Manual Transmission & Transaxle PDF

4110
MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)
FLOOR SHIFT SHIFT LEVER ASSY (MTM)

4105U03
COMPONENTS
Gasoline Engine:
Front Floor Console Panel Subassy Upper
Heat Insulator No.1
Floor Shift Lever Knob
Subassy
5.5 (56, 49 in.lbf)

Console Box Carpet
Console Panel Subassy Lower
Console Box Subassy Rear
Transmission Control Cable Assy

Clip
5.0 (51, 44 in.lbf) 12 (122, 9)
Clip
12 (122, 9)
Clip
5.0 (51, 44 in.lbf)
Floor Shift Shift Lever Assy

Nm (kgfcm, ftlbf) : Specified torque Clip Clip
D30489
AVENSIS REPAIR MANUAL (RM1018E)

4111
410DR01
REPLACEMENT
1. REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUBASSY (See page 7111)
2. REMOVE CONSOLE PANEL UPPER (See page 7111)
3. REMOVE CONSOLE PANEL SUBASSY LOWER (See page 7111)
4. REMOVE CONSOLE BOX ASSY REAR (See page 7111)
5. SEPARATE TRANSMISSION CONTROL CABLE ASSY

(a) Remove the 2 clips, separate the cable ends of the control
cable assy.
D26893
(b) Release the claws, separate the control cable assy.
D26895
6. REMOVE FLOOR SHIFT SHIFT LEVER ASSY

(a) Remove the 4 bolts and shift lever assy.
D30474
7. INSTALL FLOOR SHIFT SHIFT LEVER ASSY

(a) Install the shift lever assy with the 4 bolts.
Torque: 12 Nm (122 kgfcm, 9 ftlbf)
D30474

4112
8. CONNECT TRANSMISSION CONTROL CABLE ASSY

(a) Connect the control cable assy to the shift lever assy.
NOTICE:
Make sure that the claws are firmly engaged.
D26972
(b) Connect the end of the select cable to the shift lever assy,
Serrate Part
install the clip.
NOTICE:
The serrate part of the select cable point should face
upward when the select cable point is connected.
The clip should be inserted to the direction as shown
in the illustration.
(c) Connect the end of the shift cable to the shift lever assy.
D26894

413
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
FRONT DIFFERENTIAL OIL SEAL (C50/C250)

4104611
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 306)
SST 0952001010, 0952024010 (0952032040)
6. REMOVE FRONT DRIVE SHAFT ASSY RH (See page 306)
SST 0952001010, 0952024010 (0952032040)
7. REMOVE TRANSAXLE CASE OIL SEAL

(a) Using SST(s), remove the oil seal.
SST 0930800010
SST(s)
C94266
8. REMOVE TRANSMISSION CASE OIL SEAL

SST 0930800010
SST(s)
D25305
9. INSTALL TRANSAXLE CASE OIL SEAL

(a) Coat a new oil seal lip with MP grease.
(b) Using SST(s) and a hammer, install the oil seal.
SST 0955414010, 0995070010 (0995107200)
Drive in depth: 1.9 0.3 mm (0.075 0.012 in.)
NOTICE:
SST(s) Be careful not to damage the oil seal lip.
D25722

414
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (C50/C250)
10. INSTALL TRANSMISSION CASE OIL SEAL

SST 0955414010, 0995070010 (0995107200)
NOTICE:
D26133
11. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 306)

12. INSTALL FRONT DRIVE SHAFT ASSY RH (See page 306)
13. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgfcm, 76 ftlbf)
14. ADD MANUAL TRANSAXLE OIL

Oil grade: API GL4 or GL5
Viscosity: SAE 75 W90
Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
0 to 5 mm
(0 to 0.20 in.)
D25304
15. INSPECT MANUAL TRANSAXLE OIL (See page 412)

16. INSPECT FRONT WHEEL ALIGNMENT (See page 266)
17. CHECK ABS SPEED SENSOR SIGNAL
(a) w/ VSC (See page 05756)
(b) w/o VSC (See page 05699)

415
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
FRONT DIFFERENTIAL OIL SEAL (E354/E357)

4104612
REPLACEMENT
1. DRAIN MANUAL TRANSAXLE OIL
SST 0952001010, 0952024010 (0952032040)
SST 0952001010, 0952024010 (0952032040)
7. REMOVE FRONT TRANSAXLE CASE COVER OIL

SEAL
SST 0930800010
SST(s)
C94266
8. REMOVE TRANSMISSION CASE OIL SEAL

SST 0930800010
SST(s)
D25305
9. INSTALL FRONT TRANSAXLE CASE COVER OIL

SEAL
SST 0960810010, 0995070010 (0995107200)
Drive in depth: 0 0.5 mm (0 0.020 in.)
SST(s) NOTICE:
Be careful not to damage the oil seal lip.
D25722

416
MANUAL TRANSMISSION/TRANSAXLE FRONT DIFFERENTIAL OIL SEAL (E354/E357)
10. INSTALL TRANSMISSION CASE OIL SEAL

SST 0960832010, 0995070010 (0995107200)
NOTICE:
D26133

14. ADD MANUAL TRANSAXLE OIL

Oil grade: API GL4 or GL5
Viscosity: SAE 75 W90
Capacity: 2.5 liters (2.6 US qts, 2.2 lmp. qts)
0 to 5 mm
(0 to 0.20 in.)
D25304
15. INSPECT MANUAL TRANSAXLE OIL (See page 412)


4122
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1AZFE/1AZFSE)
MANUAL TRANSAXLE ASSY (1AZFE/1AZFSE)

410DT01
COMPONENTS
13 (133, 10)
Hood Subassy Air Cleaner Assy
Battery Clamp Subassy

Engine Room Cover Side
Radiator Support Opening Cover
5.0 (51, 44 in.lbf)
5.0 (51, 44 in.lbf)
Battery
9.0 (92, 80 in.lbf)
13 (131, 9)
Clip
Clip
Clip
Battery Tray
40 (410, 30) Clip
Engine Cover Subassy No.1 Transmission Control Cable Assy

26 (260, 19) Transverse Engine
Backup Lamp Switch Connector Engine Mounting Insulator
64 (653, 47) 52 (530, 38)
64 (653, 47)
46 (469, 34)
80 (816, 59)
44 (449, 32)
46 (469, 34)
Clutch Release Cylinder Assy 52 (530, 38)
18 (184, 13)
8.4 (85, 74 in.lbf)
13 (130, 9)
12 (120, 9)
Starter
Connector
9.0 (92, 80 in.lbf)
44 (449, 32)
46 (469, 34)
Starter Assy
Nm (kgfcm, ftlbf) : Specified torque
37 (380, 27)
Nonreusable part Manual Transaxle Assy D30082

4123
Front Drive Shaft Assy RH
64 (650, 47)
Front Drive Shaft Assy LH
Snap Ring
64 (650, 47)
Transverse Engine
Engine Mounting Bracket 64 (653, 47)
Transverse Engine
Engine Mounting Insulator
Transverse Engine
74 (755, 55)
64 (653, 47)
52 (530, 38)
Cotter Pin
35 (360, 26)
74 (755, 55)
Cotter Pin
64 (653, 47) 49 (500, 36) 8.0 (82, 71 in.lbf)
49 (500, 36)
89 (908, 66)
45 (459, 33)
52 (530, 38) 89 (908, 66) 216 (2,203, 159)
Transverse Engine 29 (296, 21)

133 (1,356, 83)
133 (1,356, 83)
Engine Under Cover LH
Engine Under Cover RH

Nonreusable part
D30473

4124
410DU01
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 509)
3. SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509)
4. REMOVE STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page 509)
5. REMOVE STEERING INTERMEDIATE SHAFT (See page 509)
9. DRAIN TRANSAXLE OIL
10. REMOVE HOOD SUBASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER SUBASSY NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUBASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE BATTERY CARRIER

(a) Remove the 4 bolts and battery carrier.
D30480
19. REMOVE STARTER ASSY (See page 1912)
20. SEPARATE WIRE HARNESS

(a) Remove the 3 bolts, and separate the 3 wire harnesses.
D30081

4125
21. SEPARATE CONNECTOR

(a) Separate the backup lamp switch connector.
D30066
22. SEPARATE CLUTCH RELEASE CYLINDER ASSY

(a) Remove the 3 bolts and separate the release cylinder.
D30064

(a) Remove the 2 clips, separate the 2 cables from the trans-
axle.
(b) Remove the 2 clips, separate the 2 cables from the brack-
et.
G24413

SST 0952001010, 0952024010 (0952032040)
26. REMOVE HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 6528)
27. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136)
SST 0902312700
28. DISCONNECT PRESSURE FEED TUBE ASSY (See page 5136)
SST 0902312700

4126
No.1 Engine Hanger No.2 Engine Hanger 29. SUSPEND ENGINE ASSY
(a) Install the No.1 and No.2 engine hangers in the correct
direction.
Parts No.:
No. 1 engine hanger: 1228128010
No. 2 engine hanger: 1228228010
Bolt: 9151261020
D25745 (b) Attach the engine chain hoist to the engine hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
30. REMOVE FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626)
31. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the manual transaxle with a transmission jack.
32. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator
LH.
D30067

MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket.
D30077
34. REMOVE MANUAL TRANSAXLE ASSY

(a) Separate the wire harness clamp.
(b) Remove the 10 bolts.
(c) Separate and remove the transaxle from the engine.
D25747

4127
35. REMOVE MANUAL TRANSMISSION CASE

PROTECTOR
(a) Remove the 2 bolts and case protector.
D30076

MOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FR
from the engine mounting bracket.
(b) Remove the 2 bolts and engine mounting bracket FR from
the transaxle.
D30078

MOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR from
the engine mounting bracket.
(b) Remove the 3 bolts and engine mounting bracket RR
from the transaxle.
D30079
38. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

BRACKET
(a)
(a) Install the engine mounting bracket RR and 3 bolts to the
transaxle.
(a) Torque: 64 Nm (653 kgfcm, 47 ftlbf)
(b) (b) Install the engine mounting insulator RR and bolt to the
(a)
engine mounting bracket RR.
D30079

BRACKET
(a) (a) Install the engine mounting bracket FR and 2 bolts to the
transaxle.
(b) (b) Install the engine mounting insulator FR, bolt and nut to
the engine mounting bracket FR.
(b) D30078

4128
40. INSTALL MANUAL TRANSMISSION CASE

PROTECTOR
(a) Install the case protector with the 2 bolts.
D30076
A 41. INSTALL MANUAL TRANSAXLE ASSY

A
(a) Align the input shaft with the clutch disc and install the
B
transaxle to the engine.
(b) Install the 10 bolts.
Torque:
C
B Bolt A: 64 Nm (653 kgfcm, 47 ftlbf)
Bolt B: 46 Nm (469 kgfcm, 34 ftlbf)
Bolt C: 44 Nm (449 kgfcm, 32 ftlbf)
D25747 (c) Connect the wire harness clamp.

BRACKET
(a) Install the engine mounting bracket LH to the transaxle
with the 3 bolt.
D30077
A A 43. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

INSULATOR
(a) Install the engine mounting insulator LH with the 5 bolts
and nut.
Torque:
A Bolt A: 52 Nm (530 kgfcm, 38 ftlbf)
B A D30067
44. INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626)

SST 0967000010
45. CONNECT PRESSURE FEED TUBE ASSY (See page 5136)
SST 0902312700
46. CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136)
SST 0902312700
47. INSTALL HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 6528)
4129
50. INSTALL TRANSMISSION CONTROL CABLE ASSY

(a) Connect the 2 cable ends, install the 2 clips.
(b) Install the 2 clips to the control cable bracket.
G24413
51. INSTALL CLUTCH RELEASE CYLINDER ASSY

B (a) Install the release cylinder with the 3 bolts.
Torque:
Bolt A: 9.0 Nm (92 kgfcm, 80 in.lbf)
A
D30064
52. CONNECT CONNECTOR

(a) Connect the backup lamp switch connector.
D30066
53. CONNECT WIRE HARNESS

B
(a) Install the 3 wire harnesses with the 3 bolts.
Torque:
Bolt A: 26 Nm (260 kgfcm, 19 ftlbf)
C Bolt B: 8.4 Nm (85 kgfcm, 74 in.lbf)
A
D30081
54. INSTALL STARTER ASSY (See page 1912)

4130
55. INSTALL BATTERY CARRIER

(a) Install the battery carrier and 4 bolts.
D30080
56. INSTALL BATTERY TRAY

57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUBASSY
Torque:
Bolt: 5.0 Nm (51 kgfcm, 44 in.lbf)
Nut: 3.5 Nm (36 kgfcm, 31 in.lbf)
59. INSTALL AIR CLEANER ASSY
Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
60. INSTALL ENGINE COVER SUBASSY NO.1
61. INSTALL ENGINE ROOM COVER SIDE
62. INSTALL RADIATOR SUPPORT OPENING COVER
63. INSTALL HOOD SUBASSY
64. INSPECT HOOD SUBASSY (See page 752)
65. ADJUST HOOD SUBASSY (See page 752)
66. ADD TRANSAXLE OIL (See page 415)
67. INSPECT TRANSAXLE OIL (See page 412)
69. INSTALL STEERING INTERMEDIATE SHAFT (See page 509)
70. INSTALL STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page)See page 509)
71. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509)
72. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 509)
73. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
74. STEERING WHEEL CENTER POINT
75. ADD POWER STEERING FLUID
76. BLEED POWER STEERING FLUID (See page 514)
77. CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 514)
78. INSPECT FLUID LEAK (See page 514)
80. INSTALL ENGINE UNDER COVER LH
81. INSTALL ENGINE UNDER COVER RH
83. HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 6519)

4131
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1CDFTV)
MANUAL TRANSAXLE ASSY (1CDFTV)

410DV01
COMPONENTS
Hood Subassy Air Cleaner Assy
13 (133, 10)

7.0 (71, 62 in.lbf)
6.0 (61, 53 in.lbf)
13 (133, 10)
5.0 (51, 44 in.lbf)
Radiator Support
Opening Cover
Radiator Reserve Tank Assy
3.5 (36, 31 in.lbf)
25 (255, 18)
8.0 (82, 71 in.lbf)
Battery Clamp
Battery Subassy
Air Tube No.1 Floor Shift Transmission

Control Cable Assy
Battery Tray
Engine Cover No.1
Clip
25 (255, 18) Clip
Clip
64 (653, 47)
37 (380, 27) Clip
Ground Cable
Starter Assy
13 (131, 9)
13 (130, 9)
52 (530, 38)
64 (653, 47)
46 (469, 34)
80 (816, 59)
Starter Connector 64 (653, 47)
20 (200, 14)
52 (530, 38)
8.0 (82, 71 in.lbf)
Transverse Engine
12 (120, 9) Engine Mounting Insulator
40 (408, 30)
40 (408, 30)
12 (120, 9)
18 (184, 13)
64 (653, 47) Manual Transmission
9.0 (92, 80 in.lbf) Case Protector
5.0 (51, 44 in.lbf)
Manual Transaxle Assy

Nonreusable part D30475

4132
64 (650, 47)
Front Drive Shaft Assy LH
Snap Ring
64 (650, 47)
Transverse Engine
64 (653, 47)
Engine Mounting Bracket
Transverse Engine
Engine Mounting
Transverse Engine
64 (653, 47)
74 (755, 55)
52 (530, 38)
35.3 (360, 26)
Cotter Pin
74 (755, 55)
Cotter Pin
64 (653, 47)
49 (500, 36) 8.0 (82, 71 in.lbf)
49 (500, 36)
89 (908, 66)
52 (530, 38)
45 (459, 33) 52 (530, 38) 89 (908, 66)
216 (2,203, 159)
Transverse Engine 133 (1,356, 83) 29 (296, 21)

133 (1,356, 83)


Nonreusable part
D30476

4133
410DY01
REPLACEMENT
1. INSPECT CENTER FRONT WHEEL
2. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page 509)
3. SEPARATE STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509)
4. REMOVE STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page 509)
5. REMOVE STEERING INTERMEDIATE SHAFT (See page 509)
9. DRAIN TRANSAXLE OIL
10. REMOVE HOOD SUBASSY
11. REMOVE RADIATOR SUPPORT OPENING COVER
12. REMOVE ENGINE ROOM COVER SIDE
13. REMOVE ENGINE COVER NO.1
14. REMOVE AIR CLEANER ASSY
15. REMOVE BATTERY CLAMP SUBASSY
16. REMOVE BATTERY
17. REMOVE BATTERY TRAY
18. REMOVE AIR TUBE NO.1 (See page 14286)
19. SEPARATE RADIATOR RESERVE TANK ASSY

(a) Remove the 2 bolts, separate the radiator reserve tank
assy.
D26902
20. REMOVE STARTER ASSY

(a) Remove the nut, disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter assy.
D26903

4134
21. DISCONNECT WIRE HARNESS

(a) Remove the bolt, disconnect the ground cable.
(b) Remove the bolt, separate the air tube.
D30815
22. DISCONNECT CONNECTOR

(a) Disconnect the backup lamp switch connector.
D26905
23. REMOVE CLUTCH ACCUMULATOR ASSY (See page 4222)

SST 0902300100
24. REMOVE CLUTCH RELEASE CYLINDER ASSY (See page 4217)
SST 0902300100
25. SEPARATE ACCUMULATOR TO FLEXIBLE HOSE

TUBE
(a) Remove the 3 bolts, separate the flexible hose tube with
brackets from the transaxle.
G24412

axle.
et.
G24413

SST 0952001010, 0952024010 (0952032040)
29. REMOVE HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 6528)
4135
30. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136)
SST 0902312700
31. DISCONNECT PRESSURE FEED TUBE ASSY (See page 5136)
SST 0902312700
Engine Hanger No.1 UPR 32. SUSPEND ENGINE ASSY

(a) Install the 2 engine hangers with the 2 bolts.
Parts No.:
No.1 engine hanger UPR (yellow) 1228427020
No.1 engine hanger UPR (black) 1228427030
No.1 engine hanger 1228127050
No.2 engine hanger (yellow) 1228227060
Engine Hanger No.2 No.2 engine hanger (black) 1228227070
Engine Hanger No.1 A79193 Bolt: 9164281025
(b) Attach the engine chain hoist to the hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
33. REMOVE FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626)
34. SUPPORT MANUAL TRANSAXLE ASSY
(a) Support the transaxle with a transmission jack.

MOUNTING INSULATOR
(a) Remove the 5 bolts, nut and engine mounting insulator
LH from the body.
D30072

MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from
the transaxle.
D30073

4136
37. REMOVE MANUAL TRANSAXLE ASSY

(a) Remove the 8 bolts.
(b) Remove the transaxle from the engine.
D26918
38. REMOVE MANUAL TRANSMISSION CASE

PROTECTOR
(a) Remove the 2 bolts and case protector.
D30076

MOUNTING BRACKET
(a) Remove the bolt, nut and engine mounting insulator FR
from the engine mounting bracket.
(b) Remove the 2 bolts and engine mounting bracket FR from
the transaxle.
D30074

MOUNTING BRACKET
(a) Remove the bolt and engine mounting insulator RR from
(b) Remove the 3 bolts and engine mounting bracket RR
from the transaxle.
D30075

(b)
BRACKET
(a) (a) Install the engine mounting bracket RR and 3 bolts to the
transaxle.
(a)
(a) (b) Install the engine mounting insulator RR and bolt to the
engine mounting bracket.
D30075

4137

(a) BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
(a) transaxle.
(b) Install the engine mounting insulator FR, bolt and nut to
(b)
(b)
D30074
43. INSTALL MANUAL TRANSMISSION CASE

PROTECTOR
(a) Install the case protector with the 2 bolts.
D30076
44. INSTALL MANUAL TRANSAXLE ASSY

A
(a) Align the input shaft with the clutch disc and install the
transaxle to the engine.
(b) Install the 8 bolts.
Torque:
B Bolt A: 64 Nm (653 kgfcm, 47 ftlbf)
D
C Bolt B: 46 Nm (469 kgfcm, 34 ftlbf)
E D26918 Bolt D: 20 Nm (200 kgfcm, 14 ftlbf)
Bolt E: 8.0 Nm (82 kgfcm, 71 in.lbf)
BRACKET
(a) Install the engine mounting bracket LH to the transaxle
with the 3 bolts.
D30073
A A 46. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING

A INSULATOR
(a) Install the engine mounting insulator LH with the 5 bolts
and nut.
A Torque:
B
A D30072

4138
47. INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSY (See page 2626)

SST 0967000010
48. CONNECT PRESSURE FEED TUBE ASSY (See page 5136)
SST 0902312700
49. CONNECT STEERING GEAR OUTLET RETURN TUBE (See page 5136)
SST 0902312700
50. INSTALL HEIGHT CONTROL SENSOR SUBASSY FR RH (W/ DISCHARGE HEAD LAMP)
(See page 6528)
53. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Connect the 2 cable ends, install the 2 clips.
(b) Install the 2 clips to the control cable bracket.
G24413
54. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE

(a) Install the flexible hose tube with the 3 bolts.
A Torque:
B
Bolt B: 5.0 Nm (51 kgfcm, 44 in.lbf)
Bolt C: 9.0 Nm (92 kgfcm, 80 in.lbf)
G24412
55. INSTALL CLUTCH RELEASE CYLINDER ASSY (See page 4217)

SST 0902300100
56. INSTALL CLUTCH ACCUMULATOR ASSY (See page 4222)
SST 0902300100
57. CONNECT CONNECTOR

(a) Connect the backup lamp switch connector.
D26905

4139
58. CONNECT WIRE HARNESS

(a) Install the ground cable with bolt.
(b)
(b) Install the air tube with bolt.
D30815
59. INSTALL STARTER ASSY

(a) Connect the starter connector.
(b) Install the starter assy to the transaxle with the 2 bolts.
(c) Install the starter wire to starter assy with the nut.
D26903
60. CONNECT RADIATOR RESERVE TANK ASSY

(a) Install the radiator reserve tank assy with the 2 bolts.
D26902
61. INSTALL AIR TUBE NO.1 (See page 14286)

62. INSTALL BATTERY TRAY
63. INSTALL BATTERY
64. INSTALL BATTERY CLAMP SUBASSY
Torque:
Bolt: 5.0 Nm (51 kgfcm, 44 in.lbf)
Nut: 3.5 Nm (36 kgfcm, 31 in.lbf)
65. INSTALL AIR CLEANER ASSY
66. INSTALL ENGINE COVER NO.1
67. INSTALL STEERING INTERMEDIATE SHAFT (See page 509)
68. INSTALL STEERING COLUMN HOLE COVER SUBASSY NO.1 (See page 509)
69. INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 509)
70. INSTALL COLUMN HOLE COVER SILENCER SHEET (See page 509)
71. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
72. STEERING WHEEL CENTER POINT
73. INSTALL ENGINE ROOM COVER SIDE
74. INSTALL RADIATOR SUPPORT OPENING COVER

4140
75. INSTALL HOOD SUBASSY

76. INSPECT HOOD SUBASSY (See page 752)
77. ADJUST HOOD SUBASSY (See page 752)
78. ADD TRANSAXLE OIL (See page 415)
79. INSPECT TRANSAXLE OIL (See page 412)
80. ADD POWER STEERING FLUID
81. BLEED POWER STEERING FLUID (See page 514)
82. CHECK POWER STEERING FULUID LEVEL IN RESERVER (See page 514)
83. INSPECT FLUID LEAK (See page 514)
86. INSTALL ENGINE UNDER COVER RH
87. INSTALL ENGINE UNDER COVER LH
89. HEADLIGHT AIM ONLY (W/ DISCHARGE HEAD LAMP) (See page 6519)

4113
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZFE/3ZZFE)
MANUAL TRANSAXLE ASSY (1ZZFE/3ZZFE)

410DS01
COMPONENTS
Air Cleaner Assy
13 (133, 10)
Hood Subassy
Battery Clamp Subassy
5.0 (51, 44 in.lbf)

Radiator Support Opening Cover 5.0 (51, 44 in.lbf)
13 (131, 9)
Battery
Clip
Battery Tray
Clip
Battery Carrier
Charcoal Canister Assy Clip
26 (260, 19) Clip
7.0 (71, 62 in.lbf)
Clip
Cylinder Head Cover No.2
Backup Lamp
23 (230, 17) SwitchConnector
Transmission Control Cable Assy
Starter Connector
Starter Assy 19 (195, 14)
47 (479, 35)
23 (230, 17)
64 (653, 47) Transverse Engine

37 (380, 27) 52 (530, 38)
13 (130, 9) 52 (530, 38)
37 (380, 27)
40 (410, 30)
Filler Plug
39 (400, 29)
Manual Transaxle Assy 64 (653, 47)
Gasket
26 (260, 19) Ground Cable 80 (816, 59)
14 (141, 10)
64 (653, 47)
25 (255, 18)
5.0 (51, 44 in.lbf)
Transverse Engine
Clutch Release Cylinder Assy Engine Mounting Bracket

4114
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE ASSY (1ZZFE/3ZZFE)
Snap Ring
Front Drive
Snap Ring
64 (653, 47)
Transverse Engine
Transverse Engine Engine Mounting Insulator
87 (887, 64)
Transverse Engine 74 (755, 55)
52 (530, 38)
Cotter Pin 35 (360, 26)
74 (755, 55)
Cotter Pin
64 (653, 47) 49 (500, 36) 8.0 (82, 71 in.lbf)
49 (500, 36)
89 (908, 66)
29 (296, 21)
45 (459, 33) 52 (530, 38) 216 (2,203, 159)
89 (908, 66)
133 (1,356, 83) 133 (1,356, 83)


412
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE OIL (MTM)
MANUAL TRANSAXLE OIL (MTM)

4100Z05
ONVEHICLE INSPECTION
1. INSPECT TRANSAXLE OIL

(a) Stop the vehicle on the level place.
(b) Remove the transmission filler plug and gasket.
(c) Check that the oil surface is within 5 mm (0.20 in.) from the
lowest position of the inner surface of the transmission fill-
er plug opening.
NOTICE:
0 to 5 mm
Excessively large or small amount of oil may cause
(0 to 0.20 in.)
D25304 troubles.
After replacing oil, drive the vehicle and check the oil
level.
(d) Check for oil leakage when the oil level is low.
(e) Install the transmission filler plug and new gasket.
Torque:
C50, C250: 39 Nm (400 kgfcm, 29 ftlbf)
E354, E357: 49 Nm (500 kgfcm, 36 ftlbf)

411
MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSAXLE SYSTEM (MTM)
MANUAL TRANSAXLE SYSTEM (MTM)

4100Y05
PROBLEM SYMPTOMS TABLE

Use the table below to help find the cause of the problem. The numbers indicate the likelihood of the possible
cause in descending order. Check each part in the order shown. Replace these parts as necessary.
: (C50 MANUAL TRANSAXLE Repair Manual Pub. No. 826E or C250 MANUAL TRANSAXLE Repair
Manual Pub. No. RM1020E or E354 MANUAL TRANSAXLE Repair Manual Pub. No. RM944E)
Symptom Suspect Area See page
6. Oil (Level low) 412
7. Oil (Wrong) C50/C250 413
Noise E354/E357 415
8. Gear (Worn or damaged)
9. Bearing (Worn or damaged)
1. Oil (Level too high) 412
2. Gasket (Damaged)
Oil leakage 3. Oil seal (Worn or damaged) C50/ C250 413
E354/E357 415
4. ORing (Worn or damaged)
1. Control cable (Faulty) 417
Hard to shift or will not shift 2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
Jumps out of gear
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)

417
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
TRANSMISSION CONTROL CABLE ASSY (MTM)

4105R02
REPLACEMENT
HINT:
COMPONENTS: See page 4110
1. REMOVE AIR CONDITIONER UNIT ASSY (See page 5555)
HINT:
Refer to the instructions for removal of the instrument panel subassy lower.
2. REMOVE EXHAUST PIPE ASSY
(a) 1ZZFE, 3ZZFE Engine (See page 152)
(b) 1AZFE, 1AZFSE Engine (See page 157)
(c) 1CDFTV Engine (See page 1510)
3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Remove the 3 nuts and heat insulator No.1.
4. REMOVE TRANSMISSION CONTROL CABLE ASSY

1ZZFE, 3ZZFE:
axle.
et.
1AZFE, 1AZFSE, 1CDFTV:
D30060
(c) Remove the 2 nuts, separate the control cable assy.
D30070

418
(d) Remove the 2 bolts, separate the control cable assy.
D30071
(e) Remove the 2 clips, separate the cable ends of the control
cable assy.
D26893
(f) Release the claws, remove the control cable assy.
D26895
5. INSTALL TRANSMISSION CONTROL CABLE ASSY

(a) Put the control cable assy through the floor hole.
(b) Install the control cable assy with the 2 bolts.
D30071
(c) Connect the control cable assy to the shift lever assy.
NOTICE:
Make sure that the claws are firmly engaged.
D26972

419
Serrate Part (d) Connect the end of the select cable to the shift lever assy
and install the clip.
NOTICE:
The serrate part of the select cable point should face
upward when the select cable point is connected.
The clip should be inserted to the direction as shown
in the illustration.
(e) Connect the end of the shift cable to the shift lever assy.
D26894
(f) Connect the control cable assy with the 2 nuts.

D30070
(g) Connect the 2 cable ends, install the 2 clips.

1ZZFE, 3ZZFE:
(h) Install the 2 clips to the control cable bracket.
1AZFE, 1AZFSE, 1CDFTV:
D30060
6. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)

(a) Install the heat insulator No.1 with the 3 nuts.
7. INSTALL EXHAUST PIPE ASSY
(a) 1ZZFE, 3ZZFE Engine (See page 152)
(b) 1AZFE, 1AZFSE Engine (See page 157)
(c) 1CDFTV Engine (See page 1510)

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4110

MANUAL TRANSMISSION/TRANSAXLE FLOOR SHIFT SHIFT LEVER ASSY (MTM)

FLOOR SHIFT SHIFT LEVER ASSY (MTM)

5.5 (56, 49 in.lbf)

Console Panel Subassy Lower

Console Box Subassy Rear

Transmission Control Cable Assy

5.0 (51, 44 in.lbf) 12 (122, 9)

Floor Shift Shift Lever Assy

AVENSIS REPAIR MANUAL (RM1018E)

5. SEPARATE TRANSMISSION CONTROL CABLE ASSY

(b) Release the claws, separate the control cable assy.

6. REMOVE FLOOR SHIFT SHIFT LEVER ASSY

7. INSTALL FLOOR SHIFT SHIFT LEVER ASSY

AVENSIS REPAIR MANUAL (RM1018E)

8. CONNECT TRANSMISSION CONTROL CABLE ASSY

AVENSIS REPAIR MANUAL (RM1018E)

FRONT DIFFERENTIAL OIL SEAL (C50/C250)

7. REMOVE TRANSAXLE CASE OIL SEAL

8. REMOVE TRANSMISSION CASE OIL SEAL

9. INSTALL TRANSAXLE CASE OIL SEAL

AVENSIS REPAIR MANUAL (RM1018E)

10. INSTALL TRANSMISSION CASE OIL SEAL

11. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 306)

14. ADD MANUAL TRANSAXLE OIL

15. INSPECT MANUAL TRANSAXLE OIL (See page 412)

AVENSIS REPAIR MANUAL (RM1018E)

FRONT DIFFERENTIAL OIL SEAL (E354/E357)

7. REMOVE FRONT TRANSAXLE CASE COVER OIL

8. REMOVE TRANSMISSION CASE OIL SEAL

9. INSTALL FRONT TRANSAXLE CASE COVER OIL

AVENSIS REPAIR MANUAL (RM1018E)

10. INSTALL TRANSMISSION CASE OIL SEAL

11. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 306)

14. ADD MANUAL TRANSAXLE OIL

15. INSPECT MANUAL TRANSAXLE OIL (See page 412)

AVENSIS REPAIR MANUAL (RM1018E)

MANUAL TRANSAXLE ASSY (1AZFE/1AZFSE)

Battery Clamp Subassy

5.0 (51, 44 in.lbf)

Engine Cover Subassy No.1 Transmission Control Cable Assy

AVENSIS REPAIR MANUAL (RM1018E)

Front Drive Shaft Assy RH

Transverse Engine 29 (296, 21)

133 (1,356, 83)

Engine Under Cover LH

Engine Under Cover RH

Nm (kgfcm, ftlbf) : Specified torque

AVENSIS REPAIR MANUAL (RM1018E)

18. REMOVE BATTERY CARRIER

19. REMOVE STARTER ASSY (See page 1912)

20. SEPARATE WIRE HARNESS

AVENSIS REPAIR MANUAL (RM1018E)

21. SEPARATE CONNECTOR

22. SEPARATE CLUTCH RELEASE CYLINDER ASSY

23. SEPARATE TRANSMISSION CONTROL CABLE ASSY

24. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 306)

AVENSIS REPAIR MANUAL (RM1018E)

33. REMOVE TRANSVERSE ENGINE ENGINE

34. REMOVE MANUAL TRANSAXLE ASSY

AVENSIS REPAIR MANUAL (RM1018E)

35. REMOVE MANUAL TRANSMISSION CASE