2005 TOYOTA AVENSIS drive shaft

C80764
Bush
C80572
D30553
D30554
D30555
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (C250)
41±61
C250 M/T REPAIR MANUAL (RM1020E)
5. REMOVE SELECTING BELLCRANK NO.2 BUSH
(a) Remove the 2 selecting bellcrank No.2 bushes from the
selecting bellcrank.
6. REMOVE SELECT SPRING SEAT NO.2
(a) Using a screwdriver, remove the select spring seat No.2
E±ring, select spring seat No.2 and select return spring
No.2 from the shift & select lever shaft.
7. REMOVE SHIFT LEVER INNER NO.2
(a) Using a pin punch (5mm) and hammer, remove the shift
inner lever slotted pin and shift lever inner No.2 from the
shift & select lever shaft.
HINT:
Make sure of the orientation of the shift lever inner No.2.
8. REMOVE SHIFT LEVER INNER NO.1
(a) Using a pin punch (5mm) and hammer, remove the shift
inner lever slotted pin, shift lever inner No.1 and shift inter
lock plate from the shift & select lever shaft.
HINT:
Make sure of the orientation of the shift lever inner No.1.
9. REMOVE SELECT INNER LEVER
(a) Using a pin punch (5mm) and hammer, remove the se-
lect inner lever slotted pin, select inner lever select return
spring No.1 and select return spring No.1 seat from shift
& select lever shaft.
HINT:
Make sure of the orientation of the select inner lever.

D30556
C80778
C94255
SST
D30557
41±62
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
10. REMOVE SELECT SPRING NO.1 SEAT SHAFT SNAP
RING
(a) Using 2 screwdrivers and a hammer, remove the select
spring No.1 seat shaft snap ring.
NOTICE:
Do not damage the shaft.
11. REMOVE SHIFT & SELECT LEVER SHAFT DUST BOOT
(a) Remove the shift & select lever shaft dust boot from the shift & select lever shaft.
12. REMOVE CONTROL SHAFT COVER OIL SEAL
(a) Using a screwdriver remove the control shaft cover oil
seal from the control shaft cover.
13. INSTALL CONTROL SHAFT COVER OIL SEAL
(a) Using SST and a hammer, install the new control shaft
cover oil seal to the control shaft cover.
SST 09950±60010 (09951±00220), 09950±70010
(09951±07100)
Drive in depth:
0.2 ± 1.2 mm (0.079 ± 0.0472 in.)
(b) Coat the control shaft cover oil seal with MP grease.
14. INSTALL SHIFT & SELECT LEVER SHAFT DUST
BOOT
(a) Coat the shift & select lever shaft dust boot with MP
grease.
(b) Install the shift & select lever shaft dust boot to the shift
& select lever shaft.
HINT:
Install the boot with the projection up and the hole side down.

D30558
D30559
D30560
D30561
C80584
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (C250)
41±63
C250 M/T REPAIR MANUAL (RM1020E)
15. INSTALL SELECT SPRING NO.1 SEAT SHAFT SNAP
RING
(a) Coat the shift & select lever shaft with MP grease, install
it and snap ring with a brass bar and hammer.
16. INSTALL SELECT INNER LEVER
(a) Coat the select spring No.1 seat with MP grease.
(b) Using a pin punch (5mm) and hammer, install the select
spring No.1 seat, select return spring No.1, select inner
lever and shift & select lever slotted pin to the shift & select
lever.
Drive in depth: 3.0 ± 4.0 mm (0.1181 ± 0.1575 in)
17. INSTALL SHIFT LEVER INNER NO.1
(a) Coat the shift inter lock plate and shift lever inner No.1
with MP grease.
(b) Using a pin punch (5mm) and hammer, install the shift
inter lock plate, shift lever inner No.1 and shift lever
slotted pin to the shift & select lever shaft.
Drive in depth: ±0.5 ± 0.5 mm (±0.0197 ± 0.0197 in)
18. INSTALL SHIFT LEVER INNER NO.2
(a) Coat the shift lever inner No.2 with Mp grease.
(b) Using a pin punch (5mm) and hammer, install the shift
lever inner No.2 E±ring and shift inner lever slotted pin to
the shift & select lever shaft.
Drive in depth: ±0.5 ± 0.5 mm (±0.0197 ± 0.0197 in)
19. INSTALL SELECT SPRING SEAT NO.2
(a) Coat the select spring seat No.2 with MP grease.
(b) Install the select spring seat No.2, select return spring
No.2. Using a plier, install a new select spring seat No.2
E±ring to the shift & select lever shaft.

4002K±01
C67867
C67868
C67869
C67870
40±58
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
INTERMEDIATE SHAFT ASSY (U34#E Series)
OVERHAUL
1. REMOVE FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 2 discs and 2 plates.
2. INSPECT FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed mark is defaced, replace
all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
3. REMOVE DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Using a screwdriver, remove the snap ring.
(b) Remove the 3 plates, flange and 3 discs.
4. INSPECT DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.

C68212
D25110
C68213
C67875
C67876
40±60
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
8. INSPECT DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
9. REMOVE DIRECT CLUTCH DRUM SUB±ASSY
[ 35605A / 3507 ]
(a) Put a match±mark on the direct clutch drum at the same
position with the cutout of the intermediate shaft assy.
(b) Apply compressed air into the oil hole shown in the il-
lustration and remove the direct clutch drum from the in-
termediate shaft.
10. INSPECT INTERMEDIATE SHAFT SUB±ASSY
[ 35708G / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
11. REMOVE DIRECT CLUTCH PISTON O±RING
[ 35606C / 3507 ]
(a) Using a screwdriver, remove the 2 O±rings.
12. REMOVE DIRECT CLUTCH DRUM O±RING
[ 35605D / 3507 ]
(a) Using a screwdriver, remove the O±ring.

4006Z±01
D08032
D08033
D08034
40±14
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
AUTOMATIC TRANSAXLE ASSY (U241E)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB±ASSY
(a) Remove the bolt and speedometer driven hole cover sub±assy from the transaxle assy.
(b) Remove the O±ring from the speedometer driven hole cover.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Remove the nut, washer and control shaft lever.
(b) Using a screwdriver, unstake the nut stopper and remove
the lock nut and stopper.
(c) Remove the 2 bolts and pull out the park/neutral position
switch.
3. REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the breather No. 2 plug.

D03564
D03565
D03905
D03566
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±21
U241E A/T REPAIR MANUAL (RM840U)
(b) Using a pin punch and hammer, drive out the manual
valve lever shaft spring pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.
(c) Remove the manual valve lever shaft and manual valve
lever.
27. REMOVE PARKING LOCK ROD SUB±ASSY
(a) Remove the parking lock rod from the manual valve lever.
28. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the trans-
axle case.
29. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle case with the oil pump side facing up.

D08046
C83145
D09182
D03606
SST
D03915
40±22
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
30. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
END Play: 0.26 ± 1.25 mm (0.0103 ± 0.0492 in.)
31. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 2 transaxle case No 1 plugs.
(b) Remove the 2 O±rings from the transaxle case plug.
32. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing with a
plastic hammer to remove the transaxle housing from the
transaxle case.
NOTICE:
Differential may be accidentally removed when the trans-
axle housing is removed.
33. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the cylindrical roller bearing from the
transaxle case.
SST 09514±35011
34. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.