TOYOTA AVENSIS 2005 Service Repair Manual

D03809
Vinyl Tape
SST
D25615
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−127
U151E, U151F A/T REPAIR MANUAL (RM1021U)
15. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Wind a vinyl tape around SST at the place 6.0 mm (0.236
in.) above from the bottom end until the thickness of the
wound tape is about 5.0 mm (0.197 in.).
SST 09950−60020 (09951−00730)
NOTICE:
Remove foreign matter such as grease on the SST before
winding the tape.
(b) Coat the rip of oil seal with a little MP grease.
(c) Using SST, install a new oil seal.
SST 09950−60020 (09951−00730), 09950−70010
(09951−07150)
Standard press in depth:
5.5−6.5 mm (0.217−0.256 in.)
NOTICE:
Stop pressing when the would vinyl tape is contact with the
transaxle housing.

4006M−03
D26445
Mark
Front
Differential
Ring Gear
D26446
Front
Differential
Ring Gear
C50237Front Differential Ring Gear
D25595
HoldTurn
SST
SST
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40−107
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FRONT DIFFERENTIAL ASSY (U151E)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match−marks on the front differential ring gear
and differential case.
(b) Remove the14 bolts.
(c) Using a plastic hammer, tap on the front differential ring
gear to remove it from the case.
2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front differ-
ential tapered roller bearing from the differential case.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00490), 09950−40011(09957−04010)

D25596
SST
D25597
HoldTurn
SST
SST
D25598
SST
C50240
C50241
Differential Case
Front Differential Pinion Shaft No.1
40−108
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST, remove the front differential case front ta-
pered roller bearing outer race.
SST 09308−00010
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00490), 09950−40011(09957−04010)
(b) Using SST, remove the front differential case rear tapered
roller bearing outer race.
SST 09308−00010
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the straight pin.
NOTICE:
Before removing the straight pin, unstake it with a pin
punch.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1from the
differential case.

C50242
Front Differential
Side Gear
Front
Differential
Side Gear
D25599
SST
D25600
SST
C50242
Front Differential
Side Gear
Front
Differential
Side Gear
C50241
Differential Case
Front Differential Pinion Shaft No.1
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion thrust
washers, 2 front differential side gears and 2 side gear
thrust washers from the differential case.
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950−70010 (09951−07100), 09215−00013
(09215−00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950−70010 (09951−07100), 09608−10010
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Apply the 2 front differential side gears, 2 side gear thrust
washers, 2 front differential pinions and 2 pinion thrust
washers with ATF and install them to the differential case.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Apply the front differential pinion shaft No.1with ATF,
install it to the differential case.

C50252
C50253
C50254
D26447
SST
40−110
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSPECT BACKLASH
(a) Using a dial indicator, inspect the backlash of the side
gear.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
Thrust washer thickness
MarkThickness
−1.625 mm (0.0640 in.)
−1.725 mm (0.0679 in.)
−1.825 mm (0.0719 in.)
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the pinion shaft
straight pin.
(b) Using a chisel and hammer, stake the differential case.
NOTICE:
Stake it after adjusting the backlash.
13. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
rear tapered roller bearing to the differential case.
SST 09316−12010, 09550−60010 (09951−00490),
09950−70010 (09951−07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.

C83736
D26448
SST
D26449
SST
D26450
Differential Assy
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40−111
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09550−60010 (09951−00490), 09950−60020
(09951−00910)
14. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
front tapered roller bearing to the differential case.
SST 09316−12010, 09550−60010 (09951−00490),
09950−70010 (09951−07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09950−70010 (09951−07150), 09950−60020
(09951−00890)
NOTICE:
Clearance is not allowed between the bearing and trans-
axle housing.
15. ADJUST DIFFERENTIAL SIDE BEARING RRELOAD
(a) Install the differential assy to the transaxle case.

D26384
C
C
C
CAB
A
D25604
SST
40−112
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Clean the matching surfaces of the transaxle case and
transaxle housing.
(c) Install the transaxle housing to the transaxle case and
tighten them with the16 bolts.
Torque:
Bolt A: 25 N
m (255 kgf
cm,18ft
lbf)
Bolt B: 33 N
m (337 kgf
cm, 24 ft
lbf)
Bolt C: 29 N
m (295 kgf
cm, 21ft
lbf)
Bolt D: 22 N
m (226 kgf
cm,16.0 ft
lbf)
HINT:
Apply seal packing or equivalent to the A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
HINT:
Usually, bolt A is a non−reusable bolt. In this case, however, it
can be used after cleaning it.
(d) Using SST, turn the differential assy right and left 2 or 3
times to settle the bearing.
SST 09564−32011
(e) Using SST and a torque wrench, measure the turning
torque of the differential.
SST 09564−32011
Turning torque at 60 rpm:
New bearing
0.20−0.69 N
m (2.0−7.0 kgf
cm,1.8−6.1in.
lbf)
Used bearing
0.10−0.35 N
m(1.0−3.6 kgf
cm, 0.9−3.1in.
lbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below to select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)

D26384
D26450
Differential Assy
D25215
90−100_C(194−230_F)
D26445
Mark
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40−113
U151E, U151F A/T REPAIR MANUAL (RM1021U)Mark ThicknessMark Thickness
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(f) Remove the16 bolts and the transaxle housing.
(g) Remove the differential assy.
16. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90−110_C(194.0−230.0_F).
NOTICE:
Do not overheat the ring gear to110_C (230.0_F) or more.
(b) Clean the contact surface of the front differential case.
(c) Align the match−marks, install the front differential ring
gear case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.

D26446
D26451
SST
D25606
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tighten the14 bolts.
Torque: 95.0 N
m (970 kgf
cm, 70 ft
lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
17. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
(b) Apply the rip of oil seal with a little MP grease.
SST 09223−15020, 09950−70010 (09951−07150)
Oil seal drive in depth: 0á0.5 mm (0á0.0197 in.)
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive into a new oil seal.
(b) Apply the lip of the oil seal with a little MP grease.
SST 09710−30050, 09950−70010 (09951−07150)
Oil seal drive in depth: 0á0.5 mm (0á0.0197 in.)

4010J−01
C89112
D26442
D26438
D26443
40−104
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TRANSMISSION VALVE BODY ASSY (U151E/U151F)
OVERHAUL
1. REMOVE SHIFT SOLENOID VALVE SL3
(a) Remove the bolt and shift solenoid valve SL3 from the
valve body assy.
2. REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Remove the shift solenoid valve SLT from the valve body
assy.
3. REMOVE SHIFT SOLENOID VALVE S4
(a) Remove the bolt and shift solenoid valve S4 from the
valve body assy.
4. REMOVE SHIFT SOLENOID VALVE SR
(a) Remove the shift solenoid valve SR from the valve body
assy.
5. REMOVE SHIFT SOLENOID VALVE DSL
(a) Remove the bolt and shift solenoid valve DSL from the
valve body assy.