TOYOTA AVENSIS 2005 Service Repair Manual

C67850
C67978
C80375
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±19
C250 M/T REPAIR MANUAL (RM1020E)
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the breaking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.75 ± 1.65 mm (0.0295 ± 0.0649 in.)
Minimum clearance: 0.75 mm (0.0295 in.)
If the clearance is less than minimum, replace the synchronizer
ring and gear cone by applying a small amount of the fine lap-
ping compound.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
55. INSPECT TRANSMISSION HUB SLEEVE NO.3
(a) Check the sliding condition between the transmission hub
sleeve No.3 and transmission clutch hub No.3.
(b) Check that spline gear's of the transmission hub sleeve
No.3 is not worn down.
(c) Using a vernier calipers, inspect the transmission hub
sleeve No.3 and gear shift fork No.3 as shown in the il-
lustration.
Standard clearance:
0.3 ± 0.5 mm (0.0012 ± 0.0020 in.)
If the clearance exceeds the standard clearance, replace the
transmission hub sleeve No.3 and gear shift fork No.3.

C67975
C67846
C67719
C80376
SST 41±20
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
56. INSPECT 5TH GEAR
(a) Using a caliper gauge, inspect 5th gear as shown in the
illustration.
Standard clearance:
29.915 ± 29.931 mm (1.1778 ± 1.1783 in.)
If the clearance exceeds the maximum, replace the 5th gear.
57. INSPECT REVERSE IDLER GEAR SUB±ASSY
(a) Using a caliper gauge, inspect the reverse idler gear sub±
assy as shown in the illustration.
Standard clearance:
18.040 ± 18.058 mm (0.7102 ± 0.7109 in.)
Maximum clearance:
18.058 mm (0.7109 in.)
If the clearance exceeds the maximum, replace idler gear.
(b) Using a micrometer, inspect the reverse idler gear shaft
as shown in the illustration.
Standard outer diameter:
17.966 ± 17.984 mm (0.7073 ± 0.7080 in.)
Minimum outer diameter:
17.966 mm (0.7073 in.)
If the outer diameter exceeds the minimum, replace the reverse
idler gear shaft.
58. INSTALL OUTPUT SHAFT (MTM) COVER
(a) Coat the output shaft cover with MP grease and install it
to the front transaxle case.
59. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Coat the new output shaft front bearing with gear oil, us-
ing SST and a press, install it.
SST 09950±60010 (09951±00550), 09950±70010
(09951±07150)
NOTICE:
Be careful not to damage the output shaft front bearing.

C81790
SST
C81791
SST
D30572
SST
C82146
SST
C80379
SST
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±21
C250 M/T REPAIR MANUAL (RM1020E)
60. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new front transaxle
case oil seal to the front transaxle case.
SST 09950±60010 (09951±00370), 09950±70010
(09951±07150)
Drive in depth: 15.6 ± 16.0 mm (0.6141 ± 0.6299 in.)
(b) Coat the lip of the front transaxle case oil seal with MP
grease.
61. INSTALL INPUT SHAFT FRONT BEARING
(a) Coat the new input shaft front bearing with MP grease, us-
ing SST and a press, install it to the front transaxle case.
SST 09950±60010 (09951±00420), 09950±70010
(09951±07150)
Drive in depth: 0 ± 0.3 mm (0 ± 0.0118 in.)
62. INSTALL SHIFT & SELECT LEVER SHAFT NEEDLE
ROLLER BEARING
(a) Using SST, install the shift & select lever shaft needle roll-
er bearing.
SST 09950±60010 (09951±00220), 09950±70010
(09951±07100)
Drive in depth: 0 ± 0.5 mm (0 ± 00020 in.)
63. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
front tapered roller bearing (inner race) to the front differ-
ential case.
SST 09350±32014 (09351±32120), 09950±60010
(09951±00530)
(b) Using SST and a press, install the front differential case
front tapered roller bearing (outer race) with shim to the
front transaxle case.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07150)

C82147
SST
D30548
SST
C67656
C81793
SST
C81793
SST 41±22
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
64. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install front differential case rear
tapered roller bearing (inner race) to the front differential
case.
SST 09350±32014 (09351±32120), 09950±60010
(09951±00530)
(b) Using SST and a press, front differential case rear ta-
pered roller bearing (outer race) with shim to the transmis-
sion case.
SST 09309±36010, 09950±60020 (09951±00710),
09950±70010 (09951±07150)
HINT:
Use a front differential case washer rear of the same thickness
as the removed one.
65. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Coat the differential case assy with gear oil, install it to the
front transaxle case.
(b) Install the manual transmission case with 16 bolts.
Torque: 29 N
m (300 kgf
cm, 22 ft
lbf)
(c) Using SST and a torque wrench, turn the differential case
assy right and left 2 or 3 times to allow the bearings to
settle.
SST 09564±32011
(d) Using SST and a torque wrench, measure the preload.
SST 09564±32011
Preload (at starting):
New bearing:
0.78 ± 1.57 N
m (7.95 ± 16.0 kgf
cm, 6.9 ± 13.89 in.
lbf)
(e) Select another shim.
MarkThickness mm (in.)MarkThickness mm (in.)
AA2.10 (0.0827)LL2.60 (0.1024)
BB2.15 (0.0846)MM2.65 (0.1043)
CC2.20 (0.0866)NN2.70 (0.1063)

C80381
SST
C80382
SST
C67659
C67658
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±23
C250 M/T REPAIR MANUAL (RM1020E)Mark Thickness mm (in.)Mark Thickness mm (in.)
DD2.25 (0.0886)PP2.75 (0.1083)
EE2.30 (0.0906)QQ2.80 (0.1102)
FF2.35 (0.0925)RR2.85 (0.1122)
GG2.40 (0.0945)SS2.90 (0.1142)
HH2.45 (0.0965)TT2.95 (0.1161)
JJ2.50 (0.0984)UU3.00 (0.1181)
KK2.55 (0.1004)±±
(f) Remove the 16 bolts and manual transmission case.
(g) Remove the differential case assy.
66. INSTALL TRANSMISSION CASE OIL SEAL
(a) Using SST and a hammer, install the transmission case
oil seal to the manual transmission case.
SST 09316±60011 (09316±00011)
Drive in depth:
9.6 ± 10.2 mm (0.3779 ± 0.4015 in.)
(b) Coat the lip of the front transmission case oil seal with MP
grease.
67. INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install the transaxle case oil
seal to the front transaxle case.
Drive in depth: 1.6 ± 2.2 mm (0.0629 ± 0.0866 in.)
SST 09710±20011 (09710±06071), 09950±70010
(09951±07150)
(b) Coat the lip of the front transaxle case oil seal with MP
grease.
68. INSTALL TRANSMISSION MAGNET
(a) Clean the transmission magnet to the front transaxle
case.
69. INSTALL BEARING LOCK PLATE
(a) Install the bearing lock plate with bolt.
Torque: 11 N
m (115 kgf
cm, 8.3 ft
lbf)

C68380
C80432
C80383
C80384
D30549
41±24
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
70. INSTALL OIL RECEIVER PIPE NO.1 (MTM)
(a) Install the oil receiver pipe No.1 with bolt to the manual
transmission case.
Torque: 17 N
m (175 kgf
cm, 13 ft
lbf)
71. INSTALL OIL RECEIVER PIPE NO.2 (MTM)
(a) Install the oil receiver pipe No.2 with bolt to the manual
transmission case.
Torque: 17 N
m (175 kgf
cm, 13 ft
lbf)
72. INSTALL REVERSE RESTRICT PIN ASSY
(a) Install the reverse restrict pin assy to the manual trans-
mission case.
HINT:
Do not set the reverse restrict pin assy in incorrect orientation.
(b) Using a pin punch (
5 mm) and hammer, install the
slotted pin to the restrict pin assy.
Drive in depth: 15.5 ± 16.5 mm (0.6102 ± 0.6496 in.)
(c) Apply sealant to the reverse restrict pin plug.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Using a hexagon wrench and torque wrench install the re-
verse restrict pin plug to the manual transmission case.
Torque: 13 N
m (130 kgf
cm, 9.3 ft
lbf)

C67657
C67656
C80586
C80386
Align alignment mark
C80387
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±25
C250 M/T REPAIR MANUAL (RM1020E)
73. INSTALL MANUAL TRANSAXLE CASE RECEIVER
(a) Install the manual transaxle case receiver with bolt to the
front transaxle case.
Torque: 11 N
m (115 kgf
cm, 8.3 ft
lbf)
74. INSTALL DIFFERENTIAL CASE ASSY
(a) Coat the differential case tapered roller bearing with gear
oil, install them to the front transaxle case.
75. INSTALL INPUT SHAFT ASSY
(a) Coat sliding and rotating surface of the input and output
shafts with gear oil, install them to the transaxle case.
76. INSTALL REVERSE IDLER GEAR SUB±ASSY
(a) Coat the reverse idler gear, shim and reverse idler gear
shaft with gear oil, install them.
HINT:
Align the mark on the reverse idler gear shaft with the bolt hole
shown in the illustration.
77. INSTALL GEAR SHIFT FORK SHAFT NO.1
(a) Coat the gear shift fork No.1 and gear shift fork No.2 with
gear oil, install them.

C80388
C80389
C80450
C80391
C80392
41±26
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
(b) Coat the gear shift fork shaft No.1 with gear oil, install it.
(c) Apply sealant to the shift fork lock bolt.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Install the gear shift fork lock bolt.
Torque: 16 N
m (160 kgf
cm, 12 ft
lbf)
(e) Using a brass bar and hammer, install the shaft snap ring
to the gear shift fork shaft No.1.
78. INSTALL GEAR SHIFT FORK SHAFT NO.3
(a) Coat the 2 shift fork balls with MP grease, install them to
the reverse shift fork.
(b) Install reverse shift fork to the shift fork shaft No.3.
(c) Using a brass bar and hammer, install 2 shift fork shaft
snap rings to the shift fork shaft No.3.
(d) Coat the shift fork shaft No.3 with gear oil, install it.

C80362
C80361
C80360
C82142
FIPG
C80358
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±27
C250 M/T REPAIR MANUAL (RM1020E)
79. INSTALL GEAR SHIFT FORK SHAFT NO.2
(a) Coat the gear shift head No.1 and gear shift fork shaft
No.2 with gear oil, install them.
(b) Coat the 2 shift lock bolts with sealant, install them to the
gear shift fork No.2 and shift head No.1.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 16 N
m (160 kgf
cm, 12 ft
lbf)
80. INSTALL REVERSE SHIFT ARM BRACKET ASSY
(a) Install the reverse shift arm bracket assy with 2 bolts to the
front transaxle case.
Torque: 17 N
m (175 kgf
cm, 13 ft
lbf)
81. INSTALL MANUAL TRANSMISSION CASE
(a) Apply FIPG to the manual transmission case, as shown
to the illustration.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or equiva-
lent
NOTICE:
Parts must be assembled within 10 minutes of application.
Otherwise, the packing (FIPG) material must be remove
and reapplied.
(b) Coat the 13 bolts with sealant, install to the manual trans-
mission case.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N
m (300 kgf
cm, 22 ft
lbf)

D30544
D30540
D30543
C68417
C67634
41±28
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
(c) Coat the 3 bolts with sealant, install to the front transaxle
case.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N
m (300 kgf
cm, 22 ft
lbf)
82. INSTALL REVERSE IDLER GEAR SHAFT BOLT
(a) Coat the reverse idler gear shaft bolt with sealant, install
it with new gasket.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N
m (300 kgf
cm, 22 ft
lbf)
83. INSTALL LOCK BALL ASSY NO.2
(a) Coat the lock ball assy No.2 with sealant, install it with a
hexagon wrench.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)
84. INSTALL SHIFT DETENT BALL
(a) Install the 2 shift detent balls, 2 shift detent ball springs
with 2 shift detent ball spring seat No.1 to the manual
transmission case.
(b) Coat the 2 shift detent ball plugs with sealant, install them
with a hexagon wrench.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)