1999 TOYOTA AVENSIS gear shift

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.

N00494
SST
Q00118
– MANUAL TRANSAXLE (E251)INPUT SHAFT
MX–29
4. MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX–24)
5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the rear ball bearing.
SST 09506–35010
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
12.35 (0.0925)52.55 (0.1004)
22.40 (0.0945)62.60 (0.1024)
32.45 (0.0965)72.65 (0.1043)
42.50 (0.0984)82.70 (0.1063)
(b) Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX–24)

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

MX02F–03
Q06204
Front
Q06205
SST Align the holes
Z00225
Q06206
SST
– MANUAL TRANSAXLE (E251)OUTPUT SHAFT
MX–35
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 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 the front of the
transmission.
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506–35010
HINT:
Align the hole of the output shaft and inner race.
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316–60011 (09316–00041)
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX–31)