lock TOYOTA AVENSIS 2005 Service Repair Manual

D03560
C56727
D03563
D03564
D03565
40−24
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
23. REMOVE MANUAL DETENT SPRING SUB−ASSY
(a) Remove the 2 bolts, the manual detent spring sub−assy
and cover.
24. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
25. REMOVE MANUAL VALVE LEVER SUB−ASSY
(a) Using a chisel and hammer, cut off and remove the
spacer.
(b) Using a pin punch (
35 mm) and hammer, drive out the
pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.
(c) Remove the manual valve lever shaft and manual valve
lever.

D26382
Parking Lock Rod Sub−assy
D03566
D08046Oil Pump Assy
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−25
U151E, U151F A/T REPAIR MANUAL (RM1021U)
26. REMOVE PARKING LOCK ROD SUB−ASSY
(a) Remove the parking lock rod from the manual valve lever.
27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the trans-
axle case.
28. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle case with the oil pump side facing up.
29. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft endplay.
Endplay: 0.262−1.244 mm (0.01−0.049 in.)

D03829
Dial Indicator
Forward Clutch Hub
D03576
Pawl Shaft Clamp
D09652
D09689
40−28
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
38. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Using a dial indicator, measure the inside diameter of the
forward clutch hub bushing
Standard inside diameter:
23.025−23.046 mm (0.9065−0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091in.)
NOTICE:
SWhen the diameter is over the maximum, replace the
multiple disc clutch hub with new one.
SCheck the contact surface of the bush in the direct
clutch shaft. If any scratch or discolor is identified, re-
place the direct clutch sub−assy with new one.
If the inside diameter is greater than the maximum, replace the
forward clutch hub.
39. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Remove the bolt and pawl shaft clamp.
(b) Remove the parking lock pawl shaft.
(c) Push the parking lock pawl.
HINT:
Failure to do so will cause interference when the underdrive
planetary gear is removed.

D03579
Underdrive
Planetary
Gear Assy
D26386
D03580
Thrust Bearing
Bearing Race
D03581Snap Ring
D03627
Underdrive
1−Wa y
Clutch
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−29
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the underdrive planetary gear assy from the
transaxle case.
NOTICE:
Be careful so that the underdrive planetary gear assy will
not fall out.
40. REMOVE PARKING LOCK PAWL
(a) Remove the spring, pawl pin and parking lock pawl.
41. REMOVE UNDERDRIVE CLUTCH ASSY
(a) Remove the underdrive clutch assy, thrust bearing and
bearing race from the transaxle case.
42. REMOVE UNDERDRIVE1WAY CLUTCH ASSY
(a) Using a screwdriver, remove the snap ring from the trans-
axle case.
(b) Remove the underdrive 1−way clutch from the transaxle
case.

D03595
Lock Washer
D03596
SST
D26398
SST
D26763
Front Planetary
Gear Assy
Brake Hub
D03615
Front Planetary Ring Gear
Brake Hub
Snap Ring
40−36
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
65. REMOVE FRONT PLANETARY GEAR ASSY
(a) Using a chisel and hammer, unstake the lock washer.
NOTICE:
Push down all claws of the washer. Otherwise SST cannot
be fully pressed against the nut, and cannot loosen the nut.
(b) Using SST, remove the nut.
SST 09387−00030, 09387−00080
(c) Using SST and a press, remove the front planetary gear
assy from the counter drive gear.
SST 09950−60010 (09951−00450), 09950−70010
(09951−07100)
(d) Remove the front planetary gear assy from the brake hub.
66. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front plan-
etary ring gear from the brake hub.

D03918
SST
D08074
Lock Washer
C89123
C
BA
Input Sun Gear
D
40−50
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST and a torque wrench, measure the turning
torque of the bearing while rotating SST at 60 rpm. When
the measured value is not within the specified value,
gradually tighten the nut until it reaches the specified val-
ue.
SST 09387−00080
Turning torque at 60 rpm:
New Bearing
0.51−1.02 Nm (5.1−10.0 kgfcm, 4.4−8.7 in.lbf)
Used Bearing
0.26−0.51Nm (2.7−5.2 kgfcm, 2.3−4.5 in.lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation
torque of tapered roller bearing is measured.
Torque: 350 Nm (3,569 kgfcm, 258 ftlbf) (a limit)
(g) Using a chisel and hammer, stake the front lock washer.
98. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
NOTICE:
SInstall the bearing race on the side of the front plane-
tary carrier. Be careful about the orientation of the
race.
SInstalling thrust bearing and front sun gears, be care-
ful about the orientation of the parts.
SInstall the bearing race on the side of the front sun
gear. Be careful about the orientation of the race.
SInstall the thrust bearing and the race after holding
the parts on the rear planetary carrier by applying
grease. Be sure the assembling order.

D03909
1−Way Clutch
Inner Race
D09638
Free
D03588
Thrust Needle
Roller Bearing
1−Way Clutch Assy
D26394
Planetary Carrier
Thrust Washer No.1
D26393
Planetary Carrier Thrust Washer No.2
Rear Planetary Sun Gear
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−53
U151E, U151F A/T REPAIR MANUAL (RM1021U)
104. INSTALL1WAY CLUTCH ASSY
(a) Install the 1−way clutch inner race to the 1−way clutch.
NOTICE:
SCheck the direction of the inner race.
SConfirm that the discrimination mark can be seen by
the worker.
(b) Check the rotating direction of 1−way clutch for the lock
or free operation, as shown in the illustration.
(c) Install the 1−way clutch and thrust needle roller bearing
to the 1−way clutch sleeve outer.
Bearing diameter: mm (in.)
InsideOutside
Bearing53.6 (2.110)69.4 (2.732)
NOTICE:
Install the thrust bearing properly so that no−colored race
will be visible.
105. INSTALL PLANETARY CARRIER THRUST WASHER
NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow
petrolatum, install it onto the planetary sun gear assy.
NOTICE:
After assembling, confirm that the projection should be
fixed surely in the hole of the planetary sun gear assembly.
106. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 2 with yellow
petrolatum, install it onto the rear planetary sun gear.

D03925
Free
Free
D03907
Outer Race
Retainer
D03627
Mark
Mark
D03581Snap Ring
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−59
U151E, U151F A/T REPAIR MANUAL (RM1021U)
119. INSPECT UNDERDRIVE1WAY CLUTCH ASSY
(a) Install the underdrive clutch assy to the 1−way clutch.
(b) Rotate the underdrive clutch assy to check the rotating
direction for the lock or free operation.
120. INSTALL UNDERDRIVE1WAY CLUTCH ASSY
(a) Install the outer race retainer to the 1−way clutch.
NOTICE:
Fix the outer race retainer to the external tooth of the one
way clutch surely.
(b) Install the 1−way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the1−way clutch outer race is
visible.
(c) Using a screwdriver, install the snap ring to the transaxle
case.
NOTICE:
The snap ring should be fixed certainly in the groove of the
transaxle case as the gap exists except in the lock of teeth.

D03580
D09691
Parking Lock Pawl
Spring
Pawl Pin
D26386
D03579
Underdrive
Planetary
Gear Assy
40−60
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
121. INSTALL UNDERDRIVE CLUTCH ASSY
(a) Coat the bearing and bearing race with petroleum jelly,
install them onto the underdrive clutch.
Bearing and bearing race diameter: mm (in.)
InsideOutside
Bearing37.73 (1.4854)58.0 (2.2835)
Race29.9 (1.1772)55.5 (2.185)
(b) Install the underdrive clutch assy to the transaxle case.
NOTICE:
Installing the underdrive clutch drum sub−assy, be sure
not to damage the oil seal ring.
122. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock pawl.
(b) Temporarily install the parking lock pawl, shaft and spring
to the transaxle case, as shown in the illustration.
123. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Install the underdrive planetary gear assy to the transaxle
case.
NOTICE:
Engage all the discs of underdrive clutch and hub splines
of the underdrive planetary gear assy firmly and assemble
them securely.

D09693
D03576Pawl Shaft Clamp
D03875
E
D25511
Dimension (1)
Dimension (2)
D08087
Thrust Bearing Race No.1
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−61
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the parking lock pawl shaft.
(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
(d) Using a straight edge and vernier calipers as shown in the
illustration, measure the gap between the top of the differ-
ential drive pinion in the underdrive planetary gear and
contact surface of the transaxle case and housing (Di-
mension E).
NOTICE:
Note down the dimension E as it is necessary for the follow-
ing process.
(e) As shown in the illustration, measure the 2 places of the
transaxle housing, calculate the dimension F using the
formula.
NOTICE:
Note down the dimension F as it is necessary for the follow-
ing process.
HINT:
Dimension F = Dimension (1)−Dimension (2)
124. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust bearing race No.1 to the transaxle case
while checking its direction.
Bearing race diameter: mm (in.)
InsideOutside
Bearing race39.5 (1.555)45.8 (1.803)