TOYOTA AVENSIS 2005 Service Repair Manual

D25112
Disc
Flange
Plate
D25113
Disc
Flange
Plate
D25114
40±62
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
groove, preventing the spring sheet from the deform-
ing.

Do not expand the snap ring excessively.
18. INSTALL DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Coat the 3 plates, 3 discs and flange with ATF, install them
to the intermediate shaft.
(b) Install the snap ring.
19. INSTALL FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Install the 2 plates, 2 discs and a flange.
(b) Install the snap ring.
20. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the forward and reverse clutch and thrust needle
roller bearing on the transaxle rear cover.
(b) Using a dial indicator, measure the reverse clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf
cm
2, 57 psi)
Pack clearance:
0.86 ± 1.26 mm (0.0339 ± 0.0496 in.)
If the pack clearance is less than the limit of pack clearance,
parts may have been assembled incorrectly, so check and reas-
semble again.
If the pack clearance is non±standard, select another flange.
HINT:
There are 4 flanges in different thickness.
Flange Thickness: mm (in.)
No.ThicknessNo.Thickness
±3.0 (0.118)23.4 (0.134)
13.2 (0.126)33.6 (0.142)

D25115
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±63
U340E A/T REPAIR MANUAL (RM824E)
21. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct and reverse clutch and thrust needle roll-
er bearing on the transaxle rear cover.
(b) Using a dial indicator and measuring terminal (SST),
measure the forward clutch pack clearance while apply-
ing and releasing compressed air (392 kPa, 4.0 kgf
cm
2,
57 psi)
SST 09350±36010 (09350±06110)
HINT:
The direct and reverse clutch will come out as you apply the
compressed air. Therefore, while the checking is being done,
press on the input shaft of the direct and reverse clutch using
stamping machine or alike so that the pressure is not applied
on the direct and reverse clutch.
Pack clearance:
0.62 ± 1.02 mm (0.0244 ± 0.0402 in.)
If the pack clearance is less than the limit of pack clearance,
parts may have been assembled incorrectly, so check and reas-
semble again..
If the pack clearance is non±standard, select another flange.
HINT:
There are 4 flanges in different thickness.
Selected flange thickness: mm (in.)
No.ThicknessNo.Thickness
±3.0 (0.118)23.4 (0.134)
13.2 (0.126)33.6 (0.142)

9808Y±01
± COMPONENTS151350
98±11
4301/FRONT AXLE HOUSING & DIFFERENTIAL
(0008± )NZE121..ATM U340E

0103N±01
± INTRODUCTIONSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL01±11
U241E A/T REPAIR MANUAL (RM840U)
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHexagon flange boltmmmmN´mkgf´cmft´lbfN´mkgf´cmft´lbf
4T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 555
130
260
480
760
1,15048 in.´lbf
9
19
35
55
836
14
29
53
84
±60
145
290
540
850
±52 in.´lbf
10
21
39
61
±
5T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
14065
160
330
600
930
1,40056 in.´lbf
12
24
43
67
1017.5
17.5
36
65
100
±75
175
360
670
1,050
±65 in.´lbf
13
26
48
76
±
6T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
17080
195
400
730
1,100
1,75069 in.´lbf
14
29
53
80
1279
21
44
80
125
±90
210
440
810
1,250
±78 in.´lbf
15
32
59
90
±
7T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.510.5
25
52
95
145
23011 0
260
530
970
1,500
2,3008
19
38
70
108
16612
28
58
105
165
±120
290
590
1,050
1,700
±9
21
43
76
123
±
8T
8
10
121.25
1.25
1.2529
61
11 0300
620
1,10022
45
8033
68
120330
690
1,25024
50
90
9T
8
10
121.25
1.25
1.2534
70
125340
710
1,30025
51
9437
78
140380
790
1,45027
57
105
10T
8
10
121.25
1.25
1.2538
78
140390
800
1,45028
58
10542
88
155430
890
1,60031
64
11 6
11 T
8
10
121.25
1.25
1.2542
87
155430
890
1,60031
64
11 647
97
175480
990
1,80035
72
130

0103M±01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess BoltStud Bolt Weld BoltClass
4T
5T
6T
7T
8T
9T
10T
11 T
No Mark
w/ WasherNo MarkNo Mark
w/ Washer
01±10± INTRODUCTIONSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
U241E A/T REPAIR MANUAL (RM840U)
STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
HOW TO DETERMINE BOLT STRENGTH

4006V±01
C83194
C83195
C83196
C83197
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
40±97
U241E A/T REPAIR MANUAL (RM840U)
TRANSMISSION VALVE BODY ASSY (U241E)
OVERHAUL
1. REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Remove the bolt and line pressure control solenoid assy.
2. REMOVE SHIFT SOLENOID VALVE SL1
(a) Remove the bolt and shift solenoid valve SL1.
3. REMOVE SHIFT SOLENOID VALVE DSL
(a) Remove the bolt and shift solenoid valve DSL.
4. REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt and shift solenoid valve SL2.

C83198
C83198
C83197
C83196
40±98
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. REMOVE SHIFT SOLENOID VALVE S4
(a) Remove the bolt and shift solenoid valve S4.
6. REMOVE MANUAL VALVE
(a) Remove the manual valve from the valve body assy.
7. INSTALL MANUAL VALVE
(a) Coat the manual valve with ATF, install it to the valve body assy.
8. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the bolt and shift solenoid valve S4.
9. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the bolt and shift solenoid valve SL2.
10. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the bolt and shift solenoid valve DSL.

C83195
C83194
D03553
A C
B

C A
CA
B B

± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
40±99
U241E A/T REPAIR MANUAL (RM840U)
11. INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the bolt and shift solenoid valve SL1.
12. INSTALL LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Install the bolt and line pressure control solenoid assy.
13. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Align the groove of the manual valve with the pin of lever.
(b) Install the 17 bolts.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 41 mm (1.614 in.)
Bolt C: 45 mm (1.771 in.)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
Tighten those bolts marked by
in the illustration
first temporarily because they are positioning bolts.

4006U±01
D25594
SST
D03686
SST
D03687
D25609
SST 40±92
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
UNDERDRIVE PLANETARY GEAR ASSY (U241E)
OVERHAUL
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST a torque wrench, measure the turning torque
of U/D planetary gear assy while rotating the torque
wrench at 60 rpm.
SST 09387±00050, 09564±16020
Turning torque at 60 rpm:
0.23 ± 5.01 N
m (2 ± 51 kgf
cm, 2.0 ± 44.3 in.
lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2. REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using SST, loosen the staked part of the nut.
SST 09930±00010 (09931±00010, 09931±00020),
09387±00050
(b) Clamp the U/D planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(c) Using SST, remove lock nut.
SST 09564±16020

D03689
SST
SST
D03690
SST
D03691
SST SST
D03826
D03827
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR ASSY (U241E)
40±93
U241E A/T REPAIR MANUAL (RM840U)
(d) Using SST, remove cylindrical roller bearing inner race.
SST 09950±00020, 09950±00030, 09950±60010
(09951±00340)
3. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Using SST and press, remove the differential drive pinion,
parking lock gear, counter driven gear with U/D planetary
ring gear and front tapered roller bearing.
SST 09387±00050
(b) Clamp the U/D planetary gear in soft jaw vise.
(c) Using SST, remove rear tapered roller bearing form the
U/D planetary gear.
SST 09950±00020, 09950±00030, 09950±60010
(09951±00320)
4. REMOVE UNDERDRIVE PLANETARY RING GEAR
(a) Using a snap ring pliers, remove the snap ring.
(b) Remove the U/D planetary ring gear from the counter
driven gear.