TOYOTA AVENSIS 2005 Service Repair Manual

C50943
D25597
SST
SST HoldTurn
D25598
SST
C50193
C50230
Differential
RH Case
Differential
Intermediate Case
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−117
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Remove 4 front differential pinions, 4 front differential pin-
ion thrust washers, front differential pinion shaft holder,
front differential planetary ring gear and differential side
gear thrust washer No.1.
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00480)
(b) Using SST, remove the front differential case rear tapered
roller bearing outer race and differential case washer.
SST 09308−00010
4. REMOVE CENTER DIFFERENTIAL PINION
(a) Using torx socket (T50), remove the15 bolts.
(b) Place the matchmarks on the differential intermediate
case and differential case.
(c) Remove the differential intermediate case from the differ-
ential case RH.

C50196
Differential Case RH
Center Differential
Side Gear
C50194
D25611
SSTSST Hold
Turn
D25596
SST
D25599
SST
40−118
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the center differential side gear, conical spring
washer and center differential side gear thrust washer No.
1RH from the differential case RH.
(e) Remove the differential spider, 5 center differential pin-
ions and 5 center differential pinion thrust washers from
the differential intermediate case.
5. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front ta-
pered roller bearing from the differential case.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00600)
(b) Using SST, remove the front differential case front ta-
pered roller bearing outer race and differential case wash-
er.
SST 09308−00010
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950−70010 (09951−07100), 09649−17010

D25600
SST
C50943
C50216
C50213
Differential
Case LH
Differential
Case No.2
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−119
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950−70010 (09951−07100), 09608−10010
8. INSTALL DIFFERENTIAL CASE SUB−ASSY NO.2
(a) Coat the front differential side gear thrust washer No.1,
front differential planetary ring gear, front differential pin-
ion No.2, front differential pinion thrust washer No.2, front
differential pinion shaft holder, front differential pinion
shaft and 2 differential pinion shafts with ATF, install them
to the differential case No.2.
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
(c) Engage the front differential side gear to the above men-
tioned front differential case.
(d) Install the differential case LH to the front differential case
and measure its center.
(e) After that, remove the differential case LH.

C50214
C50217
D25610
C51252
Differential Case RH
Center Differential
Side Gear
40−120
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(f) Using a straight edge and feeler gauge, measure the
clearance between the front differential case and the front
differential side gear.
t= Thrust washer thickness
L= Clearance
t= L−0.162−0.265 mm (0.0064−0.0104 in.)
If the clearance is not within the specified value, refer to the
table below and select a thrust washer which will ensure that the
clearance is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
If the clearance is not within the specified value, parts may have
been assembled incorrectly, so check and reassemble it.
(g) Using a pin punch and a hammer, install 3 straight pins.
(h) Using a snap ring expander, install the pinion shaft spacer
snap ring.
9. INSTALL CTR DIFFERENTIAL PLANETARY GEAR
ASSY
(a) Install the center differential side gear, conical spring
washer and center differential side gear thrust washer
No.2 RH from the differential case RH.
HINT:
Ensure that the conical washers is installed correctly.

C50950
C50205
C50206
C50207
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−121
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Hold the differential case RH by vice. Install the center dif-
ferential pinion and pinion thrust washer to the differential
spider and install them to the differential case RH.
NOTICE:
When holding the differential case RH by vise, be sure to
place an aluminum sheet between them and use a mini-
mum force.
(c) Pressing and holding the differential spider toward the dif-
ferential case RH, measure the pinion’s backlash with a
dial indicator as illustrated.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
MA0.80 (0.0313)MH1.15 (0.0453)
MB0.85 (0.0333)MJ1.20 (0.0472)
MC0.90 (0.0353)MK1.25 (0.0492)
MD0.95 (0.0373)ML1.30 (0.0512)
ME1.00 (0.0393)MM1.35 (0.0532)
MF1.05 (0.0413)MN1.40 (0.0552)
MG1.10 (0.0433)−−
(d) Temporarily install the differential side gear thrust washer
No.2 LH, center differential side gear conical spring wash-
er and differential case No.2 to the differential case LH.
HINT:
Ensure that the conical washers is installed correctly.
(e) Install the differential intermediate case to the above and
fix them with 4 bolts.

C50208
C50209
C50210
C51468
Differential
Case No.2
Differential
Case LH
40−122
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(f) Remove the differential spider, 5 center differential pin-
ions and 5 center differential pinion thrust washers from
the differential case RH. Put them in the differential inter-
mediate case and fix the case.
(g) Pressing and holding the differential spider toward the dif-
ferential intermediate case, measure the pinion’s back-
lash with a dial indicator.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
MA0.80 (0.0313)MH1.15 (0.0453)
MB0.85 (0.0333)MJ1.20 (0.0472)
MC0.90 (0.0353)MK1.25 (0.0492)
MD0.95 (0.0373)ML1.30 (0.0512)
ME1.00 (0.0393)MM1.35 (0.0532)
MF1.05 (0.0413)MN1.40 (0.0552)
MG1.10 (0.0433)−−
(h) Remove the 4 bolts and disconnect the differential case
LH from the differential intermediate case.
(i) Remove the differential case No.2 from the differential
case LH.

C51469
C50188
Differential
Case No.2
Differential
Case LH
C50193
D25612
SST
D25603
SST
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−123
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(j) Install the selected differential side gear thrust washer
No. 2 LH and center differential planetary gear to the dif-
ferential case LH.
(k) Install the differential case No. 2 to the differential case LH
again.
(l) Install the adjusted differential case RH to the intermedi-
ate case and tighten the15 bolts using a torx socket
wrench (T50).
Torque: 63 N
m (642 kgf
cm, 46 ft
lbf)
NOTICE:
Align the matchmarks.
10. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing FR to the differential case.
SST 09950−70010 (09951−07100), 09649−17010
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Using SST, install the outer race of the tapered roller bear-
ing FR.
SST 09527−17011, 09950−60020 (09951−01030)
NOTICE:
Clearance is not allowed between the plate washer and
transaxle housing.

D25613
SST
D25601
SST
C50224
D03568
C
C
C
A
AB
C
40−124
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing RR to the differential case.
SST 09316−20011, 09214−76011
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Install the front differential case shim RR to the transaxle
case.
If the bearing is new, check to select a front differential case
shim RR of proper thickness starting from the thinner ones.
If the bearing is reused, check to select a front differential case
shim RR starting from the same thickness as one installed be-
fore disassembly.
(c) Using SST, install the outer race of the front differential
case tapered roller bearing RR.
SST 09950−60020 (09951−00890), 09950−70010
(09951−07100)
NOTICE:
Clearance is not allowed between the differential case
shim and transaxle case.
12. ADJUST TAPERED POLLER BEARING PRELOAD
(a) Install the intermediate case to the differential case LH
and fix them with 4 bolts.
(b) Install the differential assy to the transaxle case.
(c) Clean the matching surfaces of the transaxle case and
transaxle housing.
(d) Install the transaxle housing to the transaxle case and
tighten them with the16 bolts.
Torque:
Bolt A: 25 N
m (255 kgf
cm,18ft
lbf)
Bolt B 33 N
m (337 kgf
cm, 24 ft
lbf)
Bolt C 29 N
m (295 kgf
cm, 21ft
lbf)
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
HINT:
Usually, bolt A is a non−reusable bolt. In this case, however, it
can be used after cleaning it.

SST
C50227
D25614
C50224
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−125
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST, turn the differential assy right and left 2or 3
times to allow the bearing settle.
SST 09564−32011
(f) Using SST and a torque wrench, measure the turning
torque of the differential case assy.
SST 09564−32011
Turning torque at 60 rpm:
New bearing
0.20−0.69 N
m (2.0−7.0 kgf
cm,1.8−6.1in.
lbf)
Used bearing
0.10−0.35 N
m(1.0−3.6 kgf
cm, 0.9−3.1in.
lbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below and select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(g) Remove the16 bolts and the transaxle housing.
(h) Remove the differential assy.

D25215
90−100_C(194−230_F)
C50186
Match−marks
C50232
C50233
D25605
SST 40−126
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90−110_C. (194.0−230.0_F)
NOTICE:
Do not overheat the ring gear to110_C (230.0_F) or more.
(b) Clean the contact surface of the front differential case.
(c) Set the match−marks, install the front differential ring gear
case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.
(d) Temporarily install the 8 bolts as shown in the illustration.
(e) Remove the 4 bolts shown in the illustration.
(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95.1N
m (970 kgf
cm, 70 ft
lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
14. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09223−15020, 09950−70010 (09951−07100)
(b) Coat the rip of oil seal with a little MP grease.