TOYOTA AVENSIS 2005 Service Repair Manual

D03807
SST
D03630Seal Bend Width 1.2 mm (0.047 in.) FIPG
C50259
C
C
C
CA
AA B
BB
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U241E A/T REPAIR MANUAL (RM840U)
115. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST and a press, install the U/D cylindrical roller
bearing.
SST 09950±60020 (09951±00810), 09950±70010
(09951±07100)
NOTICE:
Do not apply excessive pressure to it.
116. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil
on the contacting surfaces of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or equiva-
lent
(c) Install the transaxle housing and 16 bolts to the transaxle
case.
Torque:
Bolt A: 22 N
m (226 kgf
cm, 16 ft
lbf)
Bolt B and C: 29 N
m (300 kgf
cm, 22 ft
lbf)
HINT:
Apply seal packing or equivalent to the bolt A.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to
new bolts and tighten them within 10 minutes after applica-
tion.
117. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install 2 new O±rings to the 2 transaxle case No. 1 plugs.
(b) Install the 2 transaxle case No. 1 plugs to the transaxle
housing.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

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U241E A/T REPAIR MANUAL (RM840U)
118. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
End play: 0.26 ± 1.25 mm (0.0103 ± 0.0492 in.)
119. FIX AUTOMATIC TRANSAXLE ASSY
120. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with ATF, install it to the transaxle
case.
(b) Install the oil seal to the transaxle case.
121. INSTALL PARKING LOCK ROD SUB±ASSY
(a) Install the parking lock rod to the manual valve lever.
122. INSTALL MANUAL VALVE LEVER SUB±ASSY
(a) Install a new spacer and manual valve lever shaft to the
transaxle case.

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U241E A/T REPAIR MANUAL (RM840U)
(b) Using a pin punch and a hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small hole
for locating the staking position in the spacer with the
staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small
hole.
(e) Check that the spacer does not turn.
123. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle±nose pliers, install the retainer spring.
124. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N
m (205 kgf
cm, 15 ft
lbf)
Bolt length: 25 mm (0.984 in.)
125. INSTALL MANUAL DETENT SPRING SUB±ASSY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring and cover in
this order.
Torque:
Bolt A: 20 N
m (205 kgf
cm, 15 ft
lbf)
Bolt B: 12 N
m (120 kgf
cm, 9 ft
lbf)

D03904
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U241E A/T REPAIR MANUAL (RM840U)
Bolt length:
Bolt A: 27 mm (1.063 in.)
Bolt B: 16 mm (0.630 in.)
126. INSTALL B±3 ACCUMULATOR PISTON
(a) Coat a new O±ring with ATF, install it to the B
3 accumula-
tor piston.
(b) Coat the accumulator B
3 piston and spring with ATF,
install them to the transaxle case.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
Inner 60.24 (2.3716) /
15.9 (0.626)Yellowish green
Outer 74.61 (2.9374) /
21.7 (0.854)Blue
127. INSTALL C±1 ACCUMULATOR PISTON
(a) Coat 2 new O±rings with ATF, install them to the C
1 accu-
mulator piston.
(b) Coat accumulator C
1 piston with ATF, install it to the trans-
axle case.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
81.53 (3.2098) /
18.5 (0.728)Pink

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U241E A/T REPAIR MANUAL (RM840U)
128. INSTALL C±3 ACCUMULATOR PISTON
(a) Coat a new O±ring with ATF, install it to the C
3 accumula-
tor piston.
(b) Coat the C
3 accumulator piston with ATF, install it to the
transaxle case.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
90.49 (3.5626) /
19.2 (0.756)White
(c) Install the compression spring from the C3 accumulator
piston.
129. INSTALL CHECK BALL BODY
(a) Install the check ball body and spring.
130. INSTALL TRANSMISSION WIRE
(a) Coat a new O±ring with ATF, install it to the transaxle sole-
noid wire.

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D03553
A
C
A
C

A
BB B

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U241E A/T REPAIR MANUAL (RM840U)
(b) Install the solenoid wire retaining bolt
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
131. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to the
transaxle case.
132. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF,
install it to the transaxle case.
133. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No. 1 with ATF, install
it to the transaxle case.
134. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the
valve body with 17 bolts to the transaxle case.
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.)

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U241E A/T REPAIR MANUAL (RM840U)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
When installing the valve body to the transaxle case,
do not hold the solenoids.
Tighten those bolts marked by
in the illustration
first temporarily because they are positioning bolts.
(b) Connect the 5 solenoid connectors.
(c) Install the ATF temperature sensor, clamp and bolt.
Torque: 6.6 N
m (67 kgf
cm, 58 in
lbf)
135. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O±ring with ATF, install it to the oil strainer.
(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
136. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET
(a) Install a new oil pan gasket to the oil pan.

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D03900
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U241E A/T REPAIR MANUAL (RM840U)
137. I N S TA L L A U TO M AT I C TRANSAXLE OIL PAN
SUB±ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install oil pan and 18 bolts to the transaxle case.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
NOTICE:
Because the bolts should be seal bolts, apply seal packing
to new bolts and tighten them within 10 minutes after ap-
plication.
138. INSTALL SPEED SENSOR(TMC ±MADE)
(a) Coat 2 new O±rings with ATF, install them to the 2 sen-
sors.
(b) Install the 2 sensors with the 2 bolts to the transaxle case.
Torque: 11.3 N
m (115 kgf
cm, 8 ft
lbf)
139. I N S TA L L TRANSMISSION REVOLUTION
SENSOR(AISIN ±MADE)
(a) Coat 2 new O±rings with ATF, install them to the 2 sen-
sors.
(b) Install the 2 sensors with the 2 bolts to the transaxle case.
Torque: 11.3 N
m (115 kgf
cm, 8 ft
lbf)
140. INSTALL OIL COOLER TUBE UNION
(a) Coat a new O±ring with ATF, install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 N
m (276 kgf
cm, 20 ft
lbf)

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U241E A/T REPAIR MANUAL (RM840U)
141. INSTALL OIL COOLER TUBE UNION
(a) Coat a new O±ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 27 N
m (280 kgf
cm, 20 ft
lbf)
142. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat 4 new O±rings with ATF, install them to the 4 trans-
axle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
143. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the breather No. 2 plug.
144. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch onto the manual
valve lever shaft and temporarily install the 2 adjusting
bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 N
m (70 kgf
cm, 61 in.
lbf)
(c) Temporarily install control shaft lever.

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U241E A/T REPAIR MANUAL (RM840U)
(d) Turn the lever counterclockwise until it stops, and then
turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
(h) Using a screwdriver, stake the nut with the nut stopper.
(i) Install the control shaft lever, washer and nut.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
145. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB±ASSY
(a) Coat the new O±ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub±assy to the transaxle assy.
Torque: 7.0 N
m (70 kgf
cm, 61 in.
lbf)