TOYOTA AVENSIS 2005 Service Repair Manual

C68518
C83566
C83565
C83567
41±80
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
8. INSPECT FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Using a micrometer, measure the outer diameter of the
front differential pinion shaft No.1.
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the rotating surface of the front differential side gear
with gear oil.
(b) Install the 2 front differential side gear thrust washers to
the 2 front differential side gears.
HINT:
(c) Install the 2 front differential side gears, 2 front differential
pinions and front differential thrust washers to the front
differential case.
HINT:
Revolving the front differential pinion, install the 2 front differen-
tial pinions with front differential washers.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Coat the rotating surface of the front differential pinion
shaft No.1 with gear oil.
(b) Install the front differential pinion shaft No.1 to the front
differential case so that the hole for the front differential
pinion shaft straight pin is aliened with the hole in the front
differential case.
11. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and a hammer, install the front differen-
tial pinion shaft straight pin to the front differential case.

C83562
90
11 0
C58905
C70796
Machmarks
C70795
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (E355/E356)
41±81
E355,E356 M/T REPAIR MANUAL (RM867E)
12. ADJUST FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Fixing the front differential pinion to the front differential
case side. Using a dial indicator, measure the front differ-
ential side gear backlash.
Standard backlash: 0.05 ± 0.2 mm (0.0020 ± 0.0079 in.)
(b) If the backlash is out of the specification, select the front
differential side gear thrust washer and ajust it.
Thrust washer: mm (in.)
Part No.ThicknessMark
41361 ± 282301.00
(0.0397)1
41361 ± 282401.10
(0.0437)2
41361 ± 282501.20
(0.0476)3
41361 ± 282601.30
(0.0516)4
13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using a heater, heart the front differential ring gear to 90
± 100
C (194.0 ± 230.0
F).
(b) Clean the contact surface differential case.
(c) Aligning the both matchmarks, quickly install the front dif-
ferential ring gear to the front differential case.
Torque: 106 N
m (1080 kgf
cm, 77 ft
lbf)
14. INSTALL SPEEDOMETER DRIVE (MTM) GEAR
(a) Install the speedometer drive (MTM) gear to the front dif-
ferential case.

41041±01
C69529
C69530
C69532
C69799
41±72
±
MANUAL TRANSMISSION/TRANSAXLE SHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
SHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
OVERHAUL
HINT:
COMPONENTS: See page 41±1 1. REMOVE CONTROL SHIFT LEVER BUSH
(a) Remove the control shift lever bush from the selectingbellcrank No.2.
2. REMOVE SELECTING BELLCRANK DUST COVER NO.1
(a) Remove the selecting bellcrank dust cover No.1 from the selecting bellcrank No.2.
3. REMOVE SELECTING BELLCRANK SUPPORT SUB±ASSY
(a) Remove the nut, washer and selecting bell crank No.2 plate washer from the selecting bellcrank No.2.
(b) Remove the selecting bellcrank support sub±assy from the selecting bell crank No.2.

C69531
C69798
C69534
C69535
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
41±73
E355,E356 M/T REPAIR MANUAL (RM867E)
4. REMOVE SELECTING BELLCRANK DUST COVER
NO.2
(a) Remove the selecting bell crank dust cover No.2 from the
selecting bellcrank no.2.
5. REMOVE SELECTING BELLCRANK NO.2 BUSH
(a) Remove the selecting bellcrank bush from the selecting
bellcrank No.2.
6. REMOVE SHIFT LEVER INNER NO.2
(a) Fix the shift & select lever on the the vise through the soft
jaw.
NOTICE:
Do not damage the shift & select lever shaft.
(b) Using a pin punch(
5 mm), remove the shift & select lever
inner slotted pin and oil baffle.
NOTICE:
Do not damage the shift & select lever shaft.
(c) Apply the force to the select return spring No.1 and select
return spring No.2 and fix it on the vise through the soft
jaw.
(d) Using 2 screwdrivers and a hammer, remove the select
seat snap ring from the shift & select lever shaft.
NOTICE:
Do not damage the shift & select lever shaft.

C68317
C69538
C91167
Shift inter
lock plate
cover
C91169
Shift lever
inner No.1
C69539
41±74
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
7. REMOVE SELECT SPRING SEAT NO.1
(a) Using a pin punch(
5 mm), remove the shift inner lever
slotted pin from the shift & select lever shaft.
(b) Remove the shift lever assy select return spring No.1 and
select spring seat from the shift & select lever shaft.
8. REMOVE SHIFT INTER LOCK PLATE COVER
(a) Remove the shift inter lock plate cover from the shift inter
lock plate.
9. REMOVE SHIFT LEVER INNER NO.1
(a) Remove the shift lever inner No.1 from the shift inter lock
plate.
10. REMOVE SELECT SPRING NO.1 SEAT SHAFT SNAP
RING
(a) Using 2 screwdrivers and a hammer, remove the select
spring No.1 seat shaft snap ring.
NOTICE:
Do not damage the shaft.

C69540
C91169
Shift lever inner No.1
C91167
Shift inter lock plate cover
C69538
C69541
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
41±75
E355,E356 M/T REPAIR MANUAL (RM867E)
11. INSTALL SELECT SPRING NO.1 SEAT SHAFT SNAP
RING
(a) Using a brass bar and a hammer, install the select spring
No.1 seat shaft snap ring.
12. INSTALL SHIFT LEVER INNER NO.1
(a) Install the shift lever inner No.1 to the shift inter lock plate.
13. INSTALL SHIFT INTER LOCK PLATE COVER
(a) Install the shift inter lock plate cover to the shift inter lock
plate.
14. INSTALL SELECT SPRING SEAT NO.1
(a) Install the select spring seat No.1, select return spring
No.1 and shift lever inner assy to the shift & select lever
shaft.
(b) Fix the shift & select lever on the vise through the soft jaw.
(c) Using a pin punch(
5 mm), install the shift lever slotted
pin to the shift & select lever shaft.
Clearance:±0.5 ± 0.5 mm (± 0.0199 ± 0.0199 in.)

C69536
C69536
C69542
C69798
C69531
41±76
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
15. INSTALL SHIFT LEVER INNER NO.2
(a) shift lever inner No.2, select return spring No.2 and select
return spring seat No.2 to the shift & select lever shaft.
(b) Using a brass bar and a hammer, install the select seat
snap ring to the shift & select lever shaft.
(c) Install the transmission oil baffle. Using a pin punch(
5
mm) and a hammer, install the shift inner lever slotted pin
to the shift & select lever shaft.
Clearance:5.8 ± 6.8mm (0.2303 ± 0.2700 in.)
16. INSTALL SELECTING BELLCRANK NO.2 BUSH
(a) Coat the 2 selecting bellcrank No.2 bushes with MP
grease, install it to the selecting bellcrank No.2.
17. INSTALL SELECTING BELLCRANK DUST COVER
NO.2
(a) Coat the selecting bellcrank dust cover No.2 with MP
grease, install it to the selecting bellcrank No.2.

C69799
C69532
C69530
C69529
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
41±77
E355,E356 M/T REPAIR MANUAL (RM867E)
18. INSTALL SELECTING BELLCRANK SUPPORT
SUB±ASSY
(a) Install the selecting bellcrank support sub±assy to the se-
lecting bellcrank No.2.
(b) Install the selecting bellcrank No.2 plate washer, washer
and nut.
Torque:12N
m (120 kgf
cm, 9 ft
lbf)
19. INSTALL SELECTING BELLCRANK DUST COVER
NO.1
(a) Install the selecting bellcrank dust cover No.1 to the se-
lecting bellcrank No.2.
20. INSTALL CONTROL SHIFT LEVER BUSH
(a) Install the control shift lever bush to the selecting bell
crank No.2.

4103Y±01
C69636
C69637
C69638
±
MANUAL TRANSMISSION/TRANSAXLE OUTPUT SHAFT ASSY (E355/E356)
41±61
E355,E356 M/T REPAIR MANUAL (RM867E)
OUTPUT SHAFT ASSY (E355/E356)
OVERHAUL
HINT:
COMPONENTS:See page 41±1
1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a fleer gauge, measure the 1st gear thrust clear-ance.
Standard clearance:
0.25 ± 0.4 mm (0.0099 ± 0.0159 in.)
2. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clear- ance.
Standard clearance:
0.1 ± 0.35 mm (0.0004 ± 0.0139 in.)
3. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clear- ance.
Standard clearance:mm (in.)
BearingStandard clearance
KOYO made0.009 ± 0.053
(0.0004 ± 0.0021)
NSK made0.009 ± 0.051
(0.0004 ± 0.0020)
If the clearance is out of the specification, replace the 1st gear
needle roller bearing.

C69639
SST
C69640
C69641
SST
C69642
41±62
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
4. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clear-
ance.
Standard clearance:mm (in.)
BearingStandard clearance
KOYO made0.009 ± 0.053
(0.0004 ± 0.0021)
NSK made0.009 ± 0.051
(0.0004 ± 0.0020)
If the clearance is out of the specification, replace the 2nd gear
needle roller bearing.
5. REMOVE 4TH DRIVEN GEAR
(a) Using SST and a press, remove the output shaft bearing
rear (inner race) and 4th driven gear.
SST 09950±00020
6. REMOVE OUTPUT GEAR SPACER
(a) Remove the out put gear spacer from the output shaft.
7. REMOVE 2ND GEAR
(a) Using SST and a press, remove the 3rd driven gear and
2nd gear from the out put shaft.
SST 09950±00020