TOYOTA AVENSIS 1999 Supplement

WM0066
Q06203
AB
A
Q06191
MX–34
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
3. MEASURE NO.1 SHIFT FORK AND HUB SLEEVE
CLEARANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A: 37.526 mm (1.4774 in.)
Part B: 34.512 mm (1.3588 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)

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)

Q06314
MT0792
N00495
Z00390
Z00391
SST MX–36
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
5. INSTALL BALL AND INNER RACE TO OUTPUT SHAFT
HINT:
Align the groove of the inner race and ball.
6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-
CHRONIZER RING, 2ND GEAR AND 3RD DRIVEN
GEAR
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearing.
(c) Place the synchronizer rings (for the 2nd gear) on the
gear.
NOTICE:
Do not install the synchronizer ring for the 1st gear.
(d) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
7. MEASURE 2ND GEAR THRUST CLEARANCE
(See page MX–31)
8. INSTALL SPACER AND 4TH DRIVEN GEAR
(a) Install the spacer.
(b) Using a press, install the 4th driven gear.
9. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 09506–30012

Z00392SST
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
MX–37
10. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316–60011 (09316–00071)

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

MX02H–02
Z00242
Z00243
Z00244
– MANUAL TRANSAXLE (E251)OIL PUMP
MX–39
INSPECTION
1. CHECK ROTOR BODY CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and oil pump case.
Standard clearance:
0.10 – 0.16 mm (0.0039 – 0.0063 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
2. CHECK ROTOR TIP CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the tip clearance between
the drive and driven rotors.
Standard clearance:
0.08 – 0.15 mm (0.0031 – 0.0059 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
3. CHECK SIDE CLEARANCE
Using a precision straight edge and feeler gauge, measure the
side clearance of both rotors.
Standard clearance:
0.03 – 0.08 mm (0.0012 – 0.0031 in.)
Maximum clearance:
0.15 mm (0.0059 in.)

MX02I–03
Q06217
Shift Interlock Plate
Transmission Oil Baffle Shift Interlock Plate
No.1 Compression SpringControl Shaft Cover
Oil Seal
Snap Ring
No.1 Select Spring Seat
Slotted Spring Pin
No.1 Shift Inner Lever
Shift and Select Lever Shaft Snap Ring
Non–reusable partNo.2 Select Spring SeatNo.2 Compression SpringNo.2 Shift Inner LeverSlotted Spring Pin
Apply MP grease

Dust Boot

MX–40
– MANUAL TRANSAXLE (E251)SHIFT AND SELECT LEVER SHAFT
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

MX060–02
D06656
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer

Tapered Roller Bearing
and Outer Race
Differential Right Case Vehicle Speed Sensor Drive Gear
Differential Left Case

Tapered Roller Bearing
and Outer Race Ring Gear
Oil Baffle

Oil Seal x16
Shim
Oil Seal
63 (640, 46)
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable partx16
124 (1,260, 91)
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–41
DIFFERENTIAL CASE
COMPONENTS

MX09A–01
Q05166
SST
D06654
Matchmarks
MX–42
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
DISASSEMBLY
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.
1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950–40011
2. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
FROM DIFFERENTIAL RIGHT CASE
3. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap the ring gear and remove it.
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the differential right and left cases.
(b) Using a torx wrench (T50), remove the 16 torx screws.
(c) Using a plastic hammer, tap the differential left case.

Z00284
Z00286
Z00288
SST
Z00289
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–43
(d) Remove the 2 differential side gears, side gear thrust
washers, 4 differential pinions and pinion thrust washers
from the differential left case.
5. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the shim.
(e) Install the shim.
(See page MX–41)
HINT:
First select and install a shim of lesser thickness than before.
(f) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316–60011 (09316–00011, 09316–00041)
(g) Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.