2005 TOYOTA AVENSIS clutch

C70507
C69671
C69672
SST
C69674
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±67
E355,E356 M/T REPAIR MANUAL (RM867E)
23. INSPECT REVERSE GEAR
(a) Using a vernier calipers, measure the reverse gear
groove and thickness of the claw part on gear shift fork
No.1, and calculate
Standard clearance:
0.15 ± 0.35 mm (0.0060 ± 0.0139 in.)
If the clearance is bout of the specification, replace the reverse
gear and gear shift fork No.1 with the new one.
24. INSPECT TRANSMISSION CLUTCH HUB NO.1
(a) Check the sliding condition between the transmission
clutch hub No.1 and reverse gear.
(b) Check the tip of spline gear on the sleeve of reverse gear
for wear.
25. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil.
(b) Install the 3 synchromesh shifting key spring No.1 and
transmission clutch hub No.1 to the reverse gear.
NOTICE:
Do not set the reverse gear and the transmission clutch
hub No.1 in incorrect direction.
(c) Using a screwdriver, install the synchromesh sifting key
No.1 to the reverse gear.
26. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the output shaft front bear-
ing (inner race) to the output shaft.
SST 09950±60010 (09951±00430), 09950±70010
(09951±07150)

C69649
C69650
C69673
SST
SST
C69675
C83814
41±68
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
27. INSTALL SYNCHRONIZER RING SET NO.1
(a) Coat the synchronizer ring set No.1 with gear oil, install
it to the 1st gear.
NOTICE:
Align the synchronizer ring set No.1 with the hole of 1st
gear and install.
28. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil,install
it to the output shaft.
29. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil, install it to the output shaft.
30. INSTALL TRANSMISSION CLUTCH HUB NO.1
(a) Using SST and a press, install transmission clutch hub
No.1 to the output shaft.
SST 09316±60011 (09316±00031), 09950±60010
(09951±00320), 09950±70010 (09951±07100)
NOTICE:

Align the synchronizer ring No.1 with synchromesh
shifting key No.1 and install.

Make sure that the 1st gear rotates.
31. INSTALL 2ND GEAR BUSH BALL
(a) Coat the gear bush with MP grease, install it to the output
shaft.

C69646
C69645
C69644
C69643
C69679
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±69
E355,E356 M/T REPAIR MANUAL (RM867E)
32. INSTALL 2ND GEAR BUSH
(a) Coat the gear 2nd gear bush with gear oil, install it to the
output shaft.
33. INSTALL 2ND GEAR BEARING SPACER
(a) Coat the gear 2nd gear bearing spacer with gear oil,
install it to the output shaft.
34. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing with gear oil,
install it to the output shaft.
35. INSTALL SYNCHRONIZER RING SET NO.2
(a) Coat the synchronizer ring set No.2 with gear oil, install
it to the transmission clutch hub No.1
NOTICE:
Align the key groove on the synchronizer ring set No.2 with
the synchromesh shifting key No.1.
36. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil, install it to the output
shaft.

C69552
C69553
C69615
SST
C69616
C69617
41±52
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
7. REMOVE 2ND SYNCHRONIZER OUTER RING
(a) Remove the 2nd synchronizer outer ring from the trans-
mission clutch hub No.2.
8. REMOVE 4TH GEAR BEARING SPACER
(a) Remove the 4th gear bearing spacer from the transmis-
sion clutch hub No.2.
9. 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 waste to prevent the snap ring from being scat-
tered.
(b) Using SST and a press, remove the transmission clutch
hub No.2 and 3rd gear from the input shaft.
SST 09950±00020
NOTICE:
Do not tighten SST excessively.
10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
(a) Remove the 3rd gear needle roller bearing from the input
shaft.

C69618
C69619
SST
C69480
C69620
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±53
E355,E356 M/T REPAIR MANUAL (RM867E)
11. REMOVE SYNCHRONIZER RING NO.3
(a) Remove the synchronizer ring No.3 from the 3rd gear.
12. REMOVE TRANSMISSION HUB SLEEVE NO.2
(a) Remove the transmission hub sleeve No.2, 3 synchro-
mesh sifting keys and 3 synchromesh sifting key springs
from the transmission clutch hub No.2.
NOTICE:
Using a waste to prevent the sifting key and sifting key
spring from being scattered.
13. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the input shaft bearing
front (inner race) from the input shaft.
SST 09950±00020
NOTICE:
Do not tighten SST excessively.
14. INSPECT INPUT SHAFT
(a) Using V±block and dial indicator, measure the shaft run
out.
Maximum run out:0.03 mm (0.001191 in.)
If the run out exceeds the maximum, replace the input shaft.

C69624
C69625
C69626
C67843
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±55
E355,E356 M/T REPAIR MANUAL (RM867E)
(b) Using a feeler gauge, measure the clearance between
the synchronizer outer ring back and 4th gear spline end.
Standard clearance:
0.75 ± 1.65mm (0.0297 ± 0.0655 in.)
If the standard clearance is out of specification, replace the syn-
chronizer ring.
18. INSPECT SYNCHRONIZER RING NO.3
(a) Coat the 3rd gear cone with gear oil. Turn in the synchro-
nizer outer ring in one direction while pushing it to the 3rd
gear cone. Check that the ring locks.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring No.3 back and 3rd gear spline end.
Standard clearance:
0.65 ± 1.75 mm (0.0258 ± 0.0695 in.)
If the standard clearance is out of specification, replace the syn-
chronizer ring No.3.
19. INSPECT TRANSMISSION HUB SLEEVE NO.2
(a) Inspect the sliding condition between transmission hub
sleeve No.2 and transmission clutch hub No.2.
(b) Inspect tip of spline gear on the transmission hub sleeve
No.2 for wear.

C70506
SST
C69767
C69660
C69617
41±56
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
(c) Using a vernier calipers, measure the transmission hub
sleeve No.3 groove and the thickness of the claw part on
gear shift fork No.1, and calculate the clearance.
Standard clearance:
0.15 ± 0.35 mm (0.0060 ± 0.0139 in.)
If the clearance is out of the specification, replace the transmis-
sion hub sleeve No.2 and gear shift fork No.2 with the new one.
20. INSTALL INPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the input shaft front bear-
ing(inner race).
SST 09608±00071
21. INSTALL TRANSMISSION HUB SLEEVE NO.2
(a) Coat the transmission hub sleeve No.2 with gear oil.
(b) Install the 3 synchromesh key springs with transmission
hub sleeve No.2.
NOTICE:
Do not the transmission clutch hub sleeve No.2 and the
transmission clutch hub No.2 incorrect orientation.
(c) Using a screwdriver, install the synchromesh shifting key
to the input shaft.
22. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear bearing with gear oil, install it to the in-
put shaft.

C69629
C69630
SST
C69631
C69632
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
41±57
E355,E356 M/T REPAIR MANUAL (RM867E)
23. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, install it to the input shaft.
24. INSTALL SYNCHRONIZER RING NO.3
(a) Coat the synchronizer ring No.3 with gear oil, install it to
the 3rd gear.
25. 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±00041)
NOTICE:

Align the claw of clutch hub No.2 and notch of syn-
chronizer ring No.3 and install them.

Make sure that the 3rd gear should rotate.
(b) Select a snap ring so that clearance between the trans-
mission clutch hub No.2 and the clutch hub No.2 shaft
snap ring will be the standard clearance. Using a brass
bar and a hammer, install the snap ring.
Standard clearance:0.1 mm or less (0.0039 or less)
Snap ring thickness
Part No.Thickness: mm (in.)Mark
90520 ± 340032.30 ± 2.35
(0.0917 ± 0.0933)H
90520 ± 340042.35 ± 2.40
(0.0933 ± 0.0953)J
90520 ± 340052.40 ± 2.45
(0.0953 ± 0.0973)K
90520 ± 340062.45 ± 2.50
(0.0973 ± 0.0993)L
90520 ± 340072.50 ± 2.55
(0.0993 ± 0.1012)M
90520 ± 340082.55 ± 2.60
(0.1012 ± 0.1032)N
90520 ± 340092.60 ± 2.65
(0.1032 ±0.1052)P