Get MANUAL TRANSAXLE (C50, C250) Guide for Toyota Avensis 4 Door First Generation (1997-2003)

MANUAL TRANSAXLE (C50, C250)

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

MANUAL TRANSAXLE UNIT . . . . . . . . . . . . . .

MANUAL TRANSAXLE ASSEMBLY . . . . . . . .

MX–1

MX–2

MX–8

INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . MX–23

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . MX–30

SHIFT AND SELECT LEVER SHAFT . . . . . . . MX–37

DIFFERENTIAL CASE . . . . . . . . . . . . . . . . . . . . MX–38

SHIFT LEVER AND CONTROL CABLE . . . . . MX–45

MX–1

MANUALTRANSAXLE (C50, C250)

–

TROUBLESHOOTING

MX002–02

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely

cause of the problem. Check each part in order. If necessary, replace parts.

Symptom

Suspect Area

See page

1. Oil (Level low)

2. Oil (Wrong)

MX–3

MX–8

Noise

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

1. Oil (Level too high)

MX–3

MX–8

2. Gasket (Damaged)

Oilleakage

3. Oil seal (Worn or damaged)

4. O–Ring (Worn or damaged)

1. Control cable (Faulty)

MX–45

MX–8

2. Synchronizer ring (Worn or damaged)

MX–23

MX–30

MX–8

Hard to shift or will not shift

3. Shift key spring (Damaged)

MX–23

MX–30

1. Locking ball spring (Damaged)

2. Shift fork (Worn)

MX–8

Jumps out of gear

3. Gear (Worn or damaged)

4. Bearing (Worn or damaged)

AVENSIS/CORONA SUP (RM781E)

MX–2

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

MX06E–02

COMPONENTS

RH Drive Shaft

Battery

Tray

z Snap Ring

Back–Up Light SwitchConnector

Speed Sensor Connector

Engine Wire

87(890, 64)

46 (470, 34)

39(400, 29)

Air Cleaner

Case Assembly

with Air Hose

Starter

64 (650, 47)

39 (400, 29)

Ground Cable

Clip

43 (440, 32)

Washer

Control Cable

Transaxle

Snap Ring

z

LH Drive Shaft

4A–FE Engine:

43 (440, 32)

216 (2,200, 159)

52 (530, 38)

Lock NutCap

64 (650, 47)

87(890, 64)

z

Cotter Pin

12 (120, 9)

49 (500, 36)

Stiffener Plate

127(1,300, 94)

Tie Rod End

Engine Mounting

Center Member

12 (120, 9)

43 (430, 32)

z

^zGasket

Clutch Release Cylinder

z

62 (630, 46)

Engine Left

Mounting Bracket

73 (740, 54)

Front and Center

Exhaust Pipes

Hole Plug

72 (730, 53)

Hole Cover

Hole Plug

Front TransportHook

LH Engine Under Cover

RH Engine Under Cover

N·m (kgf·cm, ft·lbf)

73 (740, 54)

39 (400, 29)

: Specifiedtorque

zNon–reusable part

D09353

AVENSIS/CORONA SUP (RM781E)

MX–3

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

MX0CZ–01

REMOVAL

1.

REMOVE BATTERY AND AIR CLEANER CASE AS-

SEMBLY WITH AIR HOSE

2.

DISCONNECT CLUTCH RELEASE CYLINDER AND

LINE

(a) Remove the set bolt of the clutch line bracket.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

(b) Remove the 2 bolts and disconnect the clutch release cyl-

inder and line.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D02142

D02143

D02144

3.

DISCONNECT ENGINE WIRE FROM CLAMP

Remove the bolt and engine wire clamp from the transaxle.

4.

DISCONNECT BACK–UP LIGHT SWITCH AND SPEED

SENSOR CONNECTORS

5.

DISCONNECT GROUND CABLE

Remove the set bolt and disconnect the ground cable from the

transaxle.

6.

(a) Remove the 2 clips and washers.

(b) Remove the 2 clips from the cables.

(c) Disconnect the 2 control cables from the transaxle.

DISCONNECT CONTROL CABLE

7.

REMOVE STARTER SET BOLT

Remove the set bolt of the starter from the transaxle upper side.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

8.

REMOVE 3 TRANSAXLE UPPER SIDE MOUNTING

BOLTS

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

Starter Set Bolt

D02145

AVENSIS/CORONA SUP (RM781E)

MX–4

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

9.

INSTALL ENGINE SUPPORT FIXTURE

D02147

10. REMOVE ENGINE LEFT MOUNTING BRACKET

Remove the 4 bolts, nut and bracket.

Torque:

B

Bolt A: 52 N·m (530 kgf·cm, 38 ft·lbf)

Nut B : 87 N·m (890 kgf·cm, 64 ft·lbf)

11. REMOVE FRONT WHEEL

A

Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)

12. RAISE VEHICLE

NOTICE:

D02146

Make sure that the vehicle is securely supported.

13. REMOVE LH AND RH ENGINE UNDER COVERS

14. DRAIN TRANSAXLE OIL

Oil grade: API GL–4 or GL–5

Viscosity: SAE 75W–90

Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

15. REMOVE LH AND RH DRIVE SHAFTS

(See page SA–1)

Filler Plug

Oil Level

0 – 5 mm

Drain Plug

D08837

16. REMOVE FRONT AND CENTER EXHAUST PIPES

(a) Remove the 3 nuts and 2 gaskets from the exhaust man-

ifold.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)

(b) Remove the 2 bolts, nuts, gasket and front and center ex-

haust pipes.

Torque: 43 N·m (430 kgf·cm, 32 ft·lbf)

D02149

AVENSIS/CORONA SUP (RM781E)

MX–5

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

17. REMOVE ENGINE MOUNTING CENTER MEMBER

(a) Remove the 2 bolts and front transport hook.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

D02150

(b) Remove the 2 hole plugs and hole cover.

(c) Remove the 7 bolts and center member.

Torque:

A

B

A

Bolt A: 73 N·m (740 kgf·cm, 54 ft·lbf)

Bolt B: 72 N·m (730 kgf·cm, 53 ft·lbf)

D02151

D02152

D02153

D00193

18. REMOVE STARTER

(a) Disconnect the connector and wire from the starter.

(b) Remove the set bolt of the starter from the lower side.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

(c) Remove the starter.

19. JACK UP TRANSAXLE SLIGHTLY

Using a transmission jack, support the transaxle.

20. REMOVE ENGINE REAR MOUNTING BOLT

Torque: 87 N·m (890 kgf·cm, 64 ft·lbf)

21. REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING

BOLT

Remove the 4 bolts.

A

Torque:

Bolt A: 47 N·m (480 kgf·cm, 35 ft·lbf)

Bolt B: 23 N·m (230 kgf·cm, 17 ft·lbf)

B

AVENSIS/CORONA SUP (RM781E)

MX–6

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

22. REMOVE TRANSAXLE

Lower the engine left side and remove the transaxle from the

engine.

HINT:

At the time of installation, please refer to the following items.

S

Align the input shaft with the clutch disc and install the

transaxle to the engine.

S

Temporarily tighten the transaxle mounting bolts.

AVENSIS/CORONA SUP (RM781E)

MX–7

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLE UNIT

MX005–04

INSTALLATION

Installation is in the reverse order of removal (See page MX–3).

HINT:

After installation, check and inspect items as follows.

S

Front wheel alignment (See Pub. No. RM599E on page SA–4).

Do the road test.

S

AVENSIS/CORONA SUP (RM781E)

MX–8

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MANUAL TRANSAXLE ASSEMBLY

MX006–06

COMPONENTS

11 (115, 8)

Hole Cover

Control Cable Bracket

25 (250, 18)

29 (300, 22)

Transaxle Case Receiver

Transaxle Case

11 (115, 8)

Magnet

z Oil Seal

z Input Shaft Front Bearing

Output Shaft Cover

z Output Shaft Front Bearing

Differential Case Assembly

Bearing Lock Plate

11 (115, 8)

: Specified torque

N·m (kgf·cm, ft·lbf)

z Non–reusable part

D10268

AVENSIS/CORONA SUP (RM781E)

MX–9

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

L Straight Screw Plug

No.1 Shift Fork

25 (250, 18)

Spring Seat

Spring

Reverse Shift Arm Bracket

Reverse Shift Fork

Snap Ring

16 (160, 12)

Ball

No.1 Shift Fork

Shaft

25 (250, 18)

L

17 (175, 13)

No.3 Shift Fork Shaft

Thrust Washer

16 (160, 12)

Ball

No.3 Shift Fork

Reverse Idler Gear

Idler Gear Shaft

Output Shaft Assembly

L

25 (250, 18)

Shift Head

16 (160, 12)

No.2 Shift Fork Shaft

29 (300, 22)

16 (160, 12)

No.2 Shift Fork

Snap Ring

5th Driven Gear

z Lock Nut

118 (1200, 87)

Input Shaft

Assembly

Spacer

Needle Roller Bearing

Snap Ring

Rear Bearing Retainer

Shifting Key Spring

Shifting Key

27 (280, 20)

x 5

5th Gear

Shifting Key Spring

Synchronizer Ring

No.3 Hub Sleeve

No.3 Clutch Hub

N·m (kgf·cm, ft·lbf) : Specified torque

Snap Ring

z Non–reusable part

L Precoated part

Z18280

AVENSIS/CORONA SUP (RM781E)

MX–10

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

L

20 (200, 14)

Back–Up

Light Switch

Control Shaft Cover

40 (410, 30)

Gasket

z

L Straight Screw Plug

39(400, 29)

L

20 (200, 14)

Gasket

z

Bearing

OilReceiverPipe

L Lock Ball Assembly

39 (400, 29)

L Straight Screw Plug

13 (130, 9)

Shift and Select Lever

Shaft Assembly

OilReceiverPipe

17 (175, 13)

Transmission Case

Filler Plug

39 (400, 29)

Gasket

z

z Bushing

29 (300, 22)

Dust Boot

Transmission Case

Cover

x 13

z Oil Seal

Gasket

z

Lever Lock Pin

x 9

Drain Plug

39 (400, 29)

25 (250, 18)

18 (185, 13)

Control Shaft

Assembly

12 (120, 9)

Selecting Bellcrank

Assembly

Wave Washer

Control Bellcrank Dust Cover

Wave Washer

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

AVENSIS/CORONA SUP (RM781E)

L Precoated part

D10269

MX–11

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MX0D0–01

DISASSEMBLY

1.

REMOVE RELEASE FORK AND BEARING

HINT:

At the time of reassembly, please refer to the following item.

Apply molybdenum disulphide lithium base grease.

(See page CL–12)

2.

3.

4.

REMOVE BOLT AND SPEED SENSOR

Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)

REMOVE BACK–UP LIGHT SWITCH

Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)

REMOVE CONTROL CABLE BRACKET

Remove the 2 bolts and control cable bracket.

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

5.

REMOVE CONTROL SHAFT ASSEMBLY

Remove the 2 nuts, wave washer and control shaft assembly.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D07393

6.

REMOVE SELECTING BELLCRANK ASSEMBLY

(a) Remove the 2 bolts and selecting bellcrank assembly.

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

NOTICE:

At the time of reassembly, please refer to the following

item.

Fit the selecting bellcrank assembly pin part with the dust

cover into a groove in the control shift lever.

(b) Remove the control bellcrank dust cover from the select-

ing bellcrank assembly.

D07394

NOTICE:

At the time of reassembly, please refer to the following

item.

Apply MP grease to the inside circumferential surface of

the control bellcrank dust cover.

AVENSIS/CORONA SUP (RM781E)

MX–12

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

7.

REMOVE CONTROL SHIFT LEVER AND DUST BOOT

(a) Remove the nut and wave washer.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D07395

(b) Using a pin punch and hammer, drive out the lever lock

pin.

NOTICE:

At the time of reassembly, please refer to the following

item.

When fixing the lever lock pin, properly position the shaft

groove.

(c) Remove the control shift lever and dust boot.

NOTICE:

D07396

At the time of reassembly, please refer to the following

items.

S

Install the dust boot into a groove in the control shift

lever.

S

Be sure to install the dust boot in the correct direc-

tion, as shown in the illustration.

8.

REMOVE PLUG, LOCK BALL ASSEMBLY AND CON-

TROL SHAFT COVER ASSEMBLY

(a) Using a hexagon wrench, remove the plug and gasket.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

(b) Remove the lock ball assembly.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

(c) Remove the 4 bolts and control shaft cover assembly with

the gasket.

D09357

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

MX–13

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

9.

REMOVE SHIFT AND SELECT LEVER SHAFT AS-

SEMBLY

(a) Remove the shift and select lever shaft assembly.

NOTICE:

At the time of reassembly, please refer to the following

item.

Set the claws of the shift interlock plate into the shift head

part of the gear shift fork shaft securely.

(b) Remove the select spring seat and compression spring

from the shift and select lever shaft assembly.

10. REMOVE TRANSMISSION CASE COVER

(a) Remove the 9 bolts.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

(b) Using a brass bar and hammer, carefully tap the projec-

tion of the transmission case cover to remove the trans-

mission case cover from the transmission case.

FIPG:

D07398

Q07840

Q05783

FIPG

Part No. 08826–00090, THREE BOND 1281 or equiva-

lent

11. REMOVE LOCK NUT

(a) Engage the gear to the double meshing.

(b) Using a chisel and hammer, loosen the staked part of the

nut.

(c) Remove the lock nut.

Torque: 118 N·m (1,200 kgf·cm, 87 ft·lbf)

(d) Disengage the gear double meshing.

12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK

(a) Remove the bolt from the No.3 shift fork.

Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

(b) Remove the No.3 hub sleeve with the shift fork.

HINT:

Removal

Installation

SST

At the time of reassembly, please refer to the following item.

Using SST and a hammer, drive in the No.3 hub sleeve with the

shift fork.

SST 09636–20010

Q05825

NOTICE:

At the time of installation, please refer to the following item.

Align the synchronizer ring slots with the shifting keys.

AVENSIS/CORONA SUP (RM781E)

MX–14

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

13. INSPECT 5TH GEAR THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10–0.57 mm (0.0039–0.0024 in.)

Maximum clearance:

0.57 mm (0.0224 in.)

Q02519

14. INSPECT 5TH GEAR RADIAL CLEARANCE

Using a dial indicator, measure the radial clearance.

Standard clearance:

KOYO made:

0.015–0.058 mm (0.0006–0.0023 in.)

NSK made:

0.015–0.056 mm (0.0006–0.0022 in.)

Maximum clearance:

KOYO made:0.058 mm (0.0023 in.)

NSK made:0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

Z00658

15. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR

(a) Using 2 screwdrivers and a hammer, tap out the snap

ring.

HINT:

At the time of reassembly, please refer to the following item.

Select a snap ring that allows the minimum axial play.

Mark

A

Thickness mm (in.)

2.25(0.0886)

2.31(0.0909)

2.37(0.0933)

2.43(0.0957)

Mark

Thickness mm (in.)

2.49(0.0980)

2.55(0.1004)

2.61(0.1028)

–

E

F

G

–

Z00659

B

C

D

(b) Using a screwdriver, remove the key spring.

AVENSIS/CORONA SUP (RM781E)

MX–15

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

(c) Install a bolt and washer to the tip of the input shaft and

using SST, remove the No.3 clutch hub.

SST 09950–30011

NOTICE:

Engine Side

Select a bolt whose outer diameter is smaller than the

screw hole of the input shaft so that it can be turned easily.

(d) Remove the synchronizer ring, 5th gear and needle roller

bearing.

SST

Q05790

16. REMOVE 5TH DRIVEN GEAR

Using SST, remove the 5th driven gear.

SST 09628–62011, 09950–40011 (09957–04010),

09950–60010 (09951–00230)

SST

Q07893

N00174

Q05785

Q05786

HINT:

At the time of reassembly, please refer to the following item.

Using SST, install the 5th driven gear.

SST 09309–12020

SST

17. REMOVE REAR BEARING RETAINER

Remove the 5 bolts and retainer.

Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)

18. REMOVE BEARING SNAP RING

Using a snap ring expander, remove the 2 snap rings.

HINT:

x 5

If it is difficult to remove and install the snap rings, pull up the

shafts.

19. REMOVE REVERSE IDLER GEARSHAFTLOCKBOLT

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

20. REMOVE SNAP RING FROM NO.2 SHIFT FORK

SHAFT

Using 2 screwdrivers and a hammer, tap out the snap ring.

AVENSIS/CORONA SUP (RM781E)

MX–16

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

21. REMOVE PLUG, SEAT, SPRING AND BALL

(a) Using a hexagon wrench, remove the 3 plugs.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

(b) Using a magnetic finger, remove the 3 seats, springs and

balls.

Q07842

22. REMOVE TRANSMISSION CASE

(a) Remove the 16 bolts.

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

(b) Using a plastic hammer, carefully tap the projection of the

transmission case to remove the transmission case from

the transaxle case.

Z00668

HINT:

FIPG

At the time of reassembly, please refer to the following item.

Apply FIPG to the transaxle case, as shown in the illustration.

FIPG:

Part No. 08826–00090, THREE BOND 1281 or equiva-

lent

D07333

D07351

Q08151

23. REMOVE OIL RECEIVER PIPE

Remove the 2 bolts and oil receiver pipes from the transmission

case.

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

NOTICE:

At the time of reassembly, please refer to the following

items.

S

Prevent the oil receiver pipes from being deformed.

Install the oil receiver pipes while placing it against

the transmission case, as shown in the illustration.

S

24. REMOVE REVERSE IDLER GEAR, THRUST WASHER

AND SHAFT

AVENSIS/CORONA SUP (RM781E)

MX–17

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

25. REMOVE REVERSE SHIFT ARM BRACKET

Remove the 2 bolts and reverse shift arm bracket.

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

NOTICE:

At the time of reassembly, please refer to the following

items.

S

Set the pin on the top of the reverse shift arm into a

groove on the reverse idler gear.

Fit the claw of the reverse shift arm bracket with the

notch of the input shaft front bearing.

Install the reverse idler gear, thrust washer and shaft,

as shown in the illustration.

Align Alignment Mark

D07336

26. REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK

SHAFT

(a) Using 2 screwdrivers and a hammer, tap out the 3 snap

rings from each gear shift fork shaft.

(b) Remove the 3 bolts from the No. 1 gear shift head, No. 1

and No. 2 gear shift forks.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

Q05789

Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

(c) Pull up the No. 3 gear shift fork shaft, remove the No. 2

gear shift fork shaft.

NOTICE:

At the time of reassembly, please refer to the following

item.

To avoid the interference of the 2 balls, lift up the No. 3 gear

shift fork shaft at the position shown in the illustration.

D03039

AVENSIS/CORONA SUP (RM781E)

MX–18

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

(d) Remove the No. 1 gear shift head.

D03038

(e) Using a magnetic finger, remove the 2 balls from the re-

verse shift fork.

(f)

Remove the No. 3 gear shift fork shaft and reverse shift

fork.

(g) Pull out the No. 1 gear shift fork shaft.

(h) Remove the No. 1 and No. 2 gear shift forks.

27. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER

FROM TRANSAXLE CASE

28. REMOVE DIFFERENTIAL CASE ASSEMBLY

NOTICE:

Z00674

At the time of reassembly, please refer to the following

item.

Before reassembly, inspect the differential tapered roller

bearing preload. (See page MX–42)

29. REMOVE MAGNET FROM TRANSAXLE CASE

30. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY

(a) Using a screwdriver, remove the shifting key spring.

NOTICE:

At the time of reassembly, please refer to the following

item.

Position the shifting key springs so that their end gaps are

not aligned.

(b) Remove the 3 No. 3 shifting keys from the No. 3 clutch

hub.

AVENSIS/CORONA SUP (RM781E)

MX–19

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MX06G–02

INSPECTION

1.

INSPECT 5TH GEAR SYNCHRONIZER RING

(a) Check wear or damage.

(b) 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.

If the braking effect is insufficient, apply a small amount of the

fine lapping compound between the synchronizer ring and gear

cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE:

WM0064

Ensure the fine lapping compound is completely washed

off after rubbing.

(c) Check again the braking effect of the synchronizer ring.

(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.

Minimum clearance: 0.75 mm (0.030 in.)

If the clearance is less than the minimum, replace the synchro-

nizer ring, and apply a small amount of the fine lapping com-

pound on gear cone.

NOTICE:

Ensure the fine lapping compound is completely washed

off after rubbing.

WM0065

WM0066

Z00675

2.

INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-

ANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.5 mm (0.020 in.)

If the clearance exceeds the maximum, replace the shift fork or

hub sleeve.

3.

REMOVE TRANSAXLE CASE RECEIVER

Remove the bolt and transaxle case receiver.

4.

IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING

SST

(a) Using SST, pull out the bearing.

SST 09612–65014

AVENSIS/CORONA SUP (RM781E)

MX–20

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

(b) Using SST and a press, install a new bearing.

SST 09950–60010 (09951–00460), 09950–70010

(09951–07150)

SST

Q07845

5.

IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING

(a) Remove the bolt and bearing lock plate.

(b) Using SST, pull out the bearing.

SST 09308–00010

SST

(c) Remove the output shaft front cover.

Z00701

(d) Install the output shaft front cover.

HINT:

Case

Cover

Set the projection of the cover into the hollow in the case.

Z00703

Q07846

Q07847

(e) Using SST and a press, install a new bearing.

SST 09950–60010 (09951–00620), 09950–70010

(09951–07150)

SST

(f)

Install the bearing lock plate and torque the bolt.

Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)

6.

INSTALL TRANSAXLE CASE RECEIVER

Install the transaxle case receiver and torque the bolt.

Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)

7.

IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL

SEAL

(a) Using a screwdriver, pry out the oil seal.

(b) Using SST, drive in a new oil seal until its surface is flush

with the transaxle case.

SST 09950–60010 (09951–00400), 09950–70010

(09951–07150)

(c) Coat the lip of the oil seal with MP grease.

SST

AVENSIS/CORONA SUP (RM781E)

MX–21

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

8.

IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Using a hexagon wrench, remove the straight screw plug.

(b) Using a pin punch and hammer, drive out the slotted

spring pin.

Q07850

(c) Replace the reverse restrict pin.

(d) Using a pin punch and hammer, drive in the slotted spring

pin.

(e) Apply sealant to the screw plug threads.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

(f)

Using a hexagon wrench, install the straight screw plug.

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

Z00707

AVENSIS/CORONA SUP (RM781E)

MX–22

MANUALTRANSAXLE (C50, C250)

–

MANUALTRANSAXLEASSEMBLY

MX009–02

REASSEMBLY

Reassembly is in the reverse order of disassembly (See page MX–11).

HINT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

NOTICE:

When working with FIPG material, you must observe the following items.

S

Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-

faces.

S

Thoroughly clean all components to remove all the loose material.

Clean both sealing surfaces with a non–residue solvent.

Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.

Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must

be removed and reapplied.

AVENSIS/CORONA SUP (RM781E)

MX–23

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00A–03

COMPONENTS

Input Shaft

3rd Gear

No.2 Hub Sleeve

Shifting Key

Shifting Key Spring

Needle Roller Bearing

4th Gear

Synchronizer Ring

Snap Ring

No.2 Clutch Hub

Synchronizer Ring

Snap Ring

Rear Ball Bearing

Q07849

AVENSIS/CORONA SUP (RM781E)

MX–24

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00B–03

DISASSEMBLY

1.

INSPECT 3RD AND 4TH GEARS THRUST CLEAR-

ANCE

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

3rd Gear

4th Gear

3rd gear: 0.10–0.35 mm (0.0039–0.0138 in.)

4th gear: 0.10–0.55 mm (0.0039–0.0217 in.)

Maximum clearance:

Q05793

3rd gear: 0.35 mm (0.0138 in.)

4th gear: 0.55 mm (0.0022 in.)

2.

INSPECT 3RD AND 4TH GEARS RADIAL CLEAR-

ANCE

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Standard clearance:

KOYO made:

0.015 – 0.058 mm (0.0006 – 0.0023 in.)

NSK made:

0.015 – 0.056 mm (0.0006 – 0.0022 in.)

Maximum clearance:

D00328

KOYO made: 0.058 mm (0.0023 in.)

NSK made: 0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

3.

REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring.

4.

REMOVE REAR BALL BEARING, 4TH GEAR, NEEDLE

ROLLER BEARING, SPACER AND SYNCHRONIZER

RING FROM INPUT SHAFT

SST

(a) Using SST and a press, remove the rear ball bearing.

SST 09950–00020

(b) Remove the 4th gear, needle roller bearings, spacer and

synchronizer ring.

5.

REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring.

Q04983

AVENSIS/CORONA SUP (RM781E)

MX–25

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

6.

REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR,

SYNCHRONIZER RING AND NEEDLE ROLLER BEAR-

ING

SST

Using SST and a press, remove the No.2 hub sleeve assembly,

3rd gear, synchronizer ring and needle roller bearings.

SST 09950–00020

CM0064

7.

REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND

SPRING FROM NO.2 CLUTCH HUB

Remove the 3 shifting keys, springs and No.2 hub sleeve from

the No.2 clutch hub.

Q00817

AVENSIS/CORONA SUP (RM781E)

MX–26

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00C–03

INSPECTION

1.

INSPECT SYNCHRONIZER RING

(a) Check wear or damage.

(b) 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.

If the braking effect is insufficient, apply a small amount of the

fine lapping compound between the synchronizer ring and gear

cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE:

Ensure the fine lapping compound is completely washed

off after rubbing.

(c) Check again the braking effect of the synchronizer ring.

WM0064

WM0065

WM0066

(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.

Minimum clearance:

3rd gear: 0.65 mm (0.0256 in.)

4th gear: 0.75 mm (0.0295 in.)

If the clearance is less than the minimum, replace the synchro-

nizer ring, and apply a small amount of the fine lapping com-

pound on gear cone.

NOTICE:

Ensure the fine lapping compound is completely washed

off after rubbing.

2.

INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-

ANCE

Using a feeler gauge, measure the clearance between the hub

sleeve and shift fork.

Maximum clearance: 0.35 mm (0.014 in.)

If the clearance exceeds the maximum, replace the shift fork or

hub sleeve.

AVENSIS/CORONA SUP (RM781E)

MX–27

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

3.

INSPECT INPUT SHAFT

(a) Check the input shaft for wear or damage.

(b) Using a micrometer, measure the outer diameter of the in-

put shaft journal surface.

A

B

C

D

Minimum outer diameter:

Part A: 24.885 mm (0.9797 in.)

Part B: 28.985 mm (1.1411 in.)

Part C: 30.985 mm (1.2199 in.)

Part D: 24.985 mm (0.9834 in.)

If the outer diameter is less than the minimum, replace the input

shaft.

CM0066

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the input shaft.

CM0013

AVENSIS/CORONA SUP (RM781E)

MX–28

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

MX00D–03

REASSEMBLY

HINT:

Coat all of the sliding and rotating surfaces with gear oil before

reassembly.

Front

Side

1.

INSTALL NO.2 CLUTCH HUB INTO NO.2 HUB SLEEVE

(a) Install the 3 springs and shifting keys to the No.2 clutch

hub.

(b) Install the No.2 hub sleeve to the No. 2 clutch hub.

Q00909

Q02522

N00067

N00068

Q02525

2.

INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,

SYNCHRONIZER RING AND NO. 2 HUB SLEEVE AS-

SEMBLY TO INPUT SHAFT

(a) Apply gear oil to the needle roller bearings.

(b) Place the synchronizer ring on the gear and align the ring

slots with shifting keys.

(c) Using a press, install the 3rd gear and No.2 hub sleeve

assembly.

3.

INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play.

Mark

Thickness mm (in.)

2.30(0.0906)

Mark

Thickness mm (in.)

2.48(0.0976)

0

1

2

3

4

5

2.36(0.0929)

2.54(0.1000)

2.42(0.0953)

2.60(0.1024)

(b) Using a screwdriver and hammer, tap in the snap ring.

4.

INSPECT 3RD GEAR THRUST CLEARANCE

(See page MX–24)

5.

INSPECT SYNCHRONIZER RING, NEEDLE ROLLER

BEARING, SPACER, 4TH GEAR AND REAR BALL

BEARING

(a) Apply gear oil to the needle roller bearings.

(b) Place the synchronizer ring on the gear and align the ring

slots with the shifting keys.

AVENSIS/CORONA SUP (RM781E)

MX–29

MANUALTRANSAXLE (C50, C250)

–

INPUT SHAFT

(c) Using SST and a press, install the rear ball bearing.

SST 09608–03071

SST

SM0049

6.

INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play.

Mark

A

Thickness mm (in.)

2.29(0.0902)

Mark

D

Thickness mm (in.)

2.47(0.0972)

B

2.35(0.0925)

E

2.53(0.0996)

C

2.41(0.0949)

F

2.59(0.1020)

(b) Using a screwdriver and hammer, tap in the snap ring.

7.

INSPECT 4TH GEAR THRUST CLEARANCE

(See page MX–24)

SM0050

AVENSIS/CORONA SUP (RM781E)

MX–30

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX00E–03

COMPONENTS

Ball

Output shaft

Thrust Washer

Synchronizer Ring

Needle Roller Bearing

1st Gear

No.1 Clutch Hub

No.1 Hub Sleeve

Synchronizer Ring

Snap Ring

Shifting Key Spring

Shifting Key

Spacer

Needle Roller Bearing

2nd Gear

Output Gear Spacer

4th Driven Gear

Rear Ball Bearing

3rd Driven Gear

Q07853

AVENSIS/CORONA SUP (RM781E)

MX–31

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX00F–03

DISASSEMBLY

1.

INSPECT 1ST AND 2ND GEARS THRUST CLEAR-

ANCES

Using a feeler gauge, measure each thrust clearance.

Standard clearance:

2nd Gear

1st Gear

1st gear: 0.10–0.40 mm (0.0039–0.0157 in.)

2nd gear: 0.10–0.45 mm (0.0039–0.0177 in.)

Maximum clearance:

Q05794

SM0137

CM0065

1st gear: 0.40 mm (0.0157 in.)

2nd gear: 0.45 mm (0.0177 in.)

2.

INSPECT 1ST AND 2ND GEARS RADIAL CLEAR-

ANCE

Using a dial indicator, measure the radial clearance between

the gear and shaft.

Standard clearance:

KOYO made:

0.015 – 0.058 mm (0.0006 – 0.0023 in.)

NSK made:

0.015 – 0.056 mm (0.0006 – 0.0022 in.)

Maximum clearance:

KOYO made: 0.058 mm (0.0023 in.)

NSK made: 0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the gear,

needle roller bearing or shaft.

3.

REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR

AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT

(a) Using SST and a press, remove the ball bearing and 4th

driven gear.

SST 09950–00020

(b) Remove the output spacer.

SST

AVENSIS/CORONA SUP (RM781E)

MX–32

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

4.

REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE

ROLLER BEARING, SYNCHRONIZER RING AND

SPACER

(a) Shift the No.1 hub sleeve into the 1st gear.

N00074

MT0063

N00076

Q00818

(b) Using SST and a press, remove the 3rd driven gear.

SST 09950–00020

(c) Remove the 2nd gear, needle roller bearing, synchronizer

ring and spacer.

SST

5.

REMOVE SNAP RING

Using 2 screwdrivers and a hammer, tap out the snap ring.

6.

REMOVE NO.1 HUB SLEEVE ASSEMBLY 1ST GEAR,

SYNCHRONIZER RING, NEEDLE ROLLER BEARING,

THRUST WASHER AND BALL

(a) Using a press, remove the No.1 hub sleeve assembly, 1st

gear and synchronizer ring.

(b) Remove the needle roller bearing, thrust washer and ball.

7.

REMOVE NO.1 HUB SLEEVE, SHIFTING KEY AND

SPRING FROM NO.1 CLUTCH HUB

Remove the 3 shifting keys, springs and No.1 hub sleeve from

the No.1 clutch hub.

AVENSIS/CORONA SUP (RM781E)

MX–33

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX0D1–01

INSPECTION

1.

INSPECT 1ST GEAR SYNCHRONIZER RING

(a) Check for wear or damage.

(b) 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.

If the braking effect is insufficient, apply a small amount of the

fine lapping compound between the synchronizer ring and gear

cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE:

WM0064

Ensure the fine lapping compound is completely washed

off after rubbing.

(c) Check again the braking effect of the synchronizer ring.

(d) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.

Minimum clearance: 0.75 mm (0.0295 in.)

If the clearance is less than the minimum, replace the synchro-

nizer ring, and apply a small amount of the fine lapping com-

pound on gear cone.

NOTICE:

Ensure the fine lapping compound is completely washed

off after rubbing.

WM0065

D07357

D07358

2.

INSPECT 2ND GEAR SYNCHRONIZER RING

(a) Check for wear or damage.

(b) 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.

If the braking effect is insufficient, replace the synchronizer ring.

(c) Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.

Minimum clearance: 0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace the synchro-

nizer ring.

AVENSIS/CORONA SUP (RM781E)

MX–34

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

3.

INSPECT GEAR SHIFT FORK AND REVERSE GEAR

CLEARANCE

Using a feeler gauge, measure the clearance between the re-

verse gear and gear shift fork.

Maximum clearance: 0.35 mm (0.014 in.)

If the clearance exceeds the maximum, replace the gear shift

fork or hub sleeve.

WM0066

MT0071

CM0015

4.

INSPECT OUTPUT SHAFT

(a) Check the output shaft for wear or damage.

(b) Using a micrometer, measure the outer diameter of the

output shaft journal surface.

C

B

A

Minimum outer diameter:

Part A: 32.985 mm (1.2986 in.)

Part B: 37.985 mm (1.4955 in.)

Part C: 31.985 mm (1.2592 in.)

If the outer diameter is less than the minimum, replace the out-

put shaft.

(c) Using a dial indicator, check the shaft runout.

Maximum runout: 0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the output shaft.

AVENSIS/CORONA SUP (RM781E)

MX–35

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

MX00H–03

REASSEMBLY

HINT:

Coat all of the sliding and rotating surfaces with gear oil before

reassembly.

Front

Side

1.

INSTALL NO.1 CLUTCH HUB INTO NO.1 HUB SLEEVE

(a) Install the 3 springs and shifting keys to the No.1 clutch

hub.

(b) Install the No.1 clutch hub to the No.1 hub sleeve.

Q00819

Q00805

Q00908

N00079

N00080

2.

INSTALL BALL, THRUST WASHER, 1ST GEAR,

NEEDLE ROLLER BEARING, SYNCHRONIZER RING

AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT

SHAFT

(a) Install the ball to the shaft.

(b) Fit the thrust washer groove securely over the locking ball

when installing the thrust on the shaft.

(c) Apply gear oil to the needle roller bearing.

(d) Install the needle roller bearing, 1st gear and synchroniz-

er ring.

(e) Place the synchronizer ring on the gear and align the

clutch hub grooves with the projections on the synchro-

nizer ring.

Notch

(f)

Using a press, install the 1st gear and No.1 hub sleeve.

3.

INSTALL SNAP RING

(a) Select a snap ring that allows the minimum axial play.

Mark

A

Thickness mm (in.)

2.50(0.0984)

Mark

D

Thickness mm (in.)

2.68(0.1055)

B

2.56(0.1008)

E

2.74(0.1079)

C

2.62(0.1031)

F

2.80 (0.1102)

(b) Using a screwdriver and hammer, tap in the snap ring.

4.

INSPECT 1ST GEAR THRUST CLEARANCE

(See page MX–31)

AVENSIS/CORONA SUP (RM781E)

MX–36

MANUALTRANSAXLE (C50, C250)

–

OUTPUT SHAFT

5.

INSTALL SYNCHRONIZER RING, SPACER, NEEDLE

ROLLER BEARING, 2ND GEAR AND 3RD DRIVEN

GEAR

(a) Place the synchronizer ring on the gear and align the

clutch hub grooves with the projections on the synchro-

nizer ring.

(b) Install the spacer.

(c) Apply gear oil to the needle roller bearing.

(d) Install the 2nd gear.

Q00806

Z00711

Z00712

Z00713

(e) Using a press, install the 3rd driven gear.

6.

INSPECT 2ND GEAR THRUST CLEARANCE

(See page MX–31)

7.

INSTALL OUTPUT GEAR SPACER AND 4TH DRIVEN

GEAR

(a) Install the output gear spacer.

(b) Using a press, install the 4th driven gear.

8.

INSTALL REAR BALL BEARING

Using SST and a press, install the rear ball bearing.

SST 09316–60011 (09316–00021)

SST

AVENSIS/CORONA SUP (RM781E)

MX–37

MANUALTRANSAXLE (C50, C250)

–

SHIFTAND SELECT LEVER SHAFT

SHIFT AND SELECT LEVER SHAFT

MX00I–06

COMPONENTS

Shift and Select Lever

Shaft

Snap Ring

Compression Spring

Select Inner Lever

Shift Interlock

Plate

No. 2 Shift Inner

Lever

No. 1 Select Spring Seat

No. 2 Select Spring

Seat

Slotted Spring Pin

No. 1 Shift Inner Lever

Compression Spring

Slotted Spring Pin

E–Ring

Apply MP grease

D07696

AVENSIS/CORONA SUP (RM781E)

MX–38

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

DIFFERENTIAL CASE

MX00J–03

COMPONENTS

z Outer Race and SideBearing

Pinion Thrust Washer

z Oil Seal

Ring Gear

Pinion Gear

Pinion Shaft

Shim

77 (790, 57)

x 8

z Side Bearing and OuterRace

Side Gear

Side Gear Thrust Washer

Shim

Differential Case

Straight Pin

Speed Sensor Drive Gear

z Oil Seal

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

Z17126

AVENSIS/CORONA SUP (RM781E)

MX–39

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

MX00K–03

DISASSEMBLY

1.

REMOVE RING GEAR

(a) Place matchmarks on the ring gear and case.

(b) Remove the 8 bolts.

Matchmarks

(c) Using a copper hammer, tap on the ring gear to remove

it from the case.

D00855

2.

Speed Sensor Drive Gear Side:

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

(a) Using SST, remove the side bearing.

SST 09950–00020, 09950–00030, 09950–60010

(09951–00360)

SST

HINT:

Set the claw of SST to the bearing inner race at the position

where the speed sensor drive gear is indented.

(b) Remove the speed sensor drive gear.

Z16131

Q07848

Q00807

3.

Ring Gear Side:

SST

REMOVE SIDE BEARING FROM DIFFERENTIAL

CASE

Using SST, remove the side bearing.

SST 09950–00020, 09950–00030, 09950–60010

(09951–00360)

HINT:

Set the claw of SST to the bearing inner race at the position

where the differential case is indented.

4.

INSPECT SIDE GEAR BACKLASH

Using a dial indicator, measure the backlash of one side gear

while holding one pinion toward the case.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install the correct

thrust washer to the side gears.

5.

DISASSEMBLE DIFFERENTIAL CASE

(a) Using a pin punch and hammer, drive out the straight pin.

(b) Remove the pinion shaft from the case.

(c) Remove the 2 pinions and side gears with the 4 thrust

washers from each gear.

AVENSIS/CORONA SUP (RM781E)

MX–40

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

6.

Transmission Case Side:

IF NECESSARY, REPLACE OIL SEAL AND SIDE

BEARING OUTER RACE

SST

(a) Using a screwdriver and hammer, drive out the oil seal.

(b) Using SST, pull out the outer race and shim.

SST 09612–65014

(c) Place the shim into the case.

N00098

(d) Using SST and a hammer, drive in a new outer race.

SST 09950–60020 (09951–00710), 09950–70010

(09951–07150)

SST

Q08120

(e) Using SST and a hammer, drive in a new oil seal.

SST 09350–32014 (09351–32111, 09351–32130)

Drive in depth: 9.9 ± 0.3 mm (0.390 ± 0.012 in.)

9.9 ± 0.3 mm

SST

(f)

Coat the lip of the oil seal with MP grease.

Q08121

7.

Transaxle Case Side:

IF NECESSARY, REPLACE OIL SEAL AND SIDE

BEARING OUTER RACE

(a) Using a screwdriver and hammer, drive out the oil seal.

(b) Using SST, pull out the outer race and shim.

SST 09612–65014

SST

(c) Place the shim into the case.

N00100

(d) Using SST and a hammer, drive in a new outer race.

SST 09950–60020 (09951–00680), 09950–70010

(09951–07150)

SST

Z16127

AVENSIS/CORONA SUP (RM781E)

MX–41

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

(e) Using SST and a hammer, drive in a new oil seal.

SST 09350–32014 (09351–32130, 09351–32150)

Drive in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 in.)

1.9 ± 0.3 mm

(f)

Coat the lip of the oil seal with MP grease.

SST

Z02714

AVENSIS/CORONA SUP (RM781E)

MX–42

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

MX00L–03

REASSEMBLY

1.

ASSEMBLE DIFFERENTIAL CASE

(a) Install the correct thrust washers and side gears. Refer to

the table below, select thrust washers which will allow that

the backlash is within the specification.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

Thickness mm (in.)

0.95(0.0374)

Thickness mm (in.)

1.10(0.0433)

N00102

1.00(0.0394)

1.15(0.0453)

1.05(0.0413)

1.20(0.0472)

(b) Install the thrust washers and side gears in the differential

case.

(c) Install the pinion shaft.

(d) Using a dial indicator, check the side gear backlash. Mea-

sure the side gear backlash while holding one pinion gear

toward the case.

Standard backlash:

0.05 – 0.20 mm (0.0020 – 0.0079 in.)

If the backlash is not within the specification, install a thrust

washer of different thickness.

(e) Using a pin punch and hammer, drive in the straight pin

through the case and hole in the pinion shaft.

Q00807

Z00728

Q00808

(f)

2.

Stake the differential case.

Ring Gear Side:

INSTALL SIDE BEARING

Using SST and a press, install a new side bearing.

SST 09550–10013 (09252–10010, 09556–10011)

SST

3.

Speed Sensor Drive Side:

INSTALL SIDE BEARING

(a) Install the speed sensor drive gear.

Case Side

AVENSIS/CORONA SUP (RM781E)

MX–43

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

(b) Using SST and a press, install a new side bearing.

SST 09550–10013 (09556–10011), 09950–60010

(09951–00460), 09950–70010 (09951–07150)

SST

4.

INSTALL RING GEAR ON DIFFERENTIAL CASE

(a) Clean the contact surface of the differential case.

(b) Heat the ring gear in boiling water.

(c) Carefully take the ring gear out of the water.

(d) After the moisture on the ring gear has completely evapo-

rated, quickly install the ring gear to the differential case.

HINT:

SST

Z00729

Align the matchmarks on the differential case and contact the

ring gear.

(e) Temporarily install the 8 set bolts.

NOTICE:

The ring gear set bolts should not be tightened until the

ring gear has cooled sufficiently.

(f)

After the ring gear has cooled sufficiently, torque the ring

gear set bolts uniformly at a time.

Case

Side

Torque: 77 N·m (790 kgf·cm, 57 ft·lbf)

Q08183

5.

INSPECT DIFFERENTIAL SIDE BEARING PRELOAD

(a) Install the differential case assembly to the transaxle

case.

(b) Install the transmission case.

(c) Install and torque the case bolts.

Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

CM0061

AVENSIS/CORONA SUP (RM781E)

MX–44

MANUALTRANSAXLE (C50, C250)

–

DIFFERENTIALCASE

(d) Using SST and a torque wrench, measure the preload.

SST 09564–32011

Preload (at starting):

New bearing

0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)

Reused bearing

SST

0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)

If the preload is not within the specification, remove the trans-

mission case side outer race of the side bearing with SST.

(See page MX–39)

MT0092

Select another shim.

HINT:

The preload will change by about 0.3 – 0.4 N·m (3 – 4 kgf·cm,

2.6 – 3.5 in.·lbf) with each 0.05 mm change in shim thickness.

Mark

A

Thickness mm (in.)

2.10(0.0827)

2.15(0.0846)

2.20(0.0866)

2.25(0.0886)

2.30(0.0906)

2.35(0.0925)

2.40(0.0945)

2.45(0.0965)

2.50(0.0984)

2.55(0.1004)

Mark

L

Thickness mm (in.)

2.60(0.1024)

2.65(0.1043)

2.70(0.1063)

2.75(0.1083)

2.80 (0.1102)

2.85 (0.1122)

2.90 (0.1142)

2.95 (0.1161)

3.00 (0.1181)

–

B

M

N

C

D

P

E

Q

R

F

G

H

S

T

J

U

K

–

AVENSIS/CORONA SUP (RM781E)

MX–45

MANUALTRANSAXLE (C50, C250)

–

SHIFT LEVER AND CONTROL CABLE

MX06H–02

COMPONENTS

Console Box Assembly

Parking Brake Cover

Shift Lever Knob

Front Ash Receptacle

Shift Lever Assembly

Cap

12(120, 9)

Clip

Cap

4.9(50,43in.·lbf)

Air Duct

Clip

Washer

Transmission Control Cable Bracket

Select Control Cable

Shift Cable Grommet

Shift Control Cable

Clip

Shift Cable Grommet

Retainer

Washer

Heat Insulator

Clip

4.9(50,43in.·lbf)

Washer

43(430,32)

Gasket

z

zRivet

z

Gasket

z

62(630,46)

z

Exhaust Pipe

LH Engine Under Cover

RH Engine Under Cover

N·m (kgf·cm, ft·lbf)

: Specifiedtorque

zNon–reusable part

D09354

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE (C50, C250) for Your Toyota Avensis 4 Door First Generation (1997-2003)

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