576 in.)
If the standard clearance is out of the specification, replace the
synchronizer ring set No.2 with a new one.
22. INSPECT SYNCHRONIZER RING SET NO.1
(a) Coat the 1st gear cone with gear oil. Turn the synchroniz-
er ring set No.1. in one direction while pushing it to the 1st
gear cone. Check that the ring locks.
(b) Check the clearance between the synchronizer ring set
No.1 and 1st gear while pushing it to the cone of synchro-
nizer ring set No.1.
Standard clearance:
0.70 ± 1.45 mm (0.0278 ± 0.0576 in.)
If the standard clearance is out of the specification, replace the
synchronizer ring set No.1 with a new one.

C70507
C69671
C69672
SST
C69674
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±67
E355,E356 M/T REPAIR MANUAL (RM867E)
23. INSPECT REVERSE GEAR
(a) Using a vernier calipers, measure the reverse gear
groove and thickness of the claw part on gear shift fork
No.1, and calculate
Standard clearance:
0.15 ± 0.35 mm (0.0060 ± 0.0139 in.)
If the clearance is bout of the specification, replace the reverse
gear and gear shift fork No.1 with the new one.
24. INSPECT TRANSMISSION CLUTCH HUB NO.1
(a) Check the sliding condition between the transmission
clutch hub No.1 and reverse gear.
(b) Check the tip of spline gear on the sleeve of reverse gear
for wear.
25. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil.
(b) Install the 3 synchromesh shifting key spring No.1 and
transmission clutch hub No.1 to the reverse gear.
NOTICE:
Do not set the reverse gear and the transmission clutch
hub No.1 in incorrect direction.
(c) Using a screwdriver, install the synchromesh sifting key
No.1 to the reverse gear.
26. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the output shaft front bear-
ing (inner race) to the output shaft.
SST 09950±60010 (09951±00430), 09950±70010
(09951±07150)

C69649
C69650
C69673
SST
SST
C69675
C83814
41±68
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
27. INSTALL SYNCHRONIZER RING SET NO.1
(a) Coat the synchronizer ring set No.1 with gear oil, install
it to the 1st gear.
NOTICE:
Align the synchronizer ring set No.1 with the hole of 1st
gear and install.
28. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil,install
it to the output shaft.
29. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil, install it to the output shaft.
30. INSTALL TRANSMISSION CLUTCH HUB NO.1
(a) Using SST and a press, install transmission clutch hub
No.1 to the output shaft.
SST 09316±60011 (09316±00031), 09950±60010
(09951±00320), 09950±70010 (09951±07100)
NOTICE:

Align the synchronizer ring No.1 with synchromesh
shifting key No.1 and install.

Make sure that the 1st gear rotates.
31. INSTALL 2ND GEAR BUSH BALL
(a) Coat the gear bush with MP grease, install it to the output
shaft.

C69646
C69645
C69644
C69643
C69679
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±69
E355,E356 M/T REPAIR MANUAL (RM867E)
32. INSTALL 2ND GEAR BUSH
(a) Coat the gear 2nd gear bush with gear oil, install it to the
output shaft.
33. INSTALL 2ND GEAR BEARING SPACER
(a) Coat the gear 2nd gear bearing spacer with gear oil,
install it to the output shaft.
34. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing with gear oil,
install it to the output shaft.
35. INSTALL SYNCHRONIZER RING SET NO.2
(a) Coat the synchronizer ring set No.2 with gear oil, install
it to the transmission clutch hub No.1
NOTICE:
Align the key groove on the synchronizer ring set No.2 with
the synchromesh shifting key No.1.
36. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil, install it to the output
shaft.

SST
SST
C69676
C69641
SST
SST
C69677
SST
SST
C69678
41±70
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
37. INSTALL 3RD DRIVEN GEAR
(a) Using SST and a press, install the 3rd driven gear to the
output shaft.
SST 09608±00071, 09950±60010 (09951±00320),
09950±70010 (09951±07100)
38. INSTALL OUTPUT GEAR SPACER
(a) install the output gear spacer to the output shaft.
39. INSTALL 4TH DRIVEN GEAR
(a) Using SST and a press, install the 4th driven gear to the
output shaft.
SST 09608±00071, 09950±60010 (09951±00320),
09950±70010 (09951±07100)
40. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the output shaft front bear-
ing (inner race) to the output shaft.
SST 09506±30012, 09950±60010 (09951±00320),
09950±70010 (09951±07100)

C69639
C69638
C69637
C69636
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±71
E355,E356 M/T REPAIR MANUAL (RM867E)
41. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clear-
ance.
Standard clearance:mm (in.)
BearingStandard clearance
KOYO made0.009 ± 0.053
(0.0004 ± 0.0021)
NSK made0.009 ± 0.051
(0.0004 ± 0.0020)
If the clearance is out of the specification, replace the 2nd gear
needle roller bearing.
42. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clear-
ance.
Standard clearance:mm (in.)
BearingStandard clearance
KOYO made0.009 ± 0.053
(0.0004 ± 0.0021)
NSK made0.009 ± 0.051
(0.0004 ± 0.0020)
If the clearance is out of the specification, replace the 1st gear
needle roller bearing.
43. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clear-
ance.
Standard clearance:
0.1 ± 0.35 mm (0.0039 ± 0.0139 in.)
(b) Using a fleer gauge, measure the 1st gear thrust clear-
ance.
Standard clearance:
0.25 ± 0.4 mm (0.099 ± 0.0159 in.)
44. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a fleer gauge, measure the 1st gear thrust clear-
ance.
Standard clearance:
0.25 ± 0.4 mm (0.099 in. ± 0.0159 in.)

4103X±01
C69546
C69637
C69548
41±50
±
MANUAL TRANSMISSION/TRANSAXLE INPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
INPUT SHAFT ASSY (E355/E356)
OVERHAUL
HINT:
COMPONENTS:See page 41±1 1. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 4th gear thrust clear-ance.
Standard clearance:
0.1 ± 0.57 mm (0.0039± 0.0224 in.)
2. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 3rd gear thrust clear- ance.
Standard clearance:
0.1 ± 0.35 mm (0.0039 ± 0.0014 in.)
3. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th gear radial clear- ance.
Standard clearance: mm (in.)
BearingStandard clearance
KOYO made0.009 ± 0.053]
(0.0004 ± 0.0021)
NSK made0.009 ± 0.051
(0.0004 ± 0.00020)
If the clearance exceeds the maximum, replace the 4th gear
needle roller bearing.