Avensis 2005 Zzt250 Gearbox Fix.

[Fred6370]

First of all, I`m norwegian, so my language might not be to good, but hopefully you will understand what I mean.

And if anyone has posted something like this before, sorry!

The story:

A few weeks ago a friend and I took a roadtrip to by a car.

Long story short, the car was looking good, and the price was right.

It had only one problem. Bearing sound frome gearbox. Increases with speed, in every gear.

In my time as a mechanic, i have overhauled many gearboxes with this sound, and it is always expensive.

Changing every bearing that are worn and controllmeasuring everything...

My experince tells me that there is only one bearing who is the main problem, and I have been thinking of a way to do a quick fix....

I guess this is not anything a workshop will do for you, because of guarantee, and my garage is probably above average equipped, but as you will se, there is not much tools more than regular garage tools needed.

This post is translated frome a Norwegian forum, but hopefylly you will understand!

Car into my garage

Lift it up.

Using two sets of support, I have had a car that fell down once...

Wheel off, plasic off, dismantle end cover on gearbox

This is what you will find

10mm screw holding the gearshifter

This one...

Snap ring off.

Two flat screwdrivers and a hammer fix this

Tool to get the syncrone ring off.

There is also a snap ring inside here that have to be removed to get the tool to fit.

There you have the driving 5 gear and a needle bearing.

Put everything in correct order and have a system.

I do not have a system here, but i know where everything should be put toghether.

Air tool to get the nut off. Yes it is ugly, but it works!

Tool to get the driven fifth gear off.

Next cover off

Snap ring on the bearing that I am going to replace.

Remove it.

Using a tool with modified "feet" I could get it in the groove for the snap ring.

Using another tool holding the feet together so that it does not slip out.

Great success!

There`s youre problem

New bearing

Tap it in place

Mount snap ring on bearing

Cover first

Then fifth driven gear

Air tool again

In with fifth driving gear. On needle bearing, so that is easy

So.

Here you have to be careful

The ring in the back of syncronizing has to be hold in place while you tap it.

If not it will slip halfway out and get stucked/ destroyed

Snap ring on

Mount gear shifter

Sealant

Mount cover

Fill gear oil

Test drive and smile!!

Took me about three hours, and I took a lot of pictures during.

/Fred

[avensisd4d786]

wow great guide this should be pinned,a great credit to the forum.

[Exvec]

Great post this,would be beyond me though great pics.