2005 TOYOTA AVENSIS transmission

C80556
FIPG
C80554
D30534
D30533
D30531
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±33
C250 M/T REPAIR MANUAL (RM1020E)
98. INSTALL MANUAL TRANSMISSION CASE COVER
SUB±ASSY
(a) Apply FIPG to the transaxle case, cover as shown to the
illustration.
FIPG:
Part No. 08826±00090, THREE BOND 1281
NOTICE:
Parts must be assembled within 10 minutes of application.
Otherwise, the packing (FIPG) material must be removed
and reapplied.
(b) Install the 9 bolts with manual transmission case cover to
the manual transmission case.
Torque: 18 N
m (185 kgf
cm, 14 ft
lbf)
99. INSTALL SHIFT & SELECT LEVER SHAFT ASSY
(a) Coat the sift & select lever shaft assy with gear oil, install
it to the manual transmission case.
100. INSTALL CONTROL SHAFT COVER
(a) Coat the 4 bolts with sealant, install the new gasket, con-
trol shaft cover with the bolt.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N
m (200 kgf
cm, 14 ft
lbf)
101. INSTALL CONTROL SHIFT LEVER
(a) Install the control shift lever with shift outer lever lever lock
pin to the shift & select lever shaft assy.
(b) Install the spring washer with nut.
Torque: 12 N
m (122 kgf
cm, 8.9 ft
lbf)

D30530
D30528
D30527
D30526
SST
41±34
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
102. INSTALL LOCK BALL ASSY NO.1
(a) Coat the lock ball assy No.1 with sealant, install it to the
manual transmission case.
Torque: 29 N
m (300 kgf
cm, 22 ft
lbf)
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
103. INSTALL SELECTING BELL CRANK ASSY
(a) Install the 2 bolts with selecting bell crank assy to the
manual transmission case.
Torque: 25 N
m (250 kgf
cm, 18 ft
lbf)
104. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING
SUPPORT BRACKET
(a) Install the 3 bolts with floor shift control lever housing sup-
port bracket to the front transaxle case.
Torque: 18 N
m (184 kgf
cm, 13 ft
lbf)
105. INSTALL BACK UP LAMP SWITCH ASSY
(a) Using SST, install the back up lamp switch assy with new
gasket to the manual transmission case.
SST 09817±16011
Torque: 40 N
m (410 kgf
cm, 30 ft
lbf)
106. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB±ASSY
(a) Install a new O±ring to the speedometer driven hole cover sub±assy.
(b) Install the bolt with speedometer driven hole cover sub±assy to the manual transaxle case.
Torque: 11 N
m (115 kgf
cm, 8.3 ft
lbf)

C67604
D30525
C67602
C68381
D30524
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±35
C250 M/T REPAIR MANUAL (RM1020E)
107. INSTALL RELEASE FORK SUPPORT
(a) Install the release fork support to the front transaxle case.
Torque: 37 N
m (375 kgf
cm, 25 ft
lbf)
108. INSTALL CLUTCH RELEASE FORK BOOT
(a) Install the clutch release fork boot to the front transaxle
case.
109. INSTALL CLUTCH RELEASE BEARING ASSY
(a) Coat the clutch release bearing assy with release hub
grease, install it to the clutch release fork sub±assy.
Sealant:
Part No. 08887±01806, RELEASE HUB GREASE or
equivalent
110. INSTALL CLUTCH RELEASE FORK SUB±ASSY
(a) Install the clutch release fork sub±assy to the input shaft.
Sealant:
Part No. 08887±01806, CLUTCH SPLINE GREASE or
equivalent
(b) Apply clutch spline grease to the input shaft spline.
111. INSTALL MANUAL TRANSMISSION FILLER PLUG
(a) Install the manual transmission filler plug with new gasket
to the manual transmission case.
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)

C80550
41±36
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
112. INSTALL DRAIN (MTM) PLUG SUB±ASSY
(a) Install the drain plug with new gasket to the manual trans-
mission case.
Torque: 39 N
m (400 kgf
cm, 29 ft
lbf)

4101E±02
C67982
C80408
Match
marks
C67984
C67989
41±66
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR
(a) Remove the speedometer drive gear from the front differ-
ential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place match marks on the from the front differential ring
gear and from the front differential case.
(b) Remove the 8 bolts. Using a hammer, remove the front
differential ring gear from the front differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Fixing the front differential pinion to the from the front dif-
ferential case side. Using a dial indicator, measure the
front differential side gear back lash.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)

C67985
C67986
C67987
C67988
C68517
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
41±67
C250 M/T REPAIR MANUAL (RM1020E)
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a chisel and hammer, loosen the staked part of the
front differential case.
(b) Using a pin punch (3 mm) and a hammer, remove the
front differential pinion shaft straight pin from the front dif-
ferential case.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 from the
front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions , front differential
pinion thrust washers and front differential side gear
thrust washers No.1 from the front differential case.
HINT:
Revolving the front differential pinion, remove the 2 pinions, pin-
ion thrust washers and side gear thrust washers.
7. INSPECT FRONT DIFFERENTIAL PINION THRUST
WASHER
(a) Using a micrometer, measure the thickness of the front
differential pinion thrust washer.
Minimum thickness: 0.94 mm (0.03701 in.)
If the thickness exceed the minimum, replace the front differen-
tial pinion thrust washer.

C68518
C67988
C67987
41±68
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
8. INSPECT FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Using a micrometer, measure the outer diameter of the
front differential pinion shaft No.1.
Minimum outer diameter: 16.982 mm (0.6685 in.)
If the outer diameter exceed the minimum, replace the front dif-
ferential pinion shaft No.1.
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the sliding and rotating surface of the front differen-
tial side gear with MP grease.
(b) Install the 2 front differential side gear thrust washers to
the 2 front differential side gear.
(c) Install the 2 front differential pinions with front differential
washers to the front differential case.
HINT:
Revolving the front differential pinion, install the 2 front differen-
tial pinions with front differential washers.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Coat the front differential pinion shaft No.1 with MP
grease.
(b) Install the front differential pinion shaft No.1 to the front
differential case so that the hole for the front differential
pinion shaft straight pin is aligned with the hole in the front
differential case.

C67989
C67990
C67991
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (C250)
41±69
C250 M/T REPAIR MANUAL (RM1020E)
11. ADJUST FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Fixing the front differential pinion to the front differential
case side. Using a dial indicator, measure the front differ-
ential side gear backlash.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
HINT:

Because the thrust washer does not have any mark for
distinction, measure the thickness with a micrometer to
select a proper thrust washer.

Select washers of the same thickness for both the right
and left.
Thrust washer thickness
Parts No.Thickness mm (in.)
41361 ± 221400.95 (0.0374 in.)
41361 ± 220201.00 (0.0394 in.)
41361 ± 221501.05 (0.0413 in.)
41361 ± 220301.10 (0.0433 in.)
41361 ± 221601.15 (0.0452 in.)
41361 ± 220401.20 (0.0472 in.)
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch (
3mm) and hammer, install the front
differential pinion shaft straight pin to the front differential
case.
(b) Using a chisel and hammer, stake the front differential
case hole.