TOYOTA AVENSIS 2005 Service Repair Manual

400DN±02
AT0953
SST
AT3306
Hold
TurnLock
Free
D25367
Sample showing minimum amount of
powders in ATF
Actual Size
± AUTOMATIC TRANSMISSION / TRANSTORQUE CONVERTER CLUTCH AND DRIVE
PLATE (ATM)40±37
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE CONVERTER CLUTCH AND DRIVE PLATE (ATM)
INSPECTION
1. INSPECT TORQUE CONVERTER CLUTCH ASSY
(a) Inspect the one±way clutch.
(1) Install SST into the inner race of the one±way
clutch.
SST 09350±32014 (09351±32010)
(2) Install SST so that it fits in the notch of the converter
hub and outer race of the one±way clutch.
SST 09350±32014 (09351±32020)
(3) Check that the one±way clutch locks when it is
turned counterclockwise, and rotates smoothly
clockwise.
Clean the torque converter clutch and retest the one±way
clutch as necessary.
Replace the torque converter clutch if the one±way clutch still
fails the test.
(b) Determine the condition of the torque converter clutch
assy.
(1) If the inspection result of the torque converter clutch
assy meets the following conditions, replace the
torque converter clutch.
Malfunction item:

Any metallic sound is heard from the torque convert-
er clutch during stall test or when the shift lever is in
neutral position.

One±way clutch is free or locked in both directions.
Fine powders exceeding the sample limit is identified
in ATF. (See the sample.)
HINT:
The sample shows the auto fluid of approx. 0.25 liters (0.26 US
qts, 0.22 Imp. qts) that is taken out from the removed torque
converter clutch.
(c) Replace the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor, stir
the ATF in the torque converter clutch completely
and drain it with the face for installation facing up.

C11090
D25368
OK NG
The Bottom is
Damaged
C81014
40±38± AUTOMATIC TRANSMISSION / TRANSTORQUE CONVERTER CLUTCH AND DRIVE
PLATE (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Clean and check the oil cooler and oil pipe line.
(1) If the torque converter clutch is inspected or the ATF
is exchanged, clean the oil cooler and oil pipe line.
HINT:

Spray compressed air of 196 kPa (2 kgf/cm2, 28 psi) from
the inlet hose.

If plenty of fine powders are identified in the ATF, add new
ATF using a bucket pump and clean it again.
(2) If the ATF is cloudy, inspect the oil cooler.
(e) Prevent deformation of the torque converter clutch and
damage to the oil pump gear.
(1) When any marks due to interference are found on
the end of the bolt for the torque converter clutch
and on the bottom of the bolt hole, replace the bolt
and the torque converter clutch.
(2) All of the bolts shall have the same length.
(3) Do not lose the spring washer.
2. INSPECT DRIVE PLATE & RING GEAR SUB±ASSY
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or ring gear is dam-
aged, replace the drive plate.

40121±02
D30480
C81535
D30341
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±25
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE HOOD SUB±ASSY
2. REMOVE ENGINE COVER SUB±ASSY NO.1
(a) Remove the 2 nuts and engine cover.
3. REMOVE RADIATOR SUPPORT OPENING COVER
4. REMOVE ENGINE ROOM COVER SIDE
5. REMOVE BATTERY
6. REMOVE BATTERY CARRIER
(a) Remove the 4 bolts and battery carrier.
7. REMOVE AIR CLEANER ASSY
8. REMOVE AIR CLEANER HOSE NO.1
9. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the nut from the control shaft lever.
(b) Separate the control cable from the control shaft lever.
(c) Remove the clip and separate the control cable from the
control cable bracket.
10. SEPARATE WIRE HARNESS
(a) Remove the 3 bolts and 2 wire harnesses and wire har-
ness bracket.

D30342
D30343
D30346
D30344
40±26
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
11. SEPARATE CONNECTOR
(a) Separate the 2 wire harnesse clamps from the oil filler tube.
(b) Separate the transmission wire connector.
(c) Separate the park/neutral position switch connector.
(d) Separate the 2 speed sensor connectors.
12. REMOVE TRANSMISSION CONTROL CABLE CLAMP
(a) Remove the bolt and transmission control cable clamp from the automatic transaxle.
13. REMOVE TRANSMISSION OIL FILLER TUBE SUB±ASSY
(a) Remove the ATF level gauge.
(b) Remove the bolt and oil filler tube.
(c) Remove the O±ring from the oil filler tube.
14. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
(a) Remove the 3 bolts and control cable bracket No.1.
15. REMOVE FRONT WHEELS
16. REMOVE ENGINE UNDER COVER RH
17. REMOVE ENGINE UNDER COVER LH
18. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug gasket and drain ATF.
(b) Install a new gasket and drain plug. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
19. DRAIN COOLANT
(a)1AZ±FE (See pege 16±19)
(b)1AZ±FSE (See pege 16±31)

D30345
D25745
No. 1 Engine HangerNo. 2 Engine Hanger
C80168
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
40±27
AVENSIS REPAIR MANUAL (RM1018E)
20. SEPARATE OIL COOLER INLET TUBE NO.1
(a) Using SST, disconnect the oil cooler inlet tube No.1.
SST 09023±12700
21. SEPARATE OIL COOLER OUTLET TUBE NO.1
(a) Using SST, disconnect the oil cooler outlet tube No.1. SST 09023±12700
22. SUSPEND ENGINE ASSY
(a) Install the No.1 and No.2 engine hangers in the correctdirection.
Parts No.:
No. 1 engine hanger: 12281±28010
No. 2 engine hanger: 12282±28010
Bolt: 91512±61020
Torque: 38 N
m (387 kgf
cm, 28 ft
lbf)
(b) Attach the engine chain hoist to the engine hanger.
CAUTION:
Do not attempt to hang the engine by hooking the chain to
any other part.
23.REMOVE EXHAUST PIPE ASSY FRONT (See page 15±7)
24.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
25.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6) SST 09520±01010, 09520±24010 (09520±32040)
26. REMOVE STARTER ASSY
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the connector.
(c) Remove the 2 bolts and starter.
27. SUPPORT AUTOMATIC TRANSAXLE ASSY
(a) Support the automatic transaxle with a transmission jack.
28. REMOVE ENGINE MOUNTING MEMBER SUB±ASSYCENTER
(a) Remove the 4 bolts and center member with engine
mounting insulator FR.

D30861
D30351
G20928
D25738
C85797
40±28
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
29. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the 4 bolts, nut and engine mounting insulator
LH.
30. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket LH from
the automatic transaxle.
31. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the bolt and separate the hose clamp from the
engine mounting insulator RR.
(b) Remove the bolt from the engine mounting bracket RR.
(c) Remove the 3 nuts, bolt and engine mounting insulator
RR from suspension member.
32. SEPARATE TRANSVERSE ENGINE ENGINE
MOUNTING INSULATOR
(a) Remove the bolt and nut from the engine mounting brack-
et FR.




D30393
C85794
D25407
D25408
C85790
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±29
AVENSIS REPAIR MANUAL (RM1018E)
33. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 2 bolts and engine mounting bracket FR from
the automatic transaxle.
34. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and engine mounting bracket RR
from the automatic transaxle.
35. REMOVE FLYWHEEL HOUSING UNDER COVER
(a) Remove the flywheel housing under cover from the auto-
matic transaxle.
36. REMOVE AUTOMATIC TRANSAXLE ASSY
(a) Turn the crankshaft to remove the 6 bolts while holding
the crankshaft pulley bolt with a wrench.
(b) Remove the 9 bolts.
(c) Separate and remove the automatic transaxle.

C83051
D25371
Key
C57914
C88330
40±30
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE TORQUE CONVERTER CLUTCH ASSY
38.INSPECT TORQUE CONVERTER CLUTCH ASSY (See page 40±37) SST 09350±32014 (09351±32010, 09351±32020)
39. INSTALL TORQUE CONVERTER CLUTCH ASSY
(a) Using vernier calipers, measure the dimension A be-tween the transaxle and the end surface of the drive plate.
(b) Set the key of the front oil pump drive gear at the top and put a mark on the housing.
(c) Put a mark on the torque converter clutch so that its groove can be clearly indicated.
(d) Match the 2 marks on the transaxle case and the torque converter clutch and fit the splined part of the input shaft
to the spline part of the turbine runner.

C88300
C88301
C88654Dimension B









C89268
D25408
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±31
AVENSIS REPAIR MANUAL (RM1018E)
(e) Rotating the torque converter clutch, fit the spline part of
the stator shaft with the spline part of the stator.
HINT:
Rotate it about 180 degrees.
(f) Rotating the torque converter clutch, match the 2 marks
on the case and the torque converter clutch again and fit
the key of the oil pump drive gear into the key way of the
torque converter clutch.
NOTICE:
When rotating the torque converter clutch, do not push it
by excessive force.
(g) Using calipers and a straight edge, measure the dimen-
sion B shown in the illustration and check that B is greater
than A measured in (a).
Standard: A + 1 mm or more
40. INSTALL AUTOMATIC TRANSAXLE ASSY
(a) Install the automatic transaxle and 9 bolts to the engine.
Torque:
Bolt A: 64 N
m (650 kgf
cm, 47 ft
lbf)
Bolt B: 46 N
m (470 kgf
cm, 34 ft
lbf)
Bolt C: 44 N
m (449 kgf
cm, 32 ft
lbf)
(b) Install the 6 torque converter clutch mounting bolts.
Torque: 41 N
m (420 kgf
cm, 30 ft
lbf)
HINT:
First install green colored bolt, and then the 5 bolts.

D25407
C85794



D30393
G20928
D25738
40±32
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
41. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover to the automatic
transaxle.
42. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket RR and 3 bolts to the
automatic transaxle.
Torque: 64 N
m (652 kgf
cm, 47 ft
lbf)
43. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
BRACKET
(a) Install the engine mounting bracket FR and 2 bolts to the
automatic transaxle.
Torque: 64 N
m (652 kgf
cm, 47 ft
lbf)
44. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING
INSULATOR
(a) Install the engine mounting insulator RR and bolt to the
engine mounting bracket RR.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(b) Tighten the 3 nuts and bolt.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)