2005 TOYOTA AVENSIS clutch

410DG±01
D30520
Apply MP grease
1st Gear Thrust Washer Pin Or Ball
Output Shaft
1st Gear Needle Roller Bearing
1st Gear Thrust Washer
1st Gear
Reverse Gear
Synchronizer Ring No.1 (For 1st)
Synchromesh Shifting Key No.1
Synchromesh Shifting Key Spring No.1
Synchronizer Ring No.1 (For 2nd)
Clutch Hub No.1
Shaft Snap Ring
Transmission Clutch Hub No.1
2nd Gear Bearing Spacer
2nd Gear Needle Roller Bearing
2nd Gear
3rd Driven Gear
Output Gear Spacer
4th Driver Gear
Output Shaft Rear Bearing
x3
x3
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±47
C250 M/T REPAIR MANUAL (RM1020E)
OUTPUT SHAFT ASSY (C250)
COMPONENTS

C80559
Q04983
SST
C80560
C80561
C67821
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±39
C250 M/T REPAIR MANUAL (RM1020E)
5. REMOVE 4TH GEAR
(a) Using 2 screwdrivers and a hammer, remove the input
shaft rear bearing shaft snap ring from input shaft.
(b) Using SST and a press, remove the input shaft radial ball
bearing rear and 4th gear from input shaft.
NOTICE:
Do not tighten SST excessively.
SST 09950±00020
6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 4th gear needle roller bearing and 4th gear
bearing spacer from input shaft.
7. REMOVE SYNCHRONIZER RING NO.2 (FOR FOURTH
SYNCHRONIZER RING)
(a) Remove synchronizer ring No.2 from transmission clutch
hub No.2.
8. REMOVE 3RD GEAR
(a) Using 2 screwdrivers and a hammer, remove the clutch
hub No.2 setting shaft snap ring from the input shaft.
NOTICE:
Using a shop rug to prevent the snap ring from being scat-
tered.

CM0064
SST
C68515
C67823
C67832
CM0013
41±40
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
(b) Using SST and a press, remove the transmission clutch
hub No.2 and 3rd gear from the input shaft.
NOTICE:
Do not tighten SST excessively.
SST 09950±00020
9. REMOVE SYNCHRONIZER RING NO.2 (FOR THIRD
SYNCHRONIZER RING)
(a) Remove the synchronizer ring No.2 from the 3rd gear.
10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
(a) Remove the 3rd gear needle roller bearing from the input
shaft.
11. REMOVE TRANSMISSION HUB SLEEVE NO.2
(a) Remove the transmission hub sleeve No.2, 3 synchro-
mesh shifting keys No.2 and 3 synchromesh shifting key
springs No.2 from the transmission clutch hub No.2.
NOTICE:
Using a waste to prevent the shifting key and shifting key
spring from being scattered.
12. INSPECT INPUT SHAFT
(a) Using a dial indicator, check the shaft runout.
Maximum runout: 0.015 mm (0.00059 in.)
If the runout exceeds the maximum, replace the input shaft.

C67831
C67843
C67842
C67833
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±43
C250 M/T REPAIR MANUAL (RM1020E)
(c) Using a feeler gauge, measure the clearance between
the synchronizer ring No.2 back and 3rd gear spline end.
Standard clearance:
0.75 ± 1.65 mm (0.0295 ± 0.0649 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring No.2 and apply a small amount of the fine lapping
compound on the 3rd gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
17. INSPECT TRANSMISSION HUB SLEEVE NO.2
(a) Check the sliding condition between the transmission hub
sleeve No.2 and transmission clutch hub No.2.
(b) Check that the spline gear's edges of the transmission
hub sleeve No.2 is not worn down.
(c) Using a vernier calipers, inspect the transmission hub
sleeve No.2 and gear shift fork No.2 as shown in the il-
lustration.
Standard clearance:
0.15 ± 0.35 mm (0.0059 ± 0.0137 in.)
If the clearance exceeds the standard clearance, replace the
transmission hub sleeve No.2 and gear shift fork No.2.
18. INSTALL TRANSMISSION HUB SLEEVE NO.2
(a) Coat the transmission hub sleeve No.2 with gear oil,
install it to the transmission clutch hub No.2.
NOTICE:
Do not set the transmission hub sleeve No.2 and the trans-
mission clutch hub in incorrect orientation.
(b) Install the 2 synchromesh key springs with 3 synchro-
mesh shifting keys No.2 to the transmission clutch hub
No.2.

C67823
C67834
C82010
Key Position
For 3rd gear
C80563
SST
C67837
41±44
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
19. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear needle roller bearing with gear oil,
install it to the input shaft.
20. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, install it to the input shaft.
21. INSTALL SYNCHRONIZER RING NO.2 (FOR THIRD
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.2 with gear oil, install it to
the 3rd gear.
HINT:
The synchronizer ring No.2 (for 3rd) is a gray color.
22. INSTALL TRANSMISSION CLUTCH HUB NO.2
(a) Using SST and a press, install the transmission clutch
hub No.2 to the input shaft.
SST 09316±60011 (09316±00021)
NOTICE:
Paying attention to the proper position, fit the synchro-
mesh shifting key into the groove of the synchronizer ring.
(b) Select a snap ring that will allow the minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less.
MarkThickness mm (in)MarkThickness mm (in)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)

D30573
Key Position
For 4th gear
C80560
C80564
C80565
SST
C80566
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±45
C250 M/T REPAIR MANUAL (RM1020E)
23. INSTALL SYNCHRONIZER RING NO.2 (FOR FOURTH
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.2 with gear oil, install it to
the transmission clutch hub No.2.
HINT:
The synchronizer ring No.2 (for 4th) is a yellow copper color.
24. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing and 4th gear bear-
ing spacer with gear oil, install it to the transmission clutch
hub No.2.
25. INSTALL 4TH GEAR
(a) Coat the 4th gear with gear oil, install it to the input shaft.
26. INSTALL INPUT SHAFT REAR RADIAL BALL
BEARING
(a) Using SST and a press, install the input shaft rear radial
ball bearing to the input shaft.
(b) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less
MarkThickness mm (in)MarkThickness mm (in)
A2.29 (0.0901)D2.47 (0.0972)
B2.35 (0.0925)E2.53 (0.0996)
C2.41 (0.0948)F2.59 (0.1019)
If the clearance is less than the limit, replace the input shaft rear
radial ball bearing.

410DE±01
D30519
Input Shaft
Syncronizer Ring No.2 (For 3rd)
Syncromesh Shifting Key No.2
Syncromesh Shifting Key Spring No.2
Syncronizer Ring No.2 (For 4th)
3rd Gear Needle Roller Bearing
3rd Gear
Transmission Hub Sleeve No.2
Clutch Hub No.2 Setting Shaft Snap Ring
4th Gear Bearing Spacer
4th Gear Needle Roller Bearing
4th Gear
Input Shaft Rear Redial Ball Bearing
Input Shaft Rear Bearing
Shaft Snap Ring
Transmission Clutch Hub No.2
x3
x3
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±37
C250 M/T REPAIR MANUAL (RM1020E)
INPUT SHAFT ASSY (C250)
COMPONENTS

410DD±01
D30524
C80550
C67601
C67602
41±4
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the manual transmission filler plug and gasket
from the manual transmission case.
2. REMOVE DRAIN (MTM) PLUG SUB±ASSY
(a) Remove the drain plug and gasket from the manual trans-
mission case.
3. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB±ASSY
(a) Remove the bolt and speedometer driven hole cover sub±assy.
(b) Remove the O±ring from the speedometer driven hole cover sub±assy.
4. REMOVE CLUTCH RELEASE FORK SUB±ASSY
(a) Remove the clutch release fork sub±assy with clutch re-
lease bearing assy from the front transaxle case.
5. REMOVE CLUTCH RELEASE BEARING ASSY
(a) Remove the clutch release bearing clip and clutch release
bearing assy from the clutch release fork sub±assy.