key TOYOTA AVENSIS 1999 Supplement

MX01Z–04
– MANUAL TRANSAXLE (E251)TROUBLESHOOTING
MX–1
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX–4
MX–4
MX–9
MX–9
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O–Ring (Worn or damaged)MX–4
MX–9
MX–9
MX–9
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX–48
MX–9
MX–23
MX–30
MX–9
MX–23
MX–30
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX–9
MX–9
MX–9
MX–9

D06653
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
 Precoated partOutput Shaft AssemblyInput Shaft Assembly

Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring
Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x 7Shim
 Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring 
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–11

MT0781
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–17
(a) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
(b) Remove the 2 bolts and the oil pump assembly.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
36. REMOVE NO.5 SYNCHRONIZER RING WITH KEY
SPRING FROM NO.3 CLUTCH HUB
(a) Remove the No.5 synchronizer ring with the key spring
from the No.3 clutch hub.
(b) Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.

MX028–03
MT0791
Rear Bearing4th GearSpacer
Synchronizer Ring
Snap Ring
Needle Roller Bearing3rd GearNeedle Roller Bearing

Input Shaft Front Bearing Inner Race
Input Shaft Synchronizer Ring
No.2 Hub Sleeve
No.2 Clutch Hub
Shifting KeySpring
Snap Ring

Non–reusable part
– MANUAL TRANSAXLE (E251)INPUT SHAFT
MX–23
INPUT SHAFT
COMPONENTS

MX02B–03
Q00383
Front
MT0790
Q00183SST
Q00116
MX–28
– MANUAL TRANSAXLE (E251)INPUT SHAFT
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 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 front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506–35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)––
(b) Using a screwdriver and hammer, tap in the snap ring.

N00494
SST
Q00118
– MANUAL TRANSAXLE (E251)INPUT SHAFT
MX–29
4. MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX–24)
5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the rear ball bearing.
SST 09506–35010
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
12.35 (0.0925)52.55 (0.1004)
22.40 (0.0945)62.60 (0.1024)
32.45 (0.0965)72.65 (0.1043)
42.50 (0.0984)82.70 (0.1063)
(b) Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX–24)

MX02C–03
Q06216
4th Driven Gear3rd Driven GearNeedle Roller Bearing
1st Gear Bearing Inner Race Spacer
Inner Race
2nd Gear
Spacer
Output Shaft Rear Bearing
SpringNo.1 Hub Sleeve
Needle Roller Bearing
1st Gear
Synchronizer Ring
Ball
Output Shaft Front
Bearing
Output Shaft Shifting Key
No.1 Clutch Hub
Synchronizer Ring

Non–reusable part
MX–30
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
OUTPUT SHAFT
COMPONENTS

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)

SR0WB–01
F08960
 Gasket Union Bolt
Pressure Feed Tube
PS Vane Pump
Assembly Woodruff Key
Vane Pump Pulley
Drive Belt
Idler PulleyReturn Hose
N·m (kgf·cm, ft·lbf): Specified torque
 Non–reusable part
Pulley Cover
43 (440, 32)
39 (400, 29)
39 (400, 29)
38 (390, 28)
52 (525, 38)
SR–6– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
POWER STEERING VANE PUMP (2C–T, 2C–TE, 1CD–FTV)
COMPONENTS

SR0WC–01
F03730
F04155
SST
SR–8– STEERINGPOWER STEERING VANE PUMP (2C–T, 2C–TE,
1CD–FTV)
REMOVAL
1. REMOVE DRIVE BELT
(a) Loosen the idler pulley set nut.
(b) Loosen the belt tension adjusting bolt, and remove the
drive belt.
2. REMOVE VANE PUMP PULLEY
(a) Using SST to stop the pulley rotating, remove the pulley
set nut.
SST 09960–10010 (09962–01000, 09963–01000)
(b) Remove the pulley and woodruff key from the vane pump
shaft.
3. DISCONNECT RETURN HOSE
Remove the clip and disconnect return the hose.
4. DISCONNECT PRESSURE FEED TUBE
Remove the union bolt and gasket, and disconnect the pres-
sure feed tube.
5. REMOVE PS VANE PUMP ASSEMBLY
Remove the 3 bolts and PS vane pump assembly.
6. REMOVE PULLEY COVER
Remove the bolt and pulley cover.