2005 TOYOTA AVENSIS drive shaft

D30536
C80347
SST
D07737
D30537
D30538
SST
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±9
C250 M/T REPAIR MANUAL (RM1020E)
21. REMOVE TRANSMISSION CLUTCH HUB NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(b) Using SST, remove the transmission clutch hub No.3, 5th
gear and synchronizer ring from the input shaft.
SST 09950±40011 (09951±04020, 09952±04010,
09953±04030, 09954±04010, 09955±04071,
09957±04010), 09950±60010 (09951±00200)
(c) Remove the 3 synchromesh shifting keys and 2 synchro-
mesh shifting key springs from the transmission clutch
hub No.3.
22. REMOVE 5TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 5th gear needle roller bearing and 5th gear
bearing spacer from the input shaft.
23. REMOVE 5TH DRIVEN GEAR
(a) Using SST, remove the 5th driven gear from the output
shaft.
SST 09950±30012 (09951±03010, 09953±03010,
09954±03010, 09955±03011, 09957±04010),
09950±60010 (09951±00190)

D30539
C80351
C80352
D30540
C80353
41±10
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
24. REMOVE BEARING RETAINER REAR (MTM)
(a) Remove the 5 bolts and bearing retainer rear from the
manual transmission case.
25. REMOVE OUTPUT SHAFT REAR BEARING HOLE
SNAP RING
(a) Using a snap ring expander, remove the output shaft rear
bearing hole snap ring from the output shaft.
26. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP
RING
(a) Using a snap ring expander, remove the input shaft rear
bearing hole snap ring from the input shaft.
27. REMOVE REVERSE IDLER GEAR SHAFT BOLT
(a) Remove the reverse idler gear shaft bolt and reverse idler
gear shaft gasket from the manual transmission case.
28. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Using a shop rug to the shifting key spring from being scattered.

C80361
C80362
C80363
C80364
C80365
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±13
C250 M/T REPAIR MANUAL (RM1020E)
34. REMOVE GEAR SHIFT FORK SHAFT NO.2
(a) Remove the 2 bolts from the gear shift fork No.2 and gear
shift head No.1.
(b) Remove the gear shift fork shaft No.2 and gear shift head
No.1 from the front transaxle case.
35. REMOVE GEAR SHIFT FORK SHAFT NO.1
(a) Using 2 screwdrivers and a hammer, tap out the snap
rings.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(b) Remove the shift fork set bolt and gear shift fork shaft
No.1 from the gear shift fork No.1.
(c) Remove the shift fork No.1.

C80366
C80367
C80368
C80369
C80586
41±14
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
36. REMOVE GEAR SHIFT FORK SHAFT NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap ring
from the gear shift fork shaft No.3.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(b) Remove the shift fork shaft No.3, reverse shift fork and
gear shift fork No.2 from the manual transaxle case.
(c) Using a magnetic finger, remove the 2 reverse shift fork
balls from the reverse shift fork.
(d) Using 2 screwdrivers and a hammer, tap out the snap ring
from the shift fork shaft No.3.
HINT:
Using a shop rug to prevent the snap ring from being scattered.
(e) Remove the reverse shift fork from the gear shift fork shaft
No.3.
37. REMOVE INPUT SHAFT ASSY
(a) Remove the input shaft assy and output shaft assy from
the front transaxle case.

C81788
SST
C82144
SST
C81787
SST
D30571
SST
C67848
41±18
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
51. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing (outer race) and shim from the transmission
case.
SST 09612±65014 (09612±01040, 09612±01050)
(b) Using SST and hammer, remove the front differential
case rear tapered roller bearing (inner race) from the front
differential case.
SST 09950±40011 (09951±04010, 09952±04010,
09953±04020, 09954±04010, 09955±04061,
09957±04010, 09958±04011), 09950±60010
(09951±00360)
NOTICE:
Be careful not to damage bearing.
52. REMOVE TRANSMISSION CASE OIL SEAL
(a) Using SST and hammer, drive out the transmission case
oil seal from the manual transmission case.
SST 09950±60010 (09951±00600), 09950±70010
(09951±07100)
53. REMOVE SHIFT & SELECT LEVER SHAFT NEEDLE
ROLLER BEARING
(a) Using SST, remove the shift & select lever shaft needle
roller bearing.
SST 09319±60020
54. INSPECT SYNCHRONIZER RING NO.3
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone, check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.

C81790
SST
C81791
SST
D30572
SST
C82146
SST
C80379
SST
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±21
C250 M/T REPAIR MANUAL (RM1020E)
60. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, install a new front transaxle
case oil seal to the front transaxle case.
SST 09950±60010 (09951±00370), 09950±70010
(09951±07150)
Drive in depth: 15.6 ± 16.0 mm (0.6141 ± 0.6299 in.)
(b) Coat the lip of the front transaxle case oil seal with MP
grease.
61. INSTALL INPUT SHAFT FRONT BEARING
(a) Coat the new input shaft front bearing with MP grease, us-
ing SST and a press, install it to the front transaxle case.
SST 09950±60010 (09951±00420), 09950±70010
(09951±07150)
Drive in depth: 0 ± 0.3 mm (0 ± 0.0118 in.)
62. INSTALL SHIFT & SELECT LEVER SHAFT NEEDLE
ROLLER BEARING
(a) Using SST, install the shift & select lever shaft needle roll-
er bearing.
SST 09950±60010 (09951±00220), 09950±70010
(09951±07100)
Drive in depth: 0 ± 0.5 mm (0 ± 00020 in.)
63. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
front tapered roller bearing (inner race) to the front differ-
ential case.
SST 09350±32014 (09351±32120), 09950±60010
(09951±00530)
(b) Using SST and a press, install the front differential case
front tapered roller bearing (outer race) with shim to the
front transaxle case.
SST 09950±60020 (09951±00680), 09950±70010
(09951±07150)

D30539
D30568
SST
D30537
C80396
C80397
Key Position 41±30
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
88. INSTALL BEARING RETAINER REAR (MTM)
(a) Coat the 5 bolts with sealant, install them and bearing re-
tainer rear to the manual transmission case.
Torque: 27 N
m (280 kgf
cm, 20 ft
lbf)
89. INSTALL 5TH DRIVEN GEAR
(a) Using SST, install the 5th driven gear to the output shaft.
SST 09950±30012 (09951±03010, 09953±03010,
09954±03010, 09955±03011, 09956±03020)
90. INSTALL 5TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 5th gear needle roller bearing and spacer with
gear oil, install them to the input shaft.
91. INSTALL 5TH GEAR
(a) Coat the 5th gear with gear oil, install it to the input shaft.
92. INSTALL SYNCHRONIZER RING NO.3
(a) Coat the synchronizer ring No.3 with gear oil, install it to
the 5th gear.

410DK±01


D30564
Front Differential Pinion Front Differential Pinion Thrust Washer
N
m (kgf
cm, ft
lbf): Specified torque
77 (790, 57)
Front Differential Ring Gear Set Bolt Front Differential CaseFront Differential Side Gear
Front Differential Side Gear
Thrust Washer No.1
Front Differential Pinion
Front Differential Pinion Thrust Washer
Front Differential Pinion Shaft
Straight Pin Front Differential Side GearFront Differential Side Gear Thrust Washer No.1
Speedometer Drive (MTM)
Gear Front Differential Ring GearFront Differential Pinion Shaft No.1
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
41±65
C250 M/T REPAIR MANUAL (RM1020E)
DIFFERENTIAL CASE ASSY (C250)
COMPONENTS