TOYOTA AVENSIS 2005 Service Repair Manual

C69549
C70515
SST
C69550
C69551
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±51
E355,E356 M/T REPAIR MANUAL (RM867E)
4. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd 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 exceeds the maximum, replace the 3rd gear
needle roller bearing.
5. REMOVE 4TH GEAR
(a) Fix the input shaft assy and soft jaws to the valse.
(b) Using a 2 screwdrivers and a hammer, remove the input
shaft rear bearing shaft snap ring from the input shaft.
NOTICE:
Using a waste to prevent the snap ring from being scat-
tered.
(c) Using SST and a press, remove the input shaft rear bear-
ing and 4th gear.
SST 09950±00020
NOTICE:
Do not tighten SST excessively.
6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 4th gear needle roller bearing from the input
shaft.

C69552
C69553
C69615
SST
C69616
C69617
41±52
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
7. REMOVE 2ND SYNCHRONIZER OUTER RING
(a) Remove the 2nd synchronizer outer ring from the trans-
mission clutch hub No.2.
8. REMOVE 4TH GEAR BEARING SPACER
(a) Remove the 4th gear bearing spacer from the transmis-
sion clutch hub No.2.
9. REMOVE 3RD GEAR
(a) Using 2 screwdrivers and a hammer, remove the clutch
hub No.2 setting shaft snap ring from the input shaft.
NOTICE:
Using a waste to prevent the snap ring from being scat-
tered.
(b) Using SST and a press, remove the transmission clutch
hub No.2 and 3rd gear from the input shaft.
SST 09950±00020
NOTICE:
Do not tighten SST excessively.
10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
(a) Remove the 3rd gear needle roller bearing from the input
shaft.

C69618
C69619
SST
C69480
C69620
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±53
E355,E356 M/T REPAIR MANUAL (RM867E)
11. REMOVE SYNCHRONIZER RING NO.3
(a) Remove the synchronizer ring No.3 from the 3rd gear.
12. REMOVE TRANSMISSION HUB SLEEVE NO.2
(a) Remove the transmission hub sleeve No.2, 3 synchro-
mesh sifting keys and 3 synchromesh sifting key springs
from the transmission clutch hub No.2.
NOTICE:
Using a waste to prevent the sifting key and sifting key
spring from being scattered.
13. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the input shaft bearing
front (inner race) from the input shaft.
SST 09950±00020
NOTICE:
Do not tighten SST excessively.
14. INSPECT INPUT SHAFT
(a) Using V±block and dial indicator, measure the shaft run
out.
Maximum run out:0.03 mm (0.001191 in.)
If the run out exceeds the maximum, replace the input shaft.

ABC
C83823
C69622
C69622
C69623
41±54
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
(b) Using a micrometer, measure the outer diameter of the in-
put shaft jarnal surface.
Outer diameter: mm (in.)
Standard outer diameterMinimum outer diameter
A35.984 ± 36.000
(1.4286 ± 1.4292)35.984
(1.4286)
B35.984 ± 36.000
(1.4286 ± 1.4292)35.984
(1.4286)
C27.957 ± 27.972
(1.1100 ± 1.1105)27.957
(1.1100)
If the outer diameter is less than the minimum replace the input
shaft.
15. INSPECT 4TH GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 4th gear.
Inside diameter: mm (in.)
Standard inside diameterMaximum inside diameter
42.009 ± 42.025
(1.6678 ± 1.6684)42.025
(1.6684)
16. INSPECT 3RD GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 3rd gear.
Inside diameter: mm (in.)
Standard inside diameterMaximum inside diameter
43.009 ± 43.025
(1.7075 ± 1.7081)43.025
(1.7081)
17. INSPECT 2ND SYNCHRONIZER OUTER RING
(a) Coat the 4th gear cone with gear oil. Turn in the synchro-
nizer ring No.3 in one direction while pushing it to the 4th
gear cone. Check that the ring locks.

C69624
C69625
C69626
C67843
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±55
E355,E356 M/T REPAIR MANUAL (RM867E)
(b) Using a feeler gauge, measure the clearance between
the synchronizer outer ring back and 4th gear spline end.
Standard clearance:
0.75 ± 1.65mm (0.0297 ± 0.0655 in.)
If the standard clearance is out of specification, replace the syn-
chronizer ring.
18. INSPECT SYNCHRONIZER RING NO.3
(a) Coat the 3rd gear cone with gear oil. Turn in the synchro-
nizer outer ring in one direction while pushing it to the 3rd
gear cone. Check that the ring locks.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring No.3 back and 3rd gear spline end.
Standard clearance:
0.65 ± 1.75 mm (0.0258 ± 0.0695 in.)
If the standard clearance is out of specification, replace the syn-
chronizer ring No.3.
19. INSPECT TRANSMISSION HUB SLEEVE NO.2
(a) Inspect the sliding condition between transmission hub
sleeve No.2 and transmission clutch hub No.2.
(b) Inspect tip of spline gear on the transmission hub sleeve
No.2 for wear.

C70506
SST
C69767
C69660
C69617
41±56
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
(c) Using a vernier calipers, measure the transmission hub
sleeve No.3 groove and the thickness of the claw part on
gear shift fork No.1, and calculate the clearance.
Standard clearance:
0.15 ± 0.35 mm (0.0060 ± 0.0139 in.)
If the clearance is out of the specification, replace the transmis-
sion hub sleeve No.2 and gear shift fork No.2 with the new one.
20. INSTALL INPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the input shaft front bear-
ing(inner race).
SST 09608±00071
21. INSTALL TRANSMISSION HUB SLEEVE NO.2
(a) Coat the transmission hub sleeve No.2 with gear oil.
(b) Install the 3 synchromesh key springs with transmission
hub sleeve No.2.
NOTICE:
Do not the transmission clutch hub sleeve No.2 and the
transmission clutch hub No.2 incorrect orientation.
(c) Using a screwdriver, install the synchromesh shifting key
to the input shaft.
22. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear bearing with gear oil, install it to the in-
put shaft.

C69629
C69630
SST
C69631
C69632
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±57
E355,E356 M/T REPAIR MANUAL (RM867E)
23. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, install it to the input shaft.
24. INSTALL SYNCHRONIZER RING NO.3
(a) Coat the synchronizer ring No.3 with gear oil, install it to
the 3rd gear.
25. INSTALL TRANSMISSION CLUTCH HUB NO.2
(a) Using SST and a press, install the transmission clutch
hub No.2 to the input shaft.
SST 09316±60011 (09316±00041)
NOTICE:

Align the claw of clutch hub No.2 and notch of syn-
chronizer ring No.3 and install them.

Make sure that the 3rd gear should rotate.
(b) Select a snap ring so that clearance between the trans-
mission clutch hub No.2 and the clutch hub No.2 shaft
snap ring will be the standard clearance. Using a brass
bar and a hammer, install the snap ring.
Standard clearance:0.1 mm or less (0.0039 or less)
Snap ring thickness
Part No.Thickness: mm (in.)Mark
90520 ± 340032.30 ± 2.35
(0.0917 ± 0.0933)H
90520 ± 340042.35 ± 2.40
(0.0933 ± 0.0953)J
90520 ± 340052.40 ± 2.45
(0.0953 ± 0.0973)K
90520 ± 340062.45 ± 2.50
(0.0973 ± 0.0993)L
90520 ± 340072.50 ± 2.55
(0.0993 ± 0.1012)M
90520 ± 340082.55 ± 2.60
(0.1012 ± 0.1032)N
90520 ± 340092.60 ± 2.65
(0.1032 ±0.1052)P

C69553
C69552
C69551
C69633
SST
C69634
41±58
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
26. INSTALL 4TH GEAR BEARING SPACER
(a) Coat the 4th gear bearing spacer with gear oil,install it to
the input shaft.
27. INSTALL 2ND SYNCHRONIZER OUTER RING
(a) Coat the 2nd synchronizer outer ring with gear oil, install
it to the transmission the transmission clutch clutch hub
No.2.
NOTICE:
Align the claw of the clutch hub No.2 with the noch of the
2nd synchronizer outer ring and assemble.
28. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing with gear oil, install
it to the input shaft.
29. INSTALL 4TH GEAR
(a) Coat the 4th gear with gear oil, install it to the input shaft.
30. INSTALL INPUT SHAFT REAR RADIAL BALL
BEARING
(a) Using SST and a press, install the input shaft rear radial
ball bearing to the input shaft.
SST 09608±06041
NOTICE:

Make the groove on the bearing face to the rear and
install.

Make sure that the 3rd gear should rotate.

C69635
C69549
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±59
E355,E356 M/T REPAIR MANUAL (RM867E)
(b) Select a snap ring so that the clearance between the In-
put shaft radial ball rear bearing and the input shaft rear
bearing snap ring will be the standard clearance. Using
a brass bar and a hammer, install the snap ring.
Standard clearance:0.1 mm or less
Snap ring
Part No.thickness: mm (in.)Mark
90520±300082.35 ± 2.40
(0.0935 ± 0.0953)1
90520±300092.40 ± 2.45
(0.0953 ± 0.0973)2
90520±300102.45 ± 2.50
(0.0973 ± 0.0993)3
90520±300112.50 ± 2.55
(0.0993 ± 0.1012)4
90520±300122.55 ± 2.60
(0.1012 ± 0.1032)5
90520±300132.60 ± 2.65
(0.1032 ± 0.1052)6
90520±300212.65 ± 2.70
(0.1052 ± 0.1072)7
90520±300222.70 ± 2.75
(0.1072 ± 0.1092)8
31. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd 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 exceeds the maximum, replace the 3rd gear
needle roller bearing.

C69548
C69547
C69546
41±60
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
32. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th 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 exceeds the maximum, replace the 4th gear
needle roller bearing.
33. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 3rd gear thrust clear-
ance.
Standard clearance:
0.1 ± 0.35 mm (0.0039 ± 0.0139 in.)
34. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 4th gear thrust clear-
ance.
Standard clearance:
0.1 ± 0.57 mm (0.0039 ± 0.0226 in.)