Page 1185 of 2234
4100Z±05
D25304
0 to 5 mm
(0 to 0.20 in.)
41±2
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE OIL (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE OIL (MTM)
ON±VEHICLE INSPECTION
1. INSPECT TRANSAXLE OIL
(a) Stop the vehicle on the level place.
(b) Remove the transmission filler plug and gasket.
(c) Check that the oil surface is within 5 mm (0.20 in.) from the lowest position of the inner surface of the transmission fill-
er plug opening.
NOTICE:
Excessively large or small amount of oil may cause
troubles.
After replacing oil, drive the vehicle and check the oil
level.
(d) Check for oil leakage when the oil level is low.
(e) Install the transmission filler plug and new gasket. Torque:
C50, C250: 39 N m (400 kgfcm, 29 ftlbf)
E354, E357: 49 N m (500 kgf cm, 36 ftlbf)
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Page 1186 of 2234

4100Y±05
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM (MTM)
41±1
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
Use the table below to help find the cause of the problem. The numbers indi\
cate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
: (C50 MANUAL TRANSAXLE Repair Manual Pub. No. 826E or C250 MANUAL TRANS\
AXLE Repair
Manual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E\
)
SymptomSuspect AreaSee page
Noise
6. Oil (Level low)
7. Oil (Wrong) C50/C250
E354/E357
8. Gear (Worn or damaged)
9. Bearing (Worn or damaged)41±2
41±3
41±5
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged) C50/ C250 E354/E357
4. O±Ring (Worn or damaged)41±2
41±3
41±5
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)41±7
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
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Page 1187 of 2234
4105R±02
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
D30070
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±7
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION CONTROL CABLE ASSY (MTM)
REPLACEMENT
HINT:
COMPONENTS: See page 41±10
1.REMOVE AIR CONDITIONER UNIT ASSY (See page 55±55)
HINT:
Refer to the instructions for removal of the instrument panel sub±ass\
y lower.
2. REMOVE EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Remove the 3 nuts and heat insulator No.1.
4. REMOVE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the 2 cables from the trans-axle.
(b) Remove the 2 clips, separate the 2 cables from the brack- et.
(c) Remove the 2 nuts, separate the control cable assy.
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Page 1188 of 2234
D30071
D26893
D26895
D30071
D26972
41±8
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Remove the 2 bolts, separate the control cable assy.
(e) Remove the 2 clips, separate the cable ends of the control cable assy.
(f) Release the claws, remove the control cable assy.
5. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Put the control cable assy through the floor hole.
(b) Install the control cable assy with the 2 bolts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
(c) Connect the control cable assy to the shift lever assy.
NOTICE:
Make sure that the claws are firmly engaged.
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Page 1189 of 2234

D26894
Serrate Part
D30070
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±9
AVENSIS REPAIR MANUAL (RM1018E)
(d) Connect the end of the select cable to the shift lever assy
and install the clip.
NOTICE:
The serrate part of the select cable point should face
upward when the select cable point is connected.
The clip should be inserted to the direction as shown
in the illustration.
(e) Connect the end of the shift cable to the shift lever assy.
(f) Connect the control cable assy with the 2 nuts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
(g) Connect the 2 cable ends, install the 2 clips.
(h) Install the 2 clips to the control cable bracket.
6. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Install the heat insulator No.1 with the 3 nuts. Torque: 5.5 N m (56 kgf cm, 49 in. lbf)
7. INSTALL EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
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Page 1190 of 2234
4202Z±03
D30812
Clutch Accumulator Assy
Clutch Line
Wire Harness Clamp
Nm (kgf cm, ftlbf) : Specified torque Clutch Release Cylinder
Clutch Line
12 (120, 9)15 (155, 11)
15 (155, 11)
12 (120, 9)
Clutch Line
15 (155, 11)
±
CLUTCH CLUTCH ACCUMULATOR ASSY (1CD±FTV)
42±21
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH ACCUMULATOR ASSY (1CD±FTV)
COMPONENTS
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Page 1191 of 2234

4206G±01
D30813
(a)
(a) (b)(b)
(a)
(b)
D30813
(a)
(a) (b)(b)
(a)
(b)
D26852
SST(s)
42±22
±
CLUTCH CLUTCH ACCUMULATOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE BATTERY
2.REMOVE AIR TUBE NO.1 (See page 14±286) 3. REMOVE CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), disconnect the flexible hose tube.SST 09023±00100
HINT:
Use a container to catch the fluid.
(b) Remove a bolt, 2 nuts and clutch accumulator assy.
4. INSTALL CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), connect the 2 flexible hose tubes to the clutch accumulator assy.
SST 09023±00100
(b) Install the clutch accumulator assy with the 2 nuts and a
bolt.
Torque: 12 N m (120 kgf cm, 9 ftlbf)
(c) Using SST(s), tighten the flexible hose tube. SST 09023±00100
Torque: 15 N m (155 kgf cm, 11 ftlbf)
5.INSTALL AIR TUBE NO.1 (See page 14±286)
6. INSTALL BATTERY
7. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the brake fluid and bleed clutch syst\
em. Torque: 8.3 N m (85 kgf cm, 73 in. lbf)
8. CHECK CLUTCH FLUID LEAKAGE
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Page 1192 of 2234
4202V±03
D30477
LHD Steering Position Type:
RHD Steering PositionType:Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Gasket
Clip
Clutch Master Cylinder Assy Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Clutch Master Cylinder Assy Clip
Gasket
Nm (kgf cm, ftlbf) : Specified torque
Non±reusable part
12 (120, 9)
12 (120, 9)
15 (155, 11)
15 (155, 11)
MP grease
42±12
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH MASTER CYLINDER ASSY (MTM)
COMPONENTS
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