SERVICE SPECIFICATIONS -> Manual Transaxle (C50, C250) for Your Toyota Avensis 4 Door First Generation (1997-2003)

SS–6  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
MANUAL TRANSAXLE (C50, C250)  
SS02P–06  
SERVICE DATA  
Inputshaft roller bearing journal diameter  
Input shaft 3rd gear journal diameter  
Input shaft 4th gear journal diameter  
Input shaft 5th gear journal diameter  
Input shaft runout  
Min. 24.985 mm (0.9834 in.)  
Min. 30.985 mm (1.2199 in.)  
Min. 28.985mm(1.1411 in.)  
Min. 24.885 mm (0.9797 in.)  
Max. 0.03 mm (0.0012 in.)  
Min. 32.985 mm (1.2986 in.)  
Min. 37.985 mm (1.4955 in.)  
Min. 31.985 mm (1.2592 in.)  
Max. 0.03 mm (0.0012 in.)  
Output shaft roller bearing journal diameter  
Output shaft 1st gear journal diameter  
Output shaft 2nd gear journal diameter  
Output shaft runout  
Gear thrust clearance 1st  
STD 0.10 – 0.40 mm (0.0039 – 0.0157 in.)  
Max. 0.40 mm (0.0157 in.)  
Gear thrust clearance 2nd  
STD 0.10 – 0.45 mm (0.0039 – 0.0177 in.)  
Max. 0.45 mm (0.0177 in.)  
Gear thrust clearance 3rd  
STD 0.10 – 0.35 mm (0.0039 – 0.0138 in.)  
Max. 0.35 mm (0.0138 in.)  
Gear thrust clearance 4th  
STD 0.10 – 0.55 mm (0.0039 – 0.0217 in.)  
Max. 0.55 mm (0.0022 in.)  
Gear thrust clearance 5th  
STD 0.10 – 0.57 mm (0.0039 – 0.0244 in.)  
Max. 0.57 mm (0.0224 in.)  
Gear radial clearance 1st, 2nd, 3rd, 4th, and 5th (KOYO made)  
Gear radial clearance 1st, 2nd, 3rd, 4th, and 5th (NSK made)  
STD 0.015 – 0.058 mm (0.0006 – 0.0023 in.)  
Max. 0.058 mm (0.0023 in.)  
STD 0.015 – 0.056 mm (0.0006 – 0.0022 in.)  
Max. 0.056 mm (0.0022 in.)  
No. 3 gear shift fork to No. 3 hub sleeve clearance  
No. 2 gear shift fork to No. 2 hub sleeve clearance  
No. 1 gear shift fork to reverse gear clearance  
Synchronizer ring to gear clearance 1st, 4th and 5th  
Max. 0.5 mm (0.020 in.)  
Max. 0.35 mm (0.014 in.)  
Max. 0.35 mm (0.014 in.)  
Min. 0.75 mm (0.0295 in.)  
Min. 0.65 mm (0.0256 in.)  
Min. 0.70 mm (0.0276 in.)  
Synchronizer ring to gear clearance  
Synchronizer ring to gear clearance  
3rd  
2nd  
Drive in depth  
Control shaft cover oil seal  
Transmission case oil seal  
Transaxle case oil seal  
Select inner lever slotted spring pin  
1.0 – 2.0 mm (0.039 – 0.079 in.)  
9.9 ± 0.3 mm (0.390 ± 0.012 in.)  
1.9 ± 0.3 mm (0.075 ± 0.012 in.)  
0 ± 0.5 mm (0 ± 0.020 in.)  
No.1 shift inner lever slotted spring pin  
No.2 shift inner lever slotted spring pin  
0 ± 0.5 mm (0 ± 0.020 in.)  
3.5 ± 0.5 mm (0.138 ± 0.020 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–7  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
Input shaft snap ring thickness  
No.2 clutch hub  
Mark 0 2.30 mm (0.0906 in.)  
Mark 1 2.36 mm (0.0929 in.)  
Mark 2 2.42 mm (0.0953 in.)  
Mark 3 2.48 mm (0.0976 in.)  
Mark 4 2.54 mm (0.1000 in.)  
Mark 5 2.60 mm (0.1024 in.)  
Mark A 2.29 mm (0.0902 in.)  
Mark B 2.35 mm (0.0925 in.)  
Mark C 2.41 mm (0.0949 in.)  
Mark D 2.47 mm (0.0972 in.)  
Mark E 2.53 mm (0.0996 in.)  
Mark F 2.59 mm (0.1020 in.)  
Rear bearing  
Output shaft snap ring thickness  
No.1 clutch hub  
Mark A 2.50 mm (0.0984 in.)  
Mark B 2.56 mm (0.1008 in.)  
Mark C 2.62 mm (0.1031 in.)  
Mark D 2.68 mm (0.1055 in.)  
Mark E 2.74 mm (0.1079 in.)  
Mark F 2.80 mm (0.1102 in.)  
Mark A 2.25 mm (0.0886 in.)  
Mark B 2.31 mm (0.0909 in.)  
Mark C 2.37 mm (0.0933 in.)  
Mark D 2.43 mm (0.0957 in.)  
Mark E 2.49 mm (0.0980 in.)  
Mark F 2.55 mm (0.1004 in.)  
Mark G 2.61 mm (0.1028 in.)  
No.3 clutch hub  
Differential side bearing preload (at starting)(For use with SST)  
Newbearing 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf)  
Reusedbearing 0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf)  
Differential pinion to side gear backlash  
0.05 mm – 0.20 mm (0.0020 – 0.0079 in.)  
Differential side gear thrust washer thickness  
0.95 mm (0.0374 in.)  
1.00 mm (0.0394 in.)  
1.05 mm (0.0413 in.)  
1.10 mm (0.0433 in.)  
1.15 mm (0.0453 in.)  
1.20 mm (0.0472 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–8  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
Differential side bearing adjusting shim thickness  
Mark A 2.10 mm (0.0827 in.)  
Mark B 2.15 mm (0.0846 in.)  
Mark C 2.20 mm (0.0866 in.)  
Mark D 2.25 mm (0.0886 in.)  
Mark E 2.30 mm (0.0906 in.)  
Mark F 2.35 mm (0.0925 in.)  
Mark G 2.40 mm (0.0945 in.)  
Mark H 2.45 mm (0.0965 in.)  
Mark J 2.50 mm (0.0984 in.)  
Mark K 2.55 mm (0.1004 in.)  
Mark L 2.60 mm (0.1024 in.)  
Mark M 2.65 mm (0.1043 in.)  
Mark N 2.70 mm (0.1063 in.)  
Mark P 2.75 mm (0.1083 in.)  
Mark Q 2.80 mm (0.1102 in.)  
Mark R 2.85 mm (0.1122 in.)  
Mark S 2.90 mm (0.1142 in.)  
Mark T 2.95 mm (0.1161 in.)  
Mark U 3.00 mm (0.1181 in.)  
AVENSIS/CORONA SUP (RM781E)  
SS–9  
SERVICE SPECIFICATIONS  
–
MANUALTRANSAXLE (C50, C250)  
SS02Q–07  
TORQUE SPECIFICATION  
Parttightened  
N·m  
12  
kgf·cm  
ft·lbf  
9
Clutch release cylinder x Transaxle  
120  
400  
650  
Starter x Transaxle  
39  
29  
47  
Transaxle x Engine  
64  
Stiffener plate set bolt (See page MX–3)  
Bolt B  
Bolt A  
47  
23  
480  
230  
35  
17  
Engine left mounting bracket x Transaxle  
Bolt A  
Nut B  
52  
87  
530  
890  
38  
64  
Frontwheel  
216  
39  
62  
43  
39  
2,200  
400  
630  
440  
400  
159  
29  
46  
32  
29  
Filler and Drain plugs  
Front exhaust pipe x Exhaust manifold  
Center exhaust pipe x Tail exhaust pipe  
Front transport hook x Engine mounting center member  
Engine mounting center member (See page MX–3)  
Bolt A  
Bolt B  
73  
72  
740  
730  
54  
53  
Engine rear mounting bracket x Insulator  
Transmission case x Transaxle case  
Transmission case x Transmission case cover  
Straight screw plug (Reverse restrict pin)  
Straight screw plug  
87  
29  
18  
13  
25  
11  
77  
29  
17  
16  
39  
29  
29  
27  
118  
20  
12  
25  
12  
17  
25  
40  
11  
37  
890  
300  
185  
130  
250  
115  
790  
300  
175  
160  
400  
300  
300  
280  
1,200  
200  
120  
250  
120  
175  
250  
410  
115  
375  
64  
22  
13  
9
18  
8
Transaxle case receiver x Transaxle case  
Differential case x Ring gear  
57  
22  
13  
12  
29  
22  
22  
20  
87  
14  
9
Transaxle case x Differentialcase  
Reverse shift arm bracket set bolt  
No.1, No.2, No.3 shift forks and shift head set bolt  
Lock ball assembly (Reverse shift fork side)  
Lock ball assembly (Shift and select lever shaft side)  
Reverse idler gear shaft lock bolt  
Rear bearing retainer x Transmission case  
5th driven gear lock nut  
Control shaft cover x Transmission case  
Control shift lever x Dust boot  
Selecting bellcrank assembly x Transaxle case  
Control shaft assembly x Transaxle case  
Oil receiver pipe set bolt  
18  
9
13  
18  
30  
8
Control cable bracket x Transmission case  
Back–up light switch  
Speed sensor lock plate set bolt  
Clutch release fork support  
27  
AVENSIS/CORONA SUP (RM781E)  

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