TOYOTA AVENSIS 2005 Service Repair Manual

± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±39
U241E A/T REPAIR MANUAL (RM840U)
MarkFront Race Diameter
Inside / Outside mm (in.)Thrust Bearing Diameter
Inside / Outside mm (in.)Rear Race Diameter
Inside / Outside mm (in.)
A±53.0 (2.087) / 78.2 (3.079)52.1 (2.051) / 75.5 (2.972)
B±37.73 (1.4854) / 58.0 (2.283)29.9 (1.177) / 55.5 (2.185)
C±33.85 (1.3327) / 52.2 (2.055)±
D±23.5 (0.925) / 44.0 (1.732)±
E±36.3 (1.429) / 52.2 (2.055)34.5 (1.358) / 48.5 (1.909)
F±34.6 (1.362) / 52.2 (2.055)±
G40.3 (1.587) / 58.0 (2.283)38.6 (1.520) / 60.0 (2.362)38.6 (1.520) / 58.0 (2.283)
H±53.6 (2.110) / 69.6 (2.740)±
I±33.7 (1.327) / 48.2 (1.898)30.3 (1.193) / 46.0 (1.811)
J±53.6 (2.110) / 70.18 (2.763) or 69.6 (2.740)±

D03607
D03604
D03611
Counter Drive Gear Side:
Front Planetary Gear Side:SST
SST
40±40
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
76. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the apply tube, and apply tube clamp No. 2 with the
bolt to the transaxle housing.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
NOTICE:
Make sure to insert the tube to the stopper.
77. INSTALL BREATHER PLUG NO.2 (ATM)
78. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, install the hole snap ring to the trans-
axle case.
79. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, instal the 2 counter drive gear
bearings outer races to the transaxle case.
NOTICE:

Press±fit the bearing race until it contacts the snap
ring.

Do not apply excessive pressure to it.
SST 09950±60020 (09951±00890), 09950±70010
(09951±07150)

D03613
SST
D03614
SST
D03913
D03813
D08072
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±41
U241E A/T REPAIR MANUAL (RM840U)
(b) Using SST and a press, install the tapered roller bearing
to the counter drive gear.
SST 09649±17010
NOTICE:

Press±fit the bearing inner race until contacts the
counter drive gear.

Do not apply excessive pressure to it.
(c) Using SST and a press, install the counter drive gear and
bearing to the transaxle case.
SST 09950±60020 (09951±00890), 09950±70010
(09951±07150)
NOTICE:
Do not apply excessive pressure to it.
80. INSTALL 1ST & REVERSE BRAKE PISTON
(a) Coat 2 new O±rings with ATF.
(b) Install the 2 O±ring to the 1st & reverse brake piston.
(c) Coat a 1st & reverse brake piston with ATF, install it to the
transaxle case.
(d) Install the 1st & reverse brake return spring to the 1st &
reverse brake piston.

D03600
SST
D03615
D08063
D03916
SST
Counter Drive
GearTransaxle
Case
2nd Brake Hub
w/ Front Planetary
Gear Assy
40±42
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(e) Using SST, a press and snap ring expander, install the
piston return spring and snap ring to the transaxle case.
SST 09387±00070
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
groove, preventing the spring sheet from being de-
form.

Do not expand the snap ring excessively.
81. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear
and brake hub snap ring to the brake hub.
82. INSTALL FRONT PLANETARY GEAR ASSY
(a) Install the front planetary gear assy to the brake hub.
(b) Using SST and a press, press±fit the front planetary gear
assy.
NOTICE:
Do not apply excessive pressure to it.

D03917
D03596
SST
D03918
SST
D08074
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±43
U241E A/T REPAIR MANUAL (RM840U)
(c) Install the front planetary gear washer, as shown in the il-
lustration.
(d) Using SST, install the nut.
SST 09387±00030, 09387±00080
Torque: 268 N
m (2,728 kgf
cm, 197 ft
lbf)
(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 09950±60010 (09951±00400), 09950±70010
(09951±07100), 09387±00030, 09387±00080
Turning torque at 60 rpm:
New Bearing
0.5 ± 1.0 N
m (5.1 ± 10.0 kgf
cm, 4.4 ± 8.7 in.
lbf)
Used Bearing
0.3 ± 0.5 N
m (3.1 ± 5.1 kgf
cm, 2.7 ± 4.4 in.
lbf)
(f) Using a chesel and hammer, stake the front planetary
gear washer.

D03873
D03593
D03910
D08062
D03616
40±44
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
83. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
Bearing and race diameter: mm (in.)
insideoutside
Bearing34.6 (1.362)52.2 (2.055)
Race40.3 (1.587)58.0 (2.283)
Bearing38.6 (1.520)60.0 (2.362)
84. INSTALL REAR PLANETARY GEAR ASSY
(a) Coat a bearing race with ATF, install it to the rear planetary
gear assy.
Bearing race diameter: mm (in.)
insideoutside
Race38.6 (1.520)58.0 (2.283)
(b) Install the planetary carrier thrust washer No. 2 to the
planetary gear assy.
(c) Install the rear planetary gear to the rear planetary ring
gear.
(d) Using a screwdriver, install the snap ring to the brake hub.

D09190
D03618
A
D03815
D03619
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±45
U241E A/T REPAIR MANUAL (RM840U)
85. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
(a) Install the 5 plates and 5 discs.
86. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers,measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case.(Dimension A)
(b) Select an appropriate flange so that the piston stroke will
meet the specified value.
Pack clearance:
1.02 ± 1.21 mm (0.0402 ± 0.0476 in.)
HINT:
Piston stroke = Dimension A ±Flange thickness
Flange thickness: mm (in.)
MarkThicknessMarkThickness
11.8 (0.071)52.2 (0.087)
21.9 (0.075)62.3 (0.091)
32.0 (0.079)72.4 (0.094)
42.1 (0.083)82.5 (0.098)
(c) Install the flange.
87. INSTALL 2ND BRAKE CYLINDER
(a) Install the 2nd brake piston assy to the transaxle case.
(b) Install the snap ring and measure the inside diameter.
Inside diameter: More than 167 mm (6.57 in.)
NOTICE:

Because the taper snap ring has the positioning
direction, check it when installing.

When the diameter does not satisfy the specified val-
ue, replace the snap ring with new one.

D08078
D03909
D09638
Groove
Free
D03588
D03908
40±46
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
88. INSTALL 1WAY CLUTCH SLEEVE OUTER
(a) Install the 1±way clutch outer sleeve to the 2nd brake cyl-
inder assy.
NOTICE:
Check the positioning direction of the outer sleeve.
89. INSTALL 1 WAY CLUTCH ASSY
(a) Install the inner race to the 1±way clutch.
NOTICE:
Check the direction of the inner race.
(b) Check the rotating direction of 1±way clutch for the lock
or free operation, as shown in illustration.
(c) Install the 1±way clutch and bearing to the 1±way clutch
outer race sleeve.
Bearing diameter: mm (in.)
InsideOutside
Bearing53.6 (2.110)69.6 (2.740)
NOTICE:
Install the thrust bearing properly so that no±colored race
will be visible.
90. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 1 with petro-
leum jelly, install it onto the rear planetary sun gear.

D03791
D03587
D09162
D09163
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±47
U241E A/T REPAIR MANUAL (RM840U)
(b) Coat the bearing with petroleum jelly, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Bearing33.8 (1.331)48.2 (1.898)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
91. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle case.
(b) Temporarily install the snap ring.
92. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and snap ring surface.
(b) Select an appropriate flange so that the piston stroke will
meet the specified value.
Pack clearance: 0.62 ± 0.91 mm (0.0244 ± 0.0358 in.)
HINT:
Piston stroke = Clearance ± Flange thickness ± Snap ring thick-
ness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)53.4 (0.134)
23.1 (0.122)63.5 (0.138)
33.2 (0.126)73.6 (0.142)
43.3 (0.130)8±

D03623
D03802
D03586
D03624
B
D03922
Dimension (1) Dimension (2) 40±48
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(c) Temporarily remove the snap ring, attach the selected
flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible through the
groove of the transaxle case.
93. INSTALL DIRECT CLUTCH ASSY
(a) Install the bearing race to the direct clutch.
Bearing race diameter : mm (in.)
InsideOutside
Bearing race30.3 (1.193)46.0 (1.811)
(b) Install direct clutch assy and thrust needle roller bearing
to the rear planetary sun gear assy.
NOTICE:
The disc in the direct clutch should completely mate with
the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.
(c) Clean the connecter part of the transaxle case and rear
cover.
(d) As shown in the illustration, place a straight edge on the
direct clutch drum and measure the distance between the
the transaxle case and the straight edge using vernier cal-
ipers. (Dimension B)
(e) Measure the 2 places of the rear cover as shown in the
illustration and calculate a dimension C using the follow-
ing formula.
HINT:
Dimension C = Dimension (1) ± Dimension (2)
(f) Calculate the end play value using the following formula.
Select a thrust bearing which satisfies the end play value
and install it.
End play: 0.198 ± 0.936 mm (0.00800 ± 0.03685 in.)