TOYOTA AVENSIS 2005 Service Repair Manual

C67907
C67910
C67910
C67907
C67908
40±68
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
5. REMOVE AUTOMATIC TRANSMISSION 3WAY
SOLENOID ASSY
[ 35240 / 3512 ]
(a) Remove the bolt, and pull out the automatic transmission
3 way solenoid assy.
6. REMOVE MANUAL VALVE
[ 35418 / 3512 ]
(a) Remove the manual valve from the valve body assy.
7. INSTALL MANUAL VALVE
[ 35418 / 3512 ]
(a) Coat the manual valve with ATF and install it to the valve
body assy.
8. INSTALL AUTOMATIC TRANSMISSION 3WAY
SOLENOID ASSY
[ 35240 / 3512 ]
(a) Install the automatic transmission 3 way solenoid assy
with the bolt.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
9. INSTALL TRANSMISSION 3WAY SOLENOID ASSY
NO.2
[ 35230 / 3512 ]
(a) Install the transmission 3 way solenoid assy No. 2 with the
bolt.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)

C82123
C67904
C67905
D25170
A
C
BA
A DB



C62687
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U34#E Series)
40±69
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL LOCK UP CONTROL SOLENOID ASSY
[ 35280 / 3512 ]
(a) Install the lock up control solenoid assy with the bolt.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
11. INSTALL TRANSMISSION 3WAY SOLENOID ASSY
NO.3
[ 35250A / 3512 ]
(a) Install the transmission 3 way solenoid assy No. 3 with the
bolt.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
12. INSTALL LINE PRESSURE CONTROL SOLENOID
ASSY
[ 35290A / 3512 ]
(a) Install the line pressure control solenoid assy with the
bolt.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
13. TIGHTEN BOLT
(a) Install the valve body assembly and 13 bolts.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
Bolt length:
Bolt A: 32 mm (1.26 in.)
Bolt B: 22 mm (0.87 in.)
Bolt C: 55 mm (2.17 in.)
Bolt D: 45 mm (1.77 in.)
(b) Install the detente spring, detente spring cover and 2
bolts.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
Bolt length:
Bolt A: 14 mm (0.55 in.)
Bolt B: 45 mm (1.77 in.)
(c) Check that the manual valve lever is touching the center
of the detente spring tip roller.


 


C67914
C67911
40±70
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
(d) Fasten the upper valve body with 9 bolts.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
(e) Fasten the valve body cover lower with 14 bolts.
Torque:
8 mm bolt: 6.6 N
m (67 kgf
cm, 58 in.
lbf)
10 mm bolt: 11 N
m (110 kgf
cm, 8 ft
lbf)
(f) Fasten the solenoid with 5 bolts.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)

4002L±01
C67881
D08358
C59838
C67883
40±64
± AUTOMATIC TRANSMISSION / TRANSTRANSAXLE REAR COVER ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
TRANSAXLE REAR COVER ASSY (U34#E Series)
OVERHAUL
1. REMOVE TRANSAXLE REAR COVER PLUG
[ 35102B / 3503 ]
(a) Remove the 4 transaxle rear cover plug from the trans-
axle rear cover.
(b) Using a screwdriver, remove the O±ring from the trans-
axle rear cover plug.
2. REMOVE OVERDRIVE BRAKE RETURN SPRING
SUB±ASSY
[ 34603B / 3509 ]
(a) Using SST, a press and a screwdriver, remove the snap
ring.
SST 09387±00070
NOTICE:
Stop the press when the O/D brake piston is lowered 1 ± 2
mm (0.039 ± 0.078 in.) from the snap ring groove, prevent-
ing the O/D brake piston from being deformed.
(b) Remove the O/D brake return spring.
3. INSPECT OVERDRIVE BRAKE RETURN SPRING
SUB±ASSY
[ 34603B / 3509 ]
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.88mm (0.7039 in.)
4. REMOVE 2ND COAST & OVERDRIVE BRAKE PISTON
[ 34622B / 3509 ]
(a) Apply compressed air (392 kPa, 4.0 kgf
cm
2, 57 psi) to the
transaxle rear cover to remove the O/D brake piston.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, holding it with your hand
using a waste cloth.

Take care not to splash ATF when air±blowing.

C67884
C67885
HoldTurn
SST
C82194



C67888
D25116
A
± AUTOMATIC TRANSMISSION / TRANSTRANSAXLE REAR COVER ASSY (U34#E Series)
40±65
U340E A/T REPAIR MANUAL (RM824E)
5. REMOVE 2ND COAST & OVERDRIVE O±RING
[ 34622C / 3509 ]
(a) Using a screwdriver, remove the 2 O±ring from the 2nd
coast & O/D brake piston.
6. REMOVE CLUTCH DRUM OIL SEAL RING
[ 35617G / 3507 ]
(a) Remove the 3 oil seals.
7. REMOVE TRANSAXLE REAR COVER NEEDLE
ROLLER BEARING
[ 35102D / 3503 ]
(a) Using SST, remove the bearing.
SST 09387±00040 (09387±01020)
8. INSTALL TRANSAXLE REAR COVER NEEDLE
ROLLER BEARING
[ 35102D / 3503 ]
(a) Using SST and a press, install the new bearing to the
transaxle rear cover.
SST 09950±60010 (09951±00190, 09952±06010),
09950±70010 (09951±07100)
Standard clearance: 25.2 mm (0.992 in.)
9. INSTALL CLUTCH DRUM OIL SEAL RING
[ 35617G / 3507 ]
(a) Compress the oil seal ring from both sides to reduce di-
mension A.
Dimension A: 5.0 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the transaxle
rear cover.

C67884
C67889
D08358
C67881
40±66
± AUTOMATIC TRANSMISSION / TRANSTRANSAXLE REAR COVER ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL 2ND COAST & OVERDRIVE O±RING
[ 34622C / 3509 ]
(a) Coat the 2 new O±rings with ATF, install them to the trans-
axle rear cover.
NOTICE:
Be careful not to damage the oil seal lip.
11. INSTALL 2ND COAST & OVERDRIVE BRAKE PISTON
[ 34622B / 3509 ]
(a) Coat the piston with ATF, install it to the transaxle rear cov-
er.
NOTICE:
Be careful not to damage the oil seal lip.
12. INSTALL OVERDRIVE BRAKE RETURN SPRING
SUB±ASSY
[ 34603B / 3509 ]
(a) Using SST and a press, install the O/D brake return spring
and snap ring to the transaxle rear cover.
SST 09387±00070
NOTICE:
Stop the press when the O/D brake piston is lowered 1 ± 2
mm (0.039 ± 0.078 in.) from the snap ring groove, prevent-
ing the O/D brake piston from being deformed.
13. INSTALL TRANSAXLE REAR COVER PLUG
[ 35102B / 3503 ]
(a) Install 4 new O±rings and the 4 screw plugs to the trans-
axle rear cover.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
NOTICE:
Be careful not to damage the oil seal lip.

4002K±01
C67867
C67868
C67869
C67870
40±58
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
INTERMEDIATE SHAFT ASSY (U34#E Series)
OVERHAUL
1. REMOVE FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 2 discs and 2 plates.
2. INSPECT FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed mark is defaced, replace
all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
3. REMOVE DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Using a screwdriver, remove the snap ring.
(b) Remove the 3 plates, flange and 3 discs.
4. INSPECT DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.




C67871
C67872
C67873
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±59
U340E A/T REPAIR MANUAL (RM824E)
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed mark is defaced, replace
all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
5. REMOVE DIRECT CLUTCH RETURN SPRING
SUB±ASSY
[ 35604 / 3507 ]
(a) Using SST and a press, remove the snap ring and direct
clutch return spring from the intermediate shaft.
SST 09387±00020
6. INSPECT DIRECT CLUTCH RETURN SPRING
SUB±ASSY
[ 35604 / 3507 ]
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 32.9 mm (1.2953 in.)
7. REMOVE DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Install the direct and reverse clutch on the transaxle rear
cover.
(b) Apply compressed air (392kPa, 4.0 kgf
cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch drum and
direct clutch piston.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing
HINT:
When the piston can not be removed as it is slanted, either blow
the air again with the protruding side pushed or removed the
piston using a needle nose pliers with vinyl tape on the tip.

C68212
D25110
C68213
C67875
C67876
40±60
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
8. INSPECT DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
9. REMOVE DIRECT CLUTCH DRUM SUB±ASSY
[ 35605A / 3507 ]
(a) Put a match±mark on the direct clutch drum at the same
position with the cutout of the intermediate shaft assy.
(b) Apply compressed air into the oil hole shown in the il-
lustration and remove the direct clutch drum from the in-
termediate shaft.
10. INSPECT INTERMEDIATE SHAFT SUB±ASSY
[ 35708G / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
11. REMOVE DIRECT CLUTCH PISTON O±RING
[ 35606C / 3507 ]
(a) Using a screwdriver, remove the 2 O±rings.
12. REMOVE DIRECT CLUTCH DRUM O±RING
[ 35605D / 3507 ]
(a) Using a screwdriver, remove the O±ring.

C67876
C67875
D25111
C68200





C67871
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±61
U340E A/T REPAIR MANUAL (RM824E)
13. INSTALL DIRECT CLUTCH DRUM O±RING
[ 35605D / 3507 ]
(a) Coat the O±ring with ATF, install it to the direct clutch
drum.
NOTICE:
Be careful not to damage the O±ring.
14. INSTALL DIRECT CLUTCH PISTON O±RING
[ 35606C / 3507 ]
(a) Coat the 2 O±rings with ATF, install them to the direct
clutch piston.
NOTICE:
Be careful not to damage the O±ring.
15. INSTALL DIRECT CLUTCH DRUM SUB±ASSY
[ 35605A / 3507 ]
(a) Coat the direct clutch drum with ATF.
(b) Aligning the cutout in the intermediate shaft assy with the
match±mark on the direct clutch drum, install the direct
clutch drum to the intermediate shaft assy.
NOTICE:
Be careful not to damage the O±ring and clutch drum's lip.
16. INSTALL DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Coat the direct clutch piston with ATF, install it to the inter-
mediate shaft.
NOTICE:

Do not damage the O±ring the direct clutch piston's.
17. INSTALL DIRECT CLUTCH RETURN SPRING
SUB±ASSY
[ 35604 / 3507 ]
(a) Install the direct clutch return spring on the direct clutch
piston.
(b) Place SST on the piston return spring and compress the
springs with a press.
SST 09387±00020
(c) Using a snap ring expander , install the snap ring from the
direct clutch drum.