clutch TOYOTA AVENSIS 2005 Service Repair Manual

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.

D03907
Outer Race
Retainer
D26466
Snap
Ring
D26385
Flange
D09196
D26387
40−30
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Remove the outer race retainer from the 1−way clutch.
43. REMOVE UNDERDRIVE CLUTCH DISC NO.2
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.
44. INSPECT UNDERDRIVE CLUTCH DISC NO.2
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
SIf the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
SBefore assembling new discs, soak them in ATF for
at least15 minutes.
45. REMOVE TRANSAXLE REAR COVER SUB−ASSY
(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic
hammer to remove the transaxle rear cover from the
transaxle case.

D26388
Rear Clutch
Oil Seal
Ring Outer
D26389
D26472
SST
D26390
D26391
Brake Apply Tube
Clutch Apply Tube
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−31
U151E, U151F A/T REPAIR MANUAL (RM1021U)
46. REMOVE TRANSAXLE CASE NO.1PLUG
(a) Remove the 4 transaxle case No.1 plugs from the trans-
axle rear cover.
(b) Remove the 4 O−rings from the 4 transaxle case No.1
plugs.
47. REMOVE REAR CLUTCH OIL SEAL RING OUTER
(a) Remove the 3 rear clutch oil seal rings from the transaxle
rear cover.
48. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle−roller bearing from the
transaxle rear cover.
SST 09387−00041 (09387−01021, 09387−01030,
09387−01040)
49. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Using a screwdriver, remove the 3 apply gaskets.
50. REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and brake apply tube.
(b) Remove the clutch apply tube.
(c) Remove the brake apply tube from the clamp.

D26403
Thrust Bearing
Direct Clutch Assy
D26392
Thrust Bearing
Thrust Bearing Race
Overdrive Direct Clutch Hub
D03829
Overdrive
Direct Clutch
Drum Sub−assy
Dial Indicator
D26714Rear Planetary Sun Gear Assy
40−32
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
51. REMOVE DIRECT CLUTCH ASSY
(a) Remove the thrust bearing and the direct clutch assy from
the transaxle case.
52. REMOVE OVERDREVE DIRECT CLUTCH HUB
SUB−ASSY
(a) Remove the thrust bearing race, thrust bearing and over-
drive direct clutch hub from the planetary gear assy.
53. INSPECT OVERDRIVE DIRECT CLUTCH DRUM
SUB−ASSY
(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.
54. REMOVE REAR PLANETARY SUN GEAR ASSY
(a) Remove the rear planetary sun gear assy from the trans-
axle case.

D26404
Thrust Needle Roller Bearing
Thrust Bearing Race
D26393
Planetary
Carrier
Thrust
Washer
No.2
Rear
Planetary
Sun Gear
D26598
Thrust Needle
Roller Bearing
1−Way Clutch Assy
D03909
1−Wa y
Clutch
Inner Race
D03589
1−Way Clutch
Sleeve Outer
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−33
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Remove the thrust needle roller bearing and thrust bear-
ing race from the rear planetary sun gear assy.
(c) Remove the planetary carrier thrust washer No.2 from the
rear planetary sun gear assy.
55. REMOVE1WAY CLUTCH ASSY
(a) Remove the 1−way clutch assy and the thrust needle roll-
er bearing from the transaxle case.
(b) Remove the 1−way clutch inner race from the 1−way
clutch assy.
56. REMOVE1WAY CLUTCH SLEEVE OUTER
(a) Remove the 1−way clutch sleeve outer from the transaxle
case.

D26394
Planetary Carrier
Thrust Washer No.1
D26395
Snap Ring
D26717
D08058
Snap Ring
D26396
Second Brake
Piston Assy
40−34
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
57. REMOVE PLANETARY CARRIER THRUST WASHER
NO.1
(a) Remove the planetary carrier thrust washer No.1 from the
planetary gear assy.
58. REMOVE 2ND BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.
59. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
SIf the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
SBefore assembling new discs, soak them in ATF for
at least15 minutes.
60. REMOVE SECOND BRAKE PISTON ASSY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the second brake piston assy from the transaxle
case.

D03616
Snap Ring
D26591
Rear Planetary
Gear Assy
D03873
Thrust Bearing
Race No.2
Thrust Needle Roller BearingInput
Sun
Gear
D26397
D09189
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−35
U151E, U151F A/T REPAIR MANUAL (RM1021U)
61. REMOVE REAR PLANETARY GEAR ASSY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the rear planetary gear assy from the transaxle
case.
62. REMOVE INPUT SUN GEAR
(a) Remove the 2 thrust needle roller bearings, thrust bearing
race No.2 and input sun gear from the transaxle case.
63. REMOVE1ST & REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 6 discs and 6 plates from the trans-
axle case.
64. INSPECT1ST & REVERSE BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
SIf the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
SBefore assembling new discs, soak them in ATF for
at least15 minutes.

D03605
SSTHold
Turn
D03914
Underdrive
Clutch Drum
Oil Seal Ring
D26383
D03606
SST
Hold
Turn
D03915
Underdrive
Output
Shaft Oil
Seal Ring
40−40
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
76. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle−roller bearing from the
transaxle case.
SST 09387−00041 (09387−01010, 09387−01030,
09387−01040)
77. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 oil seal rings from the transaxle case.
78. REMOVE TRANSAXLE CASE NO.1PLUG
(a) Remove the 2 transaxle case No. 1 plugs.
(b) Remove the 2 O−rings from the 2 transaxle case No. 1
plugs.
79. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the underdrive cylindrical roller bear-
ing from the transaxle case.
SST 09514−35011
80. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.

D26400
Transaxle Apply
Tube Clamp
Differential Gear Lube Apply Tube
D26383
Underdrive
Output Shaft
Oil Seal Ring
D03915
AT F
D03807
SST
D03914
Underdrive
Clutch Drum
Oil Seal Ring
AT F 40−44
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
83. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube and transaxle
apply tube clamp with the bolt to the transaxle housing.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
NOTICE:
Make sure to insert the pipe to the stopper.
84. INSTALL TRANSAXLE CASE NO.1PLUG
(a) Install the 2 new O−rings to the 2 transaxle case No.1
plugs.
(b) Install the 2 transaxle case No.1 plugs to the transaxle
rear cover.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
85. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Coat the new oil seal ring with ATF and install it to the
transaxle housing.
86. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical
roller bearing.
SST 09950−60020 (09951−00810), 09950−70010
(09951−07100)
NOTICE:
Do not apply excessive pressure to it.
87. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Coat the 2 new oil seal rings with ATF, install them to the
transaxle rear cover.
NOTICE:
SDo not expand the gap of the oil seal ring too much.
SFix the hooks certainly. Confirm the smooth rotation.

D26407
SST
Snap Ring
C89126
SST
D26467
Snap Ring
D26410
SST
40−46
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
90. INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387−00020
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
NOTICE:
SStop the press when the spring sheet is lowered1−
2 mm (0.039−0.078 in.) from the snap ring groove, to
prevent the spring sheet from deforming.
SDo not expand the snap ring excessively.
SInstalling the spring sub−assembly, check all of the
springs are fit in the piston correctly.
SThe snap ring should be fixed surely in the groove of
the transaxle case.
91. INSTALL BREATHER PLUG NO.2 (ATM)
92. INSTALL COUNTER DRIVE GEAR BEARING
(a) Coat the counterdrive gear bearing with ATF.
(b) Using SST and a press, install the bearing outer race.
SST 09950−60020 (09951−01030), 09950−70010
(09951−07150), 09649−17010
NOTICE:
SDo not apply excessive pressure to it.
SPress−fit the bearing outer race until it contacts the
transaxle case.
(c) Using a snap ring expander, install the snap ring.
NOTICE:
Face the white mark side of the snap ring up.
93. INSTALL COUNTER DRIVE GEAR
(a) Coat the couterdrive gear with ATF.
(b) Using SST and a press, install the tapered roller bearing
to the counter drive gear.
SST 09950−70010 (09951−07150), 09649−17010
NOTICE:
Do not apply excessive pressure to it.