TOYOTA AVENSIS 2005 Service Repair Manual

410DR±01
D26893
D26895
D30474
D30474
±
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
41±11
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB±ASSY (See page 71±11)
2.REMOVE CONSOLE PANEL UPPER (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY LOWER (See page 71±11)
4.REMOVE CONSOLE BOX ASSY REAR (See page 71±11)
5. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the cable ends of the controlcable assy.
(b) Release the claws, separate the control cable assy.
6. REMOVE FLOOR SHIFT SHIFT LEVER ASSY
(a) Remove the 4 bolts and shift lever assy.
7. INSTALL FLOOR SHIFT SHIFT LEVER ASSY
(a) Install the shift lever assy with the 4 bolts. Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)

D26972
D26894
Serrate Part 41±12
± MANUAL TRANSMISSION/TRANSAXLEFLOOR SHIFT SHIFT LEVER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
8. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Connect the control cable assy to the shift lever assy.
NOTICE:
Make sure that the claws are firmly engaged.
(b) Connect the end of the select cable to the shift lever assy,
install the clip.
NOTICE:

The serrate part of the select cable point should face
upward when the select cable point is connected.

The clip should be inserted to the direction as shown
in the illustration.
(c) Connect the end of the shift cable to the shift lever assy.

4105U±03
D30489
Gasoline Engine:
Front Floor
Heat Insulator No.1
Console Box Carpet
Floor Shift Lever Knob
Sub±assy
Console Panel Sub±assy Upper
Console Panel Sub±assy Lower
Console Box Sub±assy Rear
Clip
Clip
Clip
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
ClipClip
12 (122, 9)
Floor Shift Shift Lever Assy
12 (122, 9)
N´m (kgf´cm, ft´lbf): Specified torque
5.5 (56, 49 in.
lbf)
Transmission Control Cable Assy
41±10
± MANUAL TRANSMISSION/TRANSAXLEFLOOR SHIFT SHIFT LEVER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
FLOOR SHIFT SHIFT LEVER ASSY (MTM)
COMPONENTS

4105R±02
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
D30070
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±7
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION CONTROL CABLE ASSY (MTM)
REPLACEMENT
HINT:
COMPONENTS: See page 41±10
1.REMOVE AIR CONDITIONER UNIT ASSY (See page 55±55)
HINT:
Refer to the instructions for removal of the instrument panel sub±ass\
y lower.
2. REMOVE EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Remove the 3 nuts and heat insulator No.1.
4. REMOVE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the 2 cables from the trans-axle.
(b) Remove the 2 clips, separate the 2 cables from the brack- et.
(c) Remove the 2 nuts, separate the control cable assy.

D30071
D26893
D26895
D30071
D26972
41±8
± MANUAL TRANSMISSION/TRANSAXLETRANSMISSION CONTROL CABLE ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove the 2 bolts, separate the control cable assy.
(e) Remove the 2 clips, separate the cable ends of the control
cable assy.
(f) Release the claws, remove the control cable assy.
5. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Put the control cable assy through the floor hole.
(b) Install the control cable assy with the 2 bolts.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(c) Connect the control cable assy to the shift lever assy.
NOTICE:
Make sure that the claws are firmly engaged.

D26894
Serrate Part
D30070
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±9
AVENSIS REPAIR MANUAL (RM1018E)
(d) Connect the end of the select cable to the shift lever assy
and install the clip.
NOTICE:

The serrate part of the select cable point should face
upward when the select cable point is connected.

The clip should be inserted to the direction as shown
in the illustration.
(e) Connect the end of the shift cable to the shift lever assy.
(f) Connect the control cable assy with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(g) Connect the 2 cable ends, install the 2 clips.
(h) Install the 2 clips to the control cable bracket.
6. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Install the heat insulator No.1 with the 3 nuts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
7. INSTALL EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)

41046±12
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
41±5
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (E354/E357)
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
6.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
7. REMOVE FRONT TRANSAXLE CASE COVER OILSEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
8. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
9. INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal.
SST 09608±10010, 09950±70010 (09951±07200)
Drive in depth: 0
0.5 mm (0
0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.

D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±6
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09608±32010, 09950±70010 (09951±07200)
Drive in depth: 3.5
0.5 mm (0.138
0.020 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts)
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)

41046±11
C94266
SST(s)
D25305
SST(s)
D25722
SST(s)
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
41±3
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (C50/C250)
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
6.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
7. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST(s), remove the oil seal.SST 09308±00010
8. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST(s), remove the oil seal. SST 09308±00010
9. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 1.9
0.3 mm (0.075
0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.

D26133
SST(s)
D25304
0 to 5 mm
(0 to 0.20 in.)
41±4
±
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal. SST 09554±14010, 09950±70010 (09951±07200)
Drive in depth: 9.9
0.3 mm (0.390
0.012 in.)
NOTICE:
Be careful not to damage the oil seal lip.
11.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
12.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6)
13. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
14. ADD MANUAL TRANSAXLE OIL Oil grade: API GL±4 or GL±5
Viscosity: SAE 75 W±90
Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
15.INSPECT MANUAL TRANSAXLE OIL (See page 41±2)
16.INSPECT FRONT WHEEL ALIGNMENT (See page 26±6)
17. CHECK ABS SPEED SENSOR SIGNAL
(a)w/ VSC (See page 05±756)
(b)w/o VSC (See page 05±699)