TOYOTA AVENSIS 1999 Supplement

Q06288
SST
N00100
SST
Z00292
SST
Z00293
SST MX–44
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
(h) Using SST and a hammer, drive in a new oil seal.
SST 09223–15020, 09950–70010 (09951–07150)
(i) Coat the lip of oil seal with MP grease.
6. Transaxle Case Side:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver and hammer, drive out the oil seal
from the transaxle case.
(b) Using SST, pull out the tapered roller bearing outer race.
SST 09612–65014
(c) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316–60011 (09316–00011, 09316–00041)
(d) Using SST and a hammer, drive in a new oil seal.
SST 09316–60011 (09316–00011)
(e) Coat the oil seal lip with MP grease.

Z00295
MX09B–01
Z00296
Z00297
D06655
Matchmarks
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–45
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washer to the side gear.
(b) Install the 4 pinions and thrust washers to the spider.
(c) Install the side gear and spider with the 4 pinions to the
differential left case.
(d) Using a dial indicator, measure the backlash of the pinion
gear while holding the differential left case.
Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079
in.)
HINT:
Push the pinion gear and spider with the 4 pinions to the differ-
ential left case.
(e) Install the side gear and spider with the 4 pinions to the
right side of the differential case. Check the side gear
backlash.
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)–
(g) Align the matchmarks on the differential cases.
(h) Using a plastic hammer, carefully tap the differential case
to install it.
(i) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.

Z00303
Driven Gear
Side
Q06410
SST
SST MX–46
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
(b) Heat the ring gear to about 100
C (212
F  



(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the differential left case and contact
the ring gear.
(f) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(g) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
3. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
4. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316–20011, 09316–60011 (09316–00011)
HINT:
Press the bearing on the ring side first.
5. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See page MX–21)
6. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
7. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
8. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm 22 ft·lbf)
9. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
10. INSTALL SHIM (See page MX–21)
HINT:
Install the previously selected shim.
11. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

Q00036
Z00309
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–47
12. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 – 0.3 N·m (1.8 – 3.5 kgf·cm, 1.6 – 3.0 in.·lbf)
Reused bearing (Output shaft preload plus)
0.1 – 0.2 N·m (1.1 – 2.2 kgf·cm, 1.0 – 1.9 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
HINT:
The total preload will change by about 0.1 – 0.2 N·m (1 – 2
kgf·cm, 0.9 – 1.7 in.·lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
13. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
14. REMOVE SHIM
15. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
16. REMOVE OUTPUT SHAFT ASSEMBLY
17. REMOVE DIFFERENTIAL CASE ASSEMBLY

MX09C–01
D06624
Air Cleaner Case
Assembly
with Air Hose
Air Flow Meter
Connector
D06625
Shift Lever Assembly
12 (120, 9)
Transmission Control Cable Bracket
Clip
WasherShift Cable Grommet
Retainer Shift Cable Grommet Select Control Cable
Shift Control CableConsole Box Assembly
Shift Lever Knob
Clip
Clip
Washer
WasherClip Front Ash Receptacle
Parking Brake Cover
Cap Cap
Air Duct
4.9 (50, 43 in.·lbf)Clip
4.9 (50, 43 in.·lbf)
N·m (kgf·cm, ft·lbf): Specified torque MX–48
– MANUAL TRANSAXLE (E251)SHIFT LEVER AND CONTROL CABLE
SHIFT LEVER AND CONTROL CABLE
COMPONENTS

SUSPENSION AND AXLE
FRONT DRIVE SHAFT SA–1. . . . . . . . . . . . . . . . . . .
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR
CHASSIS AND BODY (Pub. No. RM599E)
NOTE: The above pages contain only the points which differ
from the above listed manual.

SA109–02
F08959
1CD–FTV Engine
Tie Rod End
ABS Speed Sensor
Cotter Pin
Lock Cap

Non–reusable part
N·m (kgf·cm, ft·lbf) : Specified torqueLH Drive Shaft
Snap Ring

Cotter Pin
Center Bearing Bracket
64 (650, 47)
49 (500, 36)
8.0 (82, 71 in.·lbf)
216 (2,200, 159)
RH Drive Shaft
127 (1,300, 94)
Lower Suspension Arm
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–1
FRONT DRIVE SHAFT
COMPONENTS

F08949
Non–reusable part
Dynamic Damper

Dust Cover
Snap Ring Outboard Joint Shaft

Boot

Boot
Tripod
RH Inboard Joint Shaft
Snap Ring
Bearing CaseStraight Pin
Inboard Joint Shaft

Dust Cover LH
Boot ClampBearing

Snap Ring 1CD–FTV Engine

Dynamic Damper Clamp

Boot Clamp

Boot Clamp

Boot Clamp SA–2
– SUSPENSION AND AXLEFRONT DRIVE SHAFT

SA10A–02
FA1535
SST
F02688
F02721
F02724
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA–3
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608–16042 (09608–02021, 09608–02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serration on the drive shaft.
1. REMOVE FRONT WHEEL
2. DRAIN OUT GEAR OIL
3. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
4. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) While applying the brakes, remove the nut.
5. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See Pub. No. RM599E on page SA–11)
6. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See Pub. No. RM599E on page
SA–11)
7. DISCONNECT DRIVE SHAFT FROM AXLE HUB
(a) Using a plastic hammer, disconnect the drive shaft from
the axle hub.
NOTICE:
Cover the drive shaft boot and ABS speed sensor rotor with
cloth to protect it from being damaged.
(b) Push the front axle hub toward the outside of the vehicle
to separate the drive shaft from the axle hub.
8. REMOVE DRIVE SHAFTS
(a) RH drive shaft:
Remove the 2 bolts and pull out the drive shaft together
with the center bearing bracket.