TOYOTA AVENSIS 2005 Service Repair Manual

4006R±01
D09210
D08099
D08100
D04079
40±80
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
DIRECT CLUTCH ASSY (U241E)
OVERHAUL
1. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch and needle roller bearing on the
transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
0.605 ± 0.825 mm (0.02382 ± 0.03248 in.)
If the pack clearance is non±standard, inspect the discs, plates
and flange.
2. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Using a screwdriver, remove the snap ring from the direct
clutch drum.
(b) Remove the flange, 3 discs and 3 plates from the direct
clutch drum.
3. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or even
if a part of the printed mark is defaced, replace all discs.

D03677
SST
D08101
D08102
D08103
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
40±81
U241E A/T REPAIR MANUAL (RM840U)

Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE DIRECT CLUTCH RETURN SPRING
SUB±ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09387±00020
(b) Using a snap ring expander, remove the snap ring from
the direct clutch drum.
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the direct clutch drum.
(d) Remove the piston return spring from the direct clutch
drum.
(e) Install direct clutch drum on the transaxle rear cover.
(f) Holding the direct clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch piston.

D09211
D03680
D08102
D08101
D03677
SST
40±82
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. INSPECT DIRECT CLUTCH RETURN SPRING
SUB±ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 22.58 mm (0.8890 in.)
6. INSTALL DIRECT CLUTCH RETURN SPRING
SUB±ASSY
(a) Coat the direct clutch piston with ATF, and install it to the
direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch pis-
ton.
(b) Install the piston return spring to the direct clutch drum.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch ba-
lancer.
(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09387±00020
(e) Using a snap ring expander, install the snap ring to the di-
rect clutch drum.
NOTICE:

Be sure the end gap of the snap ring is not aligned
with the clutch balancer claw.

D08104
Flange
Disc
Plate
D08099
D09210
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
40±83
U241E A/T REPAIR MANUAL (RM840U)

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
7. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Install the 3 plates, 3 discs and flange.
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
8. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Park clearance:
0.605 ± 0.825 mm (0.02382 ± 0.03248 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is non±standard, select another flange.
HINT:
There are 6 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.0 (0.118)43.3 (0.130)
23.1 (0.122)53.4 (0.134)
33.2 (0.126)63.5 (0.138)

D03682
40±84
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Inspect the clutch disc rotation.
(1) Check that the disc rotates when rotating the disc
after inserting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

4006Z±01
D08032
D08033
D08034
40±14
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
AUTOMATIC TRANSAXLE ASSY (U241E)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB±ASSY
(a) Remove the bolt and speedometer driven hole cover sub±assy from the transaxle assy.
(b) Remove the O±ring from the speedometer driven hole cover.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Remove the nut, washer and control shaft lever.
(b) Using a screwdriver, unstake the nut stopper and remove
the lock nut and stopper.
(c) Remove the 2 bolts and pull out the park/neutral position
switch.
3. REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the breather No. 2 plug.

C83143
C83144
C83142
D03900
D03900
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±15
U241E A/T REPAIR MANUAL (RM840U)
4. REMOVE OIL COOLER TUBE UNION(INLET OIL
COOLER UNION)
(a) Remove the union.
(b) Remove the O±ring from the union.
5. REMOVE OIL COOLER TUBE UNION(OUTLET OIL
COOLER UNION)
(a) Remove the elbow.
(b) Remove the O±ring from the elbow.
6. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove 4 O±rings from the 4 transaxle case No. 1 plugs.
7. REMOVE SPEED SENSOR(TMC ±MADE)
(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
(b) Remove the 2 O±rings from the sensors.
8. REMOVE TRANSMISSION REVOLUTION
SENSOR(AISIN ±MADE)
(a) Remove the 2 bolts and the 2 transmission revolution
sensors from the transaxle assy.
(b) Remove the 2 O±rings from the sensors.

D09176
D09177
AT0103
D09637
40±16
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. FIX AUTOMATIC TRANSAXLE ASSY
10. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the 18 bolts.
(b) Remove the oil pan and 2 magnets.
11. REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET
(a) Remove the gasket from the oil pan.
12. INSPECT AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non±magnetic).... bushing wear
13. REMOVE TRANSMISSION WIRE
(a) Remove the 5 connectors from the shift solenoid valves.
(b) Remove the bolt, clamp and ATF temperature sensor.

D03547
D03636
D09179
D09180
D03553
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±17
U241E A/T REPAIR MANUAL (RM840U)
(c) Remove the bolt and transaxle solenoid wire from the
transaxle case.
(d) Remove the O±ring from the transaxle solenoid wire.
14. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O±ring from the oil strainer.
15. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and
the valve body assy.

C83127
C83128
C83129
D03554
D03555
40±18
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
16. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No. 1 from the trans-
axle case.
17. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2ND brake gasket from the
transaxle case.
18. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
19. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the trans-
axle case.
20. REMOVE C±3 ACCUMULATOR PISTON
(a) Remove the compression spring from the C
3 accumulator
piston.