1999 TOYOTA AVENSIS clutch

MX098–01
D06620
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Lever Housing
Support Bracket
Boot
Clutch Release
Line Bracket
Transaxle Case
Transmission
Oil Cooler
Sub–AssemblyElbow

O–Ring Vehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
PipeMagnet
Transmission
Oil Pipe

Output Shaft Cover
Tapered Roller Bearing
Outer Race

Front Oil Seal
Input Shaft Front
BearingTransmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
17 (175, 13)
47 (480, 35)
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
Gasket



17 (175, 13)
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–9
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

D06653
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
 Precoated partOutput Shaft AssemblyInput Shaft Assembly

Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring
Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x 7Shim
 Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring 
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–11

Q05849
SST
Z01304
Z01306
Q00299
Z01308
SST
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–13
11. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950–30011
12. MEASURE 5TH GEAR THRUST CLEARANCE AND
RADIAL CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 – 0.57 mm (0.0039 – 0.0224 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
(b) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009 – 0.050 mm (0.0004 – 0.0020 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
13. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of the reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
a1.75 (0.0689)f2.00 (0.0787)
b1.80 (0.0709)g2.05 (0.0807)
c1.85 (0.0729)h2.10 (0.0827)
d1.90 (0.0748)j2.15 (0.0847)
e1.95 (0.0768)––
(b) Using SST, remove the No.3 clutch hub with the synchro-
nizer ring and 5th gear.
SST 09950–30011
14. REMOVE NEEDLE ROLLER BEARING AND SPACER
15. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and
rear bearing retainer.
Sealant:
Part No. 08833–00080, THREE BOND 1344, LOCTITE
242 or equivalent

MT0781
– MANUAL TRANSAXLE (E251)MANUAL TRANSAXLE ASSEMBLY
MX–17
(a) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
(b) Remove the 2 bolts and the oil pump assembly.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
36. REMOVE NO.5 SYNCHRONIZER RING WITH KEY
SPRING FROM NO.3 CLUTCH HUB
(a) Remove the No.5 synchronizer ring with the key spring
from the No.3 clutch hub.
(b) Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.

MX028–03
MT0791
Rear Bearing4th GearSpacer
Synchronizer Ring
Snap Ring
Needle Roller Bearing3rd GearNeedle Roller Bearing

Input Shaft Front Bearing Inner Race
Input Shaft Synchronizer Ring
No.2 Hub Sleeve
No.2 Clutch Hub
Shifting KeySpring
Snap Ring

Non–reusable part
– MANUAL TRANSAXLE (E251)INPUT SHAFT
MX–23
INPUT SHAFT
COMPONENTS

Q00115
– MANUAL TRANSAXLE (E251)INPUT SHAFT
MX–25
7. REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRO-
NIZER RING AND 3RD GEAR
Using a press, remove the No.2 hub sleeve, 3rd gear and syn-
chronizer rings.
8. REMOVE NEEDLE ROLLER BEARING

MX02B–03
Q00383
Front
MT0790
Q00183SST
Q00116
MX–28
– MANUAL TRANSAXLE (E251)INPUT SHAFT
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506–35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)––
(b) Using a screwdriver and hammer, tap in the snap ring.

MX02C–03
Q06216
4th Driven Gear3rd Driven GearNeedle Roller Bearing
1st Gear Bearing Inner Race Spacer
Inner Race
2nd Gear
Spacer
Output Shaft Rear Bearing
SpringNo.1 Hub Sleeve
Needle Roller Bearing
1st Gear
Synchronizer Ring
Ball
Output Shaft Front
Bearing
Output Shaft Shifting Key
No.1 Clutch Hub
Synchronizer Ring

Non–reusable part
MX–30
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
OUTPUT SHAFT
COMPONENTS