1999 TOYOTA AVENSIS transmission

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.

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)

MX02G–03
Z17558
GasketO–Ring
Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Gear Oil Pump Drive Rotor
Oil Pump Cover Spring Holder Spring Ball Relief Valve Transmission Oil Pump
Case
N·m (kgf·cm, ft·lbf): Specified torque

Non–reusable part
10 (105, 8)
10 (105, 8)



MX–38
– MANUAL TRANSAXLE (E251)OIL PUMP
OIL PUMP
COMPONENTS

MX02I–03
Q06217
Shift Interlock Plate
Transmission Oil Baffle Shift Interlock Plate
No.1 Compression SpringControl Shaft Cover
Oil Seal
Snap Ring
No.1 Select Spring Seat
Slotted Spring Pin
No.1 Shift Inner Lever
Shift and Select Lever Shaft Snap Ring
Non–reusable partNo.2 Select Spring SeatNo.2 Compression SpringNo.2 Shift Inner LeverSlotted Spring Pin
Apply MP grease

Dust Boot

MX–40
– MANUAL TRANSAXLE (E251)SHIFT AND SELECT LEVER SHAFT
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

Z00284
Z00286
Z00288
SST
Z00289
– MANUAL TRANSAXLE (E251)DIFFERENTIAL CASE
MX–43
(d) Remove the 2 differential side gears, side gear thrust
washers, 4 differential pinions and pinion thrust washers
from the differential left case.
5. Transmission Case Side:
IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the shim.
(e) Install the shim.
(See page MX–41)
HINT:
First select and install a shim of lesser thickness than before.
(f) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316–60011 (09316–00011, 09316–00041)
(g) Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.

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

MX09C–01
D06624
Air Cleaner Case
Assembly
with Air Hose
Air Flow Meter
Connector
D06625
Shift Lever Assembly
12 (120, 9)
Transmission Control Cable Bracket
Clip
WasherShift Cable Grommet
Retainer Shift Cable Grommet Select Control Cable
Shift Control CableConsole Box Assembly
Shift Lever Knob
Clip
Clip
Washer
WasherClip Front Ash Receptacle
Parking Brake Cover
Cap Cap
Air Duct
4.9 (50, 43 in.·lbf)Clip
4.9 (50, 43 in.·lbf)
N·m (kgf·cm, ft·lbf): Specified torque MX–48
– MANUAL TRANSAXLE (E251)SHIFT LEVER AND CONTROL CABLE
SHIFT LEVER AND CONTROL CABLE
COMPONENTS