1999 TOYOTA AVENSIS differential

Z00295
MX09B–01
Z00296
Z00297
D06655
Matchmarks
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–45
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washer to the side gear.
(b) Install the 4 pinions and thrust washers to the spider.
(c) Install the side gear and spider with the 4 pinions to the
differential left case.
(d) Using a dial indicator, measure the backlash of the pinion
gear while holding the differential left case.
Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079
in.)
HINT:
Push the pinion gear and spider with the 4 pinions to the differ-
ential left case.
(e) Install the side gear and spider with the 4 pinions to the
right side of the differential case. Check the side gear
backlash.
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)–
(g) Align the matchmarks on the differential cases.
(h) Using a plastic hammer, carefully tap the differential case
to install it.
(i) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.

Z00303
Driven Gear
Side
Q06410
SST
SST MX–46
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
(b) Heat the ring gear to about 100
C (212
F  



(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the differential left case and contact
the ring gear.
(f) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(g) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
3. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
4. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316–20011, 09316–60011 (09316–00011)
HINT:
Press the bearing on the ring side first.
5. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See page MX–21)
6. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
7. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
8. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm 22 ft·lbf)
9. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
10. INSTALL SHIM (See page MX–21)
HINT:
Install the previously selected shim.
11. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

Q00036
Z00309
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–47
12. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 – 0.3 N·m (1.8 – 3.5 kgf·cm, 1.6 – 3.0 in.·lbf)
Reused bearing (Output shaft preload plus)
0.1 – 0.2 N·m (1.1 – 2.2 kgf·cm, 1.0 – 1.9 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
HINT:
The total preload will change by about 0.1 – 0.2 N·m (1 – 2
kgf·cm, 0.9 – 1.7 in.·lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
13. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
14. REMOVE SHIM
15. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
16. REMOVE OUTPUT SHAFT ASSEMBLY
17. REMOVE DIFFERENTIAL CASE ASSEMBLY

SA02Z–03
SA–10
– SUSPENSION AND AXLEFRONT DRIVE SHAFT
INSTALLATION
1. LH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Install a new snap ring to the inboard joint shaft.
(b) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(c) Set the snap ring with opening side facing downward.
(d) Using a brass bar and hammer, install the drive shaft.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
HINT:
Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feel-
ing when driving it in.
(e) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction.
(f) Check that the drive shaft cannot be removed by hand.
2. RH drive shaft:
INSTALL DRIVE SHAFT TO TRANSAXLE
(a) Coat the gear oil to the inboard joint shaft and differential case sliding surface.
(b) Install the drive shaft with the center bearing bracket.
NOTICE:
Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle.
(c) Install the 2 bolts.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
3. CONNECT DRIVE SHAFT TO AXLE HUB
NOTICE:
Be careful not to damage the boot and ABS speed sensor rotor.
4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
5. CONNECT TIE ROD END TO STEERING KNUCKLE
(a) Connect the tie rod end to the steering knuckle.
(b) Install the nut and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
6. INSTALL DRIVE SHAFT LOCK NUT
(a) While applying brakes, install the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
(b) Install the lock cap and a new cotter pin.
If the holes for the cotter pin are not aligned, tighten the nut further up to 60.
7. w/ABS:
INSTALL ABS SPEED SENSOR AND BOLT
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
8. FILL AND CHECK GEAR OIL (See page MX–4)
9. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
10. CHECK FRONT WHEEL ALIGNMENT (See Pub. No. RM599E on page SA–4)
11. CHECK ABS SPEED SENSOR SIGNAL (See Pub. No. RM599E on page DI–115)

ID–2ALPHABETICAL INDEX (A – S)
A
Page
ABBREVIATIONS USED IN THIS MANUAL
(TERMS) IN–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING (PREPARATION) PP–22. . . . . . . . . . . . .
AIR CONDITIONING
(SERVICE SPECIFICATIONS) SS–19. . . . . . . . . . . . . . . . . .
B
BODY (PREPARATION) PP–20. . . . . . . . . . . . . . . . . . . . . . . . . .
BODY (SERVICE SPECIFICATIONS) SS–18. . . . . . . . . . . . . . .
BODY ELECTRICAL (PREPARATION) PP–19. . . . . . . . . . . . . .
BODY ELECTRICAL
(SERVICE SPECIFICATIONS) SS–16. . . . . . . . . . . . . . . . . .
BRAKE (PREPARATION) PP–11. . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE (SERVICE SPECIFICATIONS) SS–11. . . . . . . . . . . . . .
BRAKE PEDAL BR–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C
CIRCUIT INSPECTION
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP BO–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMBINATION METER BE–2. . . . . . . . . . . . . . . . . . . . . . . . . .
COMBUSTION TYPE POWER HEATER AC–9. . . . . . . . . . . .
COMPRESSOR AND MAGNETIC CLUTCH
(1CD–FTV) AC–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER FAN (1CD–FTV) AC–30. . . . . . . . . . . . . . . . . . . .
CURTAIN SHIELD AIRBAG ASSEMBLY RS–20. . . . . . . . . . . .
D
DIAGNOSTIC TROUBLE CODE CHART
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CASE (E251) MX–41. . . . . . . . . . . . . . . . . . . . .
DRIVE BELT SR–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT (1CD–FTV) AC–1. . . . . . . . . . . . . . . . . . . . . . . . .
E
ELECTRICAL TYPE POWER HEATER AC–23. . . . . . . . . . . . .
F
FOG LIGHT SYSTEM BE–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOR ALL OF VEHICLES IN–9. . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT SA–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
G
GENERAL INFORMATION
(HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS) IN–18. . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
(HOW TO USE THIS MANUAL) IN–1. . . . . . . . . . . . . . . . .
GENERAL INFORMATION
(REPAIR INSTRUCTIONS) IN–4. . . . . . . . . . . . . . . . . . . . .
H
HOW TO PROCEED WITH TROUBLESHOOTING
(HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS) IN–19. . . . . . . . . . . . . . . . . . . . . Page
HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS IN–18. . . . . . . . . . . . . . . . . . . . . .
HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE
(HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS) IN–29. . . . . . . . . . . . . . . . . . . . .
HOW TO USE THIS MANUAL IN–1. . . . . . . . . . . . . . . . . . . . .
I
IDENTIFICATION INFORMATION IN–3. . . . . . . . . . . . . . . . . .
INPUT SHAFT (E251) MX–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL BO–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
M
MANIFOLD GAUGE SET (1CD–FTV) AC–4. . . . . . . . . . . . . . .
MANUAL TRANSAXLE (E251)
(PREPARATION) PP–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE (E251)
(SERVICE SPECIFICATIONS) SS–4. . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE ASSEMBLY (E251) MX–9. . . . . . . . . .
MANUAL TRANSAXLE UNIT (E251) MX–2. . . . . . . . . . . . . . . .
O
OIL PUMP (E251) MX–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT (E251) MX–30. . . . . . . . . . . . . . . . . . . . . . . . . .
P
PARTS LOCATION
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING FLUID SR–3. . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING VANE PUMP
(2C–T, 2C–TE, 1CD–FTV) SR–6. . . . . . . . . . . . . . . . . . . . . .
PRE–CHECK
(SUPPLEMENTAL RESTRAINT SYSTEM)
(DIAGNOSTICS) DI–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION (FOR ALL OF VEHICLES) IN–9. . . . . . . . . . .
R
REFRIGERANT LINE AC–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY (1CD–FTV) AC–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS IN–4. . . . . . . . . . . . . . . . . . . . . . . . .
ROOF HEADLINING (Liftback) BO–27. . . . . . . . . . . . . . . . . . . . .
ROOF HEADLINING (Sedan) BO–22. . . . . . . . . . . . . . . . . . . . . .
ROOF HEADLINING (Wagon) BO–32. . . . . . . . . . . . . . . . . . . . .
S
SHIFT AND SELECT LEVER SHAFT (E251) MX–40. . . . . . . . .
SHIFT LEVER AND CONTROL CABLE (E251) MX–48. . . . . . .
SIDE AIRBAG ASSEMBLY RS–9. . . . . . . . . . . . . . . . . . . . . . . .
SIDE AND CURTAIN SHIELD AIRBAG SENSOR
ASSEMBLY RS–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SLIDING ROOF BO–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRS AIRBAG RS–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD BOLT (SERVICE SPECIFICATIONS) SS–1. . . .
STEERING (PREPARATION) PP–12. . . . . . . . . . . . . . . . . . . . . .
STEERING (SERVICE SPECIFICATIONS) SS–13. . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM
(DIAGNOSTICS) DI–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM
(PREPARATION) PP–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .