Page 2769 of 5135

4200B±04
±
CLUTCH CLUTCH SYSTEM (MTM)
42±1
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH SYSTEM (MTM)
PROBLEM SYMPTOMS TABLE
HINT:
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.
SymptomSuspect AreaSee page
Clutch grabs/chatters
1. Engine mounting (Loosen)
2. Clutch disc assy (Runout is excessive)
3. Clutch disc assy (Oily)
4. Clutch disc assy (Worn out)
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc assy (Glazed)
7. Diaphragm spring (Out of tip alignment)±
42±26
42±26
42±26
42±26
42±26
42±26
Clutch pedal spongy
1. Clutch Line (Air in line)
2. Master cylinder (Damaged)
3. Release cylinder rubber (Damaged)±
42±13
42±17
Clutch noisy1. Clutch release bearing assy (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)42±26
42±26
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc assy (Oily)
3. Clutch disc assy (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel sub±assy (Distortion)42±2
42±26
42±26
42±26
42±26 ±
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc assy (Out of true)
6. Clutch disc assy (Runout of excessive)
7. Clutch disc assy (Lining broken)
8. Clutch disc assy (Dirty or burned)
9. Clutch disc assy (Oily)
10.Clutch disc assy (Lack of spline grease)42±2
±
42±13
42±17
42±26
42±26
42±26
42±26
42±26
42±26
Page 2770 of 5135

410DY±01
D26902
D26903
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±33
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2.REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
3.SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
4.REMOVE STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
5.REMOVE STEERING INTERMEDIATE SHAFT (See page 50±9)
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER RH
8. REMOVE ENGINE UNDER COVER LH
9. DRAIN TRANSAXLE OIL
Torque: 49 N m (500 kgf cm, 36 ft lbf)
10. REMOVE HOOD SUB±ASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUB±ASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18.REMOVE AIR TUBE NO.1 (See page 14±286)
19. SEPARATE RADIATOR RESERVE TANK ASSY
(a) Remove the 2 bolts, separate the radiator reserve tankassy.
20. REMOVE STARTER ASSY
(a) Remove the nut, disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.
Page 2771 of 5135

D30815
D26905
G24412
G24413
41±34
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
21. DISCONNECT WIRE HARNESS
(a) Remove the bolt, disconnect the ground cable.
(b) Remove the bolt, separate the air tube.
22. DISCONNECT CONNECTOR
(a) Disconnect the back±up lamp switch connector.
23.REMOVE CLUTCH ACCUMULATOR ASSY (See page 42±22) SST 09023±00100
24.REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 42±17) SST 09023±00100
25. SEPARATE ACCUMULATOR TO FLEXIBLE HOSETUBE
(a) Remove the 3 bolts, separate the flexible hose tube with brackets from the transaxle.
26. SEPARATE 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.
27.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
28.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
29. REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)\
(See page 65±28)
Page 2772 of 5135

A79193Engine Hanger No.1
Engine Hanger No.2
Engine Hanger No.1 UPR
D30072
D30073
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±35
AVENSIS REPAIR MANUAL (RM1018E)
30.DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51±36)
SST 09023±12700
31.DISCONNECT PRESSURE FEED TUBE ASSY (See page 51±36)
SST 09023±12700
32. SUSPEND ENGINE ASSY
(a) Install the 2 engine hangers with the 2 bolts.Parts No.:
No.1 engine hanger UPR (yellow) 12284±27020
No.1 engine hanger UPR (black) 12284±27030
No.1 engine hanger 12281±27050
No.2 engine hanger (yellow) 12282±27060
No.2 engine hanger (black) 12282±27070
Bolt: 91642±81025
Torque: 37 N m (377 kgf cm, 27 ft lbf)
(b) Attach the engine chain hoist to the hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
33.REMOVE FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26)
34. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the transaxle with a transmission jack.
35. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator LH from the body.
36. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from
the transaxle.
Page 2773 of 5135

D26918
D30076
D30074
D30075
D30075
(b)
(a)
(a)
(a) 41±36
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE MANUAL TRANSAXLE ASSY
(a) Remove the 8 bolts.
(b) Remove the transaxle from the engine.
38. REMOVE MANUAL TRANSMISSION CASE
PROTECTOR
(a) Remove the 2 bolts and case protector.
39. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FR
from the engine mounting bracket.
(b) Remove the 2 bolts and engine mounting bracket FR from
the transaxle.
40. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR from
the engine mounting bracket.
(b) Remove the 3 bolts and engine mounting bracket RR
from the transaxle.
41. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket RR and 3 bolts to the
transaxle.
Torque: 64 Nm (653 kgfcm, 47 ftlbf)
(b) Install the engine mounting insulator RR and bolt to the
engine mounting bracket.
Torque: 87 Nm (887 kgfcm, 64 ftlbf)
Page 2774 of 5135

D30074
(a)
(b)
(a)
(b)
D30076
D26918
A
B
CD
E
D30073
D30072
A
A
A
A
B
A
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (1CD±FTV)
41±37
AVENSIS REPAIR MANUAL (RM1018E)
42. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
transaxle.
Torque: 64 Nm (653 kgfcm, 47 ftlbf)
(b) Install the engine mounting insulator FR, bolt and nut to
the engine mounting bracket.
Torque: 52 Nm (530 kgfcm, 38 ftlbf)
43. INSTALL MANUAL TRANSMISSION CASE
PROTECTOR
(a) Install the case protector with the 2 bolts.
Torque: 18 Nm (184 kgfcm, 13 ftlbf)
44. INSTALL MANUAL TRANSAXLE ASSY
(a) Align the input shaft with the clutch disc and install the
transaxle to the engine.
(b) Install the 8 bolts.
Torque:
Bolt A: 64 Nm (653 kgfcm, 47 ftlbf)
Bolt B: 46 Nm (469 kgfcm, 34 ftlbf)
Bolt C: 40 Nm (408 kgfcm, 30 ftlbf)
Bolt D: 20 Nm (200 kgfcm, 14 ftlbf)
Bolt E: 8.0 Nm (82 kgfcm, 71 in.lbf)
45. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket LH to the transaxle
with the 3 bolts.
Torque: 64 Nm (653 kgfcm, 47 ftlbf)
46. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
INSULATOR
(a) Install the engine mounting insulator LH with the 5 bolts
and nut.
Torque:
Bolt A: 52 Nm (530 kgfcm, 38 ftlbf)
Bolt B: 80 Nm (816 kgfcm, 59 ftlbf)
Page 2775 of 5135

G24413
G24412
AB
D26905
41±38
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
47.INSTALL FRONT SUSPENSION CROSSMEMBER SUB±ASSY (See page 26±26) SST 09670±00010
48.CONNECT PRESSURE FEED TUBE ASSY (See page 51±36)
SST 09023±12700
49.CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 51±36) SST 09023±12700
50. INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 65±28)
51.INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30±6)
52.INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30±6) 53. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Connect the 2 cable ends, install the 2 clips.
(b) Install the 2 clips to the control cable bracket.
54. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE
(a) Install the flexible hose tube with the 3 bolts.Torque:
Bolt A: 12 N m (120 kgf cm, 9 ft lbf)
Bolt B: 5.0 N m (51 kgf cm, 44 in. lbf)
Bolt C: 9.0 N m (92 kgf cm, 80 in. lbf)
55.INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 42±17) SST 09023±00100
56.INSTALL CLUTCH ACCUMULATOR ASSY (See page 42±22) SST 09023±00100
57. CONNECT CONNECTOR
(a) Connect the back±up lamp switch connector.
Page 2776 of 5135

D30815
(b)(a)
D26903
D26902
±
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CD±FTV)
41±39
AVENSIS REPAIR MANUAL (RM1018E)
58. CONNECT WIRE HARNESS
(a) Install the ground cable with bolt.
Torque: 13 N m (131 kgf cm, 9 ft lbf)
(b) Install the air tube with bolt. Torque: 25 N m (255 kgf cm, 18 ft lbf)
59. INSTALL STARTER ASSY
(a) Connect the starter connector.
(b) Install the starter assy to the transaxle with the 2 bolts. Torque: 37 N m (380 kgf cm, 27 ft lbf)
(c) Install the starter wire to starter assy with the nut. Torque: 13 N m (130 kgf cm, 9 ft lbf)
60. CONNECT RADIATOR RESERVE TANK ASSY
(a) Install the radiator reserve tank assy with the 2 bolts. Torque: 6.0 N m (61 kgf cm, 53 in. lbf)
61.INSTALL AIR TUBE NO.1 (See page 14±286)
62. INSTALL BATTERY TRAY
63. INSTALL BATTERY
64. INSTALL BATTERY CLAMP SUB±ASSY Torque:
Bolt: 5.0 N m (51 kgf cm, 44 in. lbf)
Nut: 3.5 N m (36 kgf cm, 31 in. lbf)
65. INSTALL AIR CLEANER ASSY
Torque: 7.0 N m (71 kgf cm, 62 in. lbf)
66. INSTALL ENGINE COVER NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
67.INSTALL STEERING INTERMEDIATE SHAFT (See page 50±9)
68.INSTALL STEERING COLUMN HOLE COVER SUB±ASSY NO.1 (See page 50±9)
69.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
70.INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 50±9)
71. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
72. STEERING WHEEL CENTER POINT
73. INSTALL ENGINE ROOM COVER SIDE
74. INSTALL RADIATOR SUPPORT OPENING COVER