2005 TOYOTA AVENSIS transmission

C80543
C80544
SST
C68516
C68012
C68013
41±50
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
10. REMOVE 1ST GEAR
(a) Using 2 screwdrivers and a hammer, remove the clutch
hub No.1 shaft snap ring from the output shaft.
HINT:
Using a shop rug to prevent the shaft snap ring from being
scatted.
(b) Using SST and a press, remove the clutch hub No.1 assy
and 1st gear from the output shaft.
SST 09950±00020
11. REMOVE SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Remove the synchronizer ring No.1 from the 1st gear.
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
13. REMOVE 1ST GEAR THRUST WASHER
(a) Remove the 1st gear thrust washer from the output shaft.

C68014
C68015
C80545
AB C
C80439
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±51
C250 M/T REPAIR MANUAL (RM1020E)
14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
(a) Remove the 1st gear thrust washer pin or ball from the
output shaft.
15. REMOVE REVERSE GEAR
(a) Remove the reverse gear, 3 synchromesh shifting keys
and 3 synchromesh keys springs.
HINT:
Using a waste to prevent the shifting key and shifting key spring
from being scatted.
16. INSPECT OUTPUT SHAFT
(a) Using a dial indicator, check the shaft runout.
Minimum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the output shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Standard outer diameter:
Part A: 31.985 ±32.000 mm (1.2592 ± 1.2598 in.)
Part B: 37.985 ±38.000 mm (1.4955 ± 1.2598 in.)
Part C: 32.985 ±33.000 mm (1.2986 ± 1.2992 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
SST 99999±60009

C68017
C68017
C68514
C68023
C68239
41±52
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
17. INSPECT 2ND GEAR
(a) Using a cylinder gauge, measure the clearance of the 2nd
gear.
Standard clearance:
38.015 ± 38.031 mm (1.4966 ± 1.4972 in.)
Maximum clearance:
38.031 mm (1.4972 in.)
If the clearance exceeds the maximum, replace the 1st gear.
18. INSPECT 1ST GEAR
(a) Using a cylinder gauge, measure the clearance of the 1st
gear.
Standard clearance:
44.015 ± 44.031 mm (1.7328 ± 1.7335 in.)
Maximum clearance:
44.031 mm (1.7335 in.)
If the clearance exceeds the maximum, replace the 1st gear.
19. INSPECT 1ST GEAR THRUST WASHER
(a) Using a micrometer, measure the 1st gear thrust washer.
Standard thickness:
5.975 ± 6.025 mm (0.2352 ± 0.2372 in.)
Minimum thickness:
5.975 mm (0.2352 in.)
If the clearance exceeds the minimum, replace the 1st gear.
20. INSPECT SYNCHRONIZER RING NO.1 (FOR SECOND
SYNCHRONIZER RING)
(a) Coat the 2nd gear cone with gear oil. 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.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.70 ± 1.30 mm (0.0276 ± 0.0512 in.)
Minimum clearance:
0.70 mm (0.0276in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.

C68021
C68022
C68409
C68240
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±53
C250 M/T REPAIR MANUAL (RM1020E)
21. INSPECT SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Coat the 1st gear cone with gear oil. 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.
(b) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Standard clearance:
0.75 ± 1.65 mm (0.0295 ± 0.0650 in.)
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
22. INSPECT REVERSE GEAR
(a) Using a vernier caliper, measure the clearance between
the reverse gear and shift fork.
Maximum clearance: 0.35 mm (0.014 in.)
If the clearance exceeds the maximum, replace the shift form
or reverse gear.
23. INSPECT TRANSMISSION CLUTCH HUB NO.1
(a) Check that the transmission clutch hub No.1 and reverse
gear slides smoothly.
(b) Check that the spline gear's edges of the reverse gear is
not worn down.

C68241
C68014
C68013
C68012
C68310
41±54
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
24. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil, install it to the trans-
mission clutch hub No.1.
HINT:
Do not set the reverse gear and transmission clutch hub No.1
in incorrect orientation.
(b) Install the 3 synchromesh shifting key springs and 3 syn-
chromesh shifting keys.
25. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
(a) Coat the 1st gear thrust washer pin or ball with gear oil,
install it to the output shaft.
26. INSTALL 1ST GEAR THRUST WASHER
(a) Coat the 1st gear thrust washer with gear oil, install it to
the output shaft.
27. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil, install
it to the output shaft.
28. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil, install it to the output shaft.

C68311
C80547
SST
C68244
C68246
D30552
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±55
C250 M/T REPAIR MANUAL (RM1020E)
29. INSTALL SYNCHRONIZER RING NO.1 (FOR FIRST
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.1 with gear oil, install it to
the 1st gear.
30. INSTALL TRANSMISSION CLUTCH HUB NO.1
(a) Using SST and a press, install the transmission clutch
hub No.1 to the output shaft
SST 09316±60011 (09316±00031)
HINT:

The 1st gear can be turned.

While checking the 1st gear thrust washer pin or ball is in-
serted into the groove of the 1st gear thrust washer, press
and fit the clutch hub No.1.
(b) Select a snap ring that will allow the minimum axial play.
Standard clearance:
0.1 mm (0.039 in.) or less
MarkThickness mm (in.)MarkThickness mm (in.)
A2.50 (0.0984)D2.68 (0.1055)
B2.56 (0.1008)E2.74 (0.1079)
C2.62 (0.1031)F2.80 (0.1102)
(c) Using brass bar and hammer, install the snap ring to the
output shaft.
31. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing and 2nd gear
bearing spacer with gear oil, install them to the output
shaft.
32. INSTALL SYNCHRONIZER RING NO.1 (FOR SECOND
SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.1 with gear oil, install it to
the 2nd gear.

C68248
C80548
SST
C68005
C82013
SST
C82014
SST
41±56
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
33. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil, install it to the output
shaft.
34. INSTALL 3RD DRIVEN GEAR
(a) Using SST and a press, install the 3rd driven gear to the
output shaft.
SST 09950±00020
35. INSTALL OUTPUT GEAR SPACER
(a) Install the output gear spacer to the output shaft.
36. INSTALL 4TH DRIVEN GEAR
(a) Using SST and a press, 4th driven gear to the output
shaft.
SST 09612±22011
37. INSTALL OUTPUT SHAFT REAR BEARING
(a) Using SST and a press, install the output shaft rear bear-
ing to the output shaft.
SST 09612±22011

C68254
C68309
C68312
C80538
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (C250)
41±57
C250 M/T REPAIR MANUAL (RM1020E)
38. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clear-
ance between the gear and shaft.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 2nd gear
or needle roller bearing.
39. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clear-
ance between the gear and shaft.
Standard clearance:
0.015 ± 0.058 mm (0.0006 ± 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the 1st gear,
needle roller bearing.
40. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clear-
ance.
Standard clearance:
0.1 ± 0.45 mm (0.0039 ± 0.0177 in.)
Maximum clearance:
0.45 mm (0.0177 in.)
41. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 1st gear thrust clear-
ance.
Standard clearance:
0.10 ± 0.40 mm (0.0039 ± 0.0157 in.)
Maximum clearance:
0.40 mm (0.0157 in.)