2005 TOYOTA AVENSIS manual transmission

C69536
C69536
C69542
C69798
C69531
41±76
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
15. INSTALL SHIFT LEVER INNER NO.2
(a) shift lever inner No.2, select return spring No.2 and select
return spring seat No.2 to the shift & select lever shaft.
(b) Using a brass bar and a hammer, install the select seat
snap ring to the shift & select lever shaft.
(c) Install the transmission oil baffle. Using a pin punch(
5
mm) and a hammer, install the shift inner lever slotted pin
to the shift & select lever shaft.
Clearance:5.8 ± 6.8mm (0.2303 ± 0.2700 in.)
16. INSTALL SELECTING BELLCRANK NO.2 BUSH
(a) Coat the 2 selecting bellcrank No.2 bushes with MP
grease, install it to the selecting bellcrank No.2.
17. INSTALL SELECTING BELLCRANK DUST COVER
NO.2
(a) Coat the selecting bellcrank dust cover No.2 with MP
grease, install it to the selecting bellcrank No.2.

C69799
C69532
C69530
C69529
± MANUAL TRANSMISSION/TRANSAXLESHIFT & SELECT LEVER SHAFT ASSY (E355/E356)
41±77
E355,E356 M/T REPAIR MANUAL (RM867E)
18. INSTALL SELECTING BELLCRANK SUPPORT
SUB±ASSY
(a) Install the selecting bellcrank support sub±assy to the se-
lecting bellcrank No.2.
(b) Install the selecting bellcrank No.2 plate washer, washer
and nut.
Torque:12N
m (120 kgf
cm, 9 ft
lbf)
19. INSTALL SELECTING BELLCRANK DUST COVER
NO.1
(a) Install the selecting bellcrank dust cover No.1 to the se-
lecting bellcrank No.2.
20. INSTALL CONTROL SHIFT LEVER BUSH
(a) Install the control shift lever bush to the selecting bell
crank No.2.

4103Y±01
C69636
C69637
C69638
±
MANUAL TRANSMISSION/TRANSAXLE OUTPUT SHAFT ASSY (E355/E356)
41±61
E355,E356 M/T REPAIR MANUAL (RM867E)
OUTPUT SHAFT ASSY (E355/E356)
OVERHAUL
HINT:
COMPONENTS:See page 41±1
1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a fleer gauge, measure the 1st gear thrust clear-ance.
Standard clearance:
0.25 ± 0.4 mm (0.0099 ± 0.0159 in.)
2. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clear- ance.
Standard clearance:
0.1 ± 0.35 mm (0.0004 ± 0.0139 in.)
3. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clear- ance.
Standard clearance:mm (in.)
BearingStandard clearance
KOYO made0.009 ± 0.053
(0.0004 ± 0.0021)
NSK made0.009 ± 0.051
(0.0004 ± 0.0020)
If the clearance is out of the specification, replace the 1st gear
needle roller bearing.

C69639
SST
C69640
C69641
SST
C69642
41±62
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
4. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clear-
ance.
Standard clearance:mm (in.)
BearingStandard clearance
KOYO made0.009 ± 0.053
(0.0004 ± 0.0021)
NSK made0.009 ± 0.051
(0.0004 ± 0.0020)
If the clearance is out of the specification, replace the 2nd gear
needle roller bearing.
5. REMOVE 4TH DRIVEN GEAR
(a) Using SST and a press, remove the output shaft bearing
rear (inner race) and 4th driven gear.
SST 09950±00020
6. REMOVE OUTPUT GEAR SPACER
(a) Remove the out put gear spacer from the output shaft.
7. REMOVE 2ND GEAR
(a) Using SST and a press, remove the 3rd driven gear and
2nd gear from the out put shaft.
SST 09950±00020

C69643
C69644
C69641
C69646
C83814
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±63
E355,E356 M/T REPAIR MANUAL (RM867E)
8. REMOVE SYNCHRONIZER RING SET NO.2
(a) Remove the synchronizer ring set No.2 from the transmis-
sion clutch hub No.1.
9. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing from the out-
put shaft.
10. REMOVE 2ND GEAR BEARING SPACER
(a) Remove the 2nd gear bearing spacer from the output
shaft.
11. REMOVE 2ND GEAR BUSH
(a) Remove the 2nd gear bush from the output shaft.
12. REMOVE 2ND GEAR BUSH BALL
(a) Using a magnetic finger, remove the 2nd gear bush ball
from the output shaft.

SST
C69648
C69649
C69650
SST
C69651
C69652
41±64
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
13. REMOVE 1ST GEAR
(a) Using SST and a press, remove the transmission clutch
hub No.1 and 1st gear from the output shaft.
SST 09950±00020
14. REMOVE SYNCHRONIZER RING SET NO.1
(a) Remove the synchronizer ring set No.1 from the 1st gear.
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
16. REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the output shaft front
bearing (inner race) from the output shaft.
SST 09950±00020, 09950±60010 (09951±00320),
09950±70010 (09951±07150)
NOTICE:
Do not tighten SST excessively.
17. REMOVE REVERSE GEAR
(a) Remove the reverse gear, 3 synchromesh shifting keys
and 3 synchromesh shifting key springs from the trans-
mission clutch hub No.1.

C69653
C91168
AA
B
C69655
C69655
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±65
E355,E356 M/T REPAIR MANUAL (RM867E)
18. INSPECT OUTPUT SHAFT
(a) Using V ± block and a dial indicator, measure the shaft run
out.
Maximum run out:0.03 mm (0.0012 in.)
If the run out exceeds the maximum, replace the input shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft jarnal surface.
Outer diameter: mm (in.)
PartStandard outer diameterminimum outer diameter
A37.610 ± 37.626
(1.4931 ± 1.4938)37.610
(1.4931)
B34.802 ± 34.512
(1.3816 ± 1.3701)34.802
(1.3816)
If the outer diameter is less than the minimum replace the input
shaft.
19. INSPECT 2ND GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 2 nd gear.
Inside diameter: mm (in.)
Standard inside diameterMaximum inside diameter
50.009±50.025
(1.9854 ± 1.9860)50.025
(1.9860)
If the inside diameter exceeds the maximum, replace the 2nd
gear.
20. INSPECT 1ST GEAR
(a) Using a cylinder gauge, measure the inside diameter of
the 1st gear.
Inside diameter: mm (in.)
Standard inside diameterMaximum inside diameter
51.009±51.025
(2.0250 ± 2.0257)51.025
(2.0257)
If the inside diameter exceeds the maximum, replace the 1st
gear.

C69657
C69656
C69658
C69659
41±66
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
21. INSPECT SYNCHRONIZER RING SET NO.2
(a) Coat the cone of the 2nd gear with gear oil, check that it
does not turn in the both circumference directions wile
pushing it to the synchronizer ring No.2.
(b) Check the clearance between the synchronizer ring No.2
and 2nd gear while pushing it to the synchronizer ring
No.2.
Standard clearance:
0.70 ± 1.45 mm (0.0278 ± 0.0576 in.)
If the standard clearance is out of the specification, replace the
synchronizer ring set No.2 with a new one.
22. INSPECT SYNCHRONIZER RING SET NO.1
(a) Coat the 1st gear cone with gear oil. Turn the synchroniz-
er ring set No.1. in one direction while pushing it to the 1st
gear cone. Check that the ring locks.
(b) Check the clearance between the synchronizer ring set
No.1 and 1st gear while pushing it to the cone of synchro-
nizer ring set No.1.
Standard clearance:
0.70 ± 1.45 mm (0.0278 ± 0.0576 in.)
If the standard clearance is out of the specification, replace the
synchronizer ring set No.1 with a new one.