TOYOTA AVENSIS 2005 Service Repair Manual

D30536
C80347
SST
D07737
D30537
D30538
SST
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±9
C250 M/T REPAIR MANUAL (RM1020E)
21. REMOVE TRANSMISSION CLUTCH HUB NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(b) Using SST, remove the transmission clutch hub No.3, 5th
gear and synchronizer ring from the input shaft.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04030, 09954±04010, 09955±04071,
09957±04010), 09950±60010 (09951±00200)
(c) Remove the 3 synchromesh shifting keys and 2 synchro-
mesh shifting key springs from the transmission clutch
hub No.3.
22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 5th gear needle roller bearing and 5th gear
bearing spacer from the input shaft.
23. REMOVE 5TH DRIVEN GEAR
(a) Using SST, remove the 5th driven gear from the output
shaft.
SST 09950±30012 (09951±03010, 09953±03010,
09954±03010, 09955±03011, 09957±04010),
09950±60010 (09951±00190)

D30539
C80351
C80352
D30540
C80353
41±10
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
24. REMOVE BEARING RETAINER REAR (MTM)
(a) Remove the 5 bolts and bearing retainer rear from the
manual transmission case.
25. REMOVE OUTPUT SHAFT REAR BEARING HOLE
SNAP RING
(a) Using a snap ring expander, remove the output shaft rear
bearing hole snap ring from the output shaft.
26. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP
RING
(a) Using a snap ring expander, remove the input shaft rear
bearing hole snap ring from the input shaft.
27. REMOVE REVERSE IDLER GEAR SHAFT BOLT
(a) Remove the reverse idler gear shaft bolt and reverse idler
gear shaft gasket from the manual transmission case.
28. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Using a shop rug to the shifting key spring from being scattered.

C67634
C67635
D30541
D30542
D30543
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±11
C250 M/T REPAIR MANUAL (RM1020E)
29. REMOVE SHIFT DETENT BALL
(a) Using a hexagon wrench, remove the 2 shift detent ball
plugs from the manual transmission case.
(b) Using a magnetic finger, remove the 2 seats, springs and
balls from the manual transmission case.
(c) Using a hexagon wrench, remove the shift detent ball
plug from the front transaxle case.
(d) Using a magnetic finger, remove the seat, spring and ball
from the front transaxle case.
30. REMOVE LOCK BALL ASSY NO.2
(a) Using a hexagon wrench, remove the lock ball assy No.2
from the manual transmission case.

D30544
C80358
C67642
C80359
C80360
41±12
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
31. REMOVE MANUAL TRANSMISSION CASE
(a) Remove the 3 bolts from the front transaxle case.
(b) Remove the 13 bolts from the manual transmission case.
(c) Carefully tap the transmission case with a brass bar and
hammer and remove it from the transaxle case.
32. REMOVE REVERSE IDLER GEAR SUB±ASSY
(a) Remove the revers idler gear, thrust washer and reverse
idler gear shaft from the front transaxle case.
33. REMOVE REVERSE SHIFT ARM BRACKET ASSY
(a) Remove the 2 bolts and reverse shift arm bracket assy
from the front transaxle case.

C80361
C80362
C80363
C80364
C80365
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±13
C250 M/T REPAIR MANUAL (RM1020E)
34. REMOVE GEAR SHIFT FORK SHAFT NO.2
(a) Remove the 2 bolts from the gear shift fork No.2 and gear
shift head No.1.
(b) Remove the gear shift fork shaft No.2 and gear shift head
No.1 from the front transaxle case.
35. REMOVE GEAR SHIFT FORK SHAFT NO.1
(a) Using 2 screwdrivers and a hammer, tap out the snap
rings.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(b) Remove the shift fork set bolt and gear shift fork shaft
No.1 from the gear shift fork No.1.
(c) Remove the shift fork No.1.

C80366
C80367
C80368
C80369
C80586
41±14
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
36. REMOVE GEAR SHIFT FORK SHAFT NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the gear shift fork shaft No.3.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(b) Remove the shift fork shaft No.3, reverse shift fork and
gear shift fork No.2 from the manual transaxle case.
(c) Using a magnetic finger, remove the 2 reverse shift fork
balls from the reverse shift fork.
(d) Using 2 screwdrivers and a hammer, tap out the snap ring
from the shift fork shaft No.3.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(e) Remove the reverse shift fork from the gear shift fork shaft
No.3.
37. REMOVE INPUT SHAFT ASSY
(a) Remove the input shaft assy and output shaft assy from
the front transaxle case.

C67656
C67657
D30546
D30547
C67644
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±15
C250 M/T REPAIR MANUAL (RM1020E)
38. REMOVE DIFFERENTIAL CASE ASSY
(a) Remove the differential case assy from the front transaxle
case.
39. REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Remove the bolt and manual transaxle case receiver from
the front transaxle case.
40. REMOVE REVERSE RESTRICT PIN ASSY
(a) Using a hexagon wrench, remove the reverse restrict pin
plug from the manual transmission case.
(b) Using a pin punch (
5 mm) and hammer, drive out the
slotted spring pin and reverse restrict pin assy from the
manual transmission case.
41. REMOVE OIL RECEIVER PIPE NO.1 (MTM)
(a) Remove the bolt and oil receiver pipe No.1 from the
manual transmission case.
NOTICE:
Be careful not to damage the oil receiver pipe No.1.

C80374
C67658
C67659
C81783
SST
C81783
SST
41±16
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
42. REMOVE OIL RECEIVER PIPE NO.2 (MTM)
(a) Remove the bolt and oil receiver pipe No.2 from the
manual transmission case.
NOTICE:
Be careful not to damage the oil receiver pipe No.2.
43. REMOVE BEARING LOCK PLATE
(a) Remove the bolt and bearing lock plate from the front
transaxle case.
44. REMOVE TRANSMISSION MAGNET
(a) Remove the transmission magnet from the front transaxle
case.
45. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST, remove the input shaft front bearing from the
front transaxle case.
SST 09612±65014 (09612±01050, 09612±01060)
46. REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST, remove the front transaxle case oil seal from
the front transaxle case.
SST 09612±65014 (09612±01040, 09612±01050)

C82141
SST
C67719
C81785
SST
C82145
SST
C81789
SST
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±17
C250 M/T REPAIR MANUAL (RM1020E)
47. REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST, remove the output shaft front bearing from the
front transaxle case.
SST 09308±00010
NOTICE:
Do not apply unreasonable force to the front transaxle case
when installing it.
48. REMOVE OUTPUT SHAFT (MTM) COVER
(a) Remove the output shaft cover from the front transaxle
case.
49. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front ta-
pered roller bearing (outer race) and shim from the front
transaxle case.
SST 09612±65014 (09612±01040, 09612±01050),
(b) Using SST, remove the front differential case front ta-
pered roller bearing (inner race) from the front differential
case.
SST 09950±00020, 09950±00030, 09950±40011
(09957±04010), 09950±60010 (09951±00360)
NOTICE:
Be careful not to damage bearing.
50. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST and hammer, remove the transaxle case oil
seal from the front transaxle case.
SST 09950±60010 (09951±00530), 09950±70010
(09951±07150)

C81788
SST
C82144
SST
C81787
SST
D30571
SST
C67848
41±18
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
51. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing (outer race) and shim from the transmission
case.
SST 09612±65014 (09612±01040, 09612±01050)
(b) Using SST and hammer, remove the front differential
case rear tapered roller bearing (inner race) from the front
differential case.
SST 09950±40011 (09951±04010, 09952±04010,
09953±04020, 09954±04010, 09955±04061,
09957±04010, 09958±04011), 09950±60010
(09951±00360)
NOTICE:
Be careful not to damage bearing.
52. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST and hammer, drive out the transmission case
oil seal from the manual transmission case.
SST 09950±60010 (09951±00600), 09950±70010
(09951±07100)
53. REMOVE SHIFT & SELECT LEVER SHAFT NEEDLE
ROLLER BEARING
(a) Using SST, remove the shift & select lever shaft needle
roller bearing.
SST 09319±60020
54. INSPECT SYNCHRONIZER RING NO.3
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone, check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.