TOYOTA AVENSIS 2005 Service Repair Manual

C89113
C89115
C89115
C89112
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E/U151F)
40−105
U151E, U151F A/T REPAIR MANUAL (RM1021U)
6. REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt and shift solenoid valve SL2 from the
valve body assy.
7. REMOVE SHIFT SOLENOID VALVE SL1
(a) Remove the bolt and shift solenoid valve SL1 from the
valve body assy.
8. REMOVE MANUAL VALVE
(a) Remove the manual valve from the valve body assy.
9. INSTALL MANUAL VALVE
(a) Install the manual valve to the valve body assy.
10. INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the shift solenoid valve SL1 to the valve body assy
with the bolt.
Torque: 6.6 N
m (67 kgf
cm, 58 in.
lbf)
11. INSTALL LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Install the shift solenoid valve SLT to the valve body assy
with the bolt.
Torque: 6.6 N
m (67 kgf
cm, 58 in.
lbf)
12. INSTALL SHIFT SOLENOID VALVE SL3
(a) Install the shift solenoid valve SL3 to the valve body assy
with the bolt.
Torque: 6.6 N
m (67 kgf
cm, 58 in.
lbf)

C89113
D26443
D26438
D26442
40−106
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the shift solenoid valve SL2 to the valve body assy
with the bolt.
Torque:10.8 N
m(110 kgf
cm, 8 ft
lbf)
14. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the shift solenoid valve DSL to the valve body assy
with the bolt.
Torque:10.8 N
m(110 kgf
cm, 8 ft
lbf)
15. INSTALL SHIFT SOLENOID VALVE SR
(a) Install the shift solenoid valve SR to the valve body assy.
16. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the shift solenoid valve S4 to the valve body assy
with the bolt.
Torque:10.8 N
m(110 kgf
cm, 8 ft
lbf)

4006K−03
D25593
SST Underdrive
Planetary Gear
D25594
SST
D03686
SST
D03687
Underdrive
Planetary Gear
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40−99
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE PLANETARY GEAR ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST, fix the underdrive planetary gear assy.
SST 09387−00050
(b) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387−00050
Turning torque at 60 rpm.:
0.50−1.42 N
m (5.1−14.5 kgf
cm, 0.06−0.17 in.
lbf)
HINT:
Use a torque wrench with a fulcrum length of160 mm (6.3 in.).
2. REMOVE FRONT PLANETARY GEAR NUT
(a) Using SST, loosen the staked part of the lock nut.
SST 09930−00010 (09931−00010, 09931−00020),
09387−00050
(b) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.

D25609
Underdrive
Planetary Gear
D03689
SST
HoldTurn
D26437
SST
D03691
SST SST
Hold
Turn
D03826
Snap Ring
40−100− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Using a socket wrench, remove the lock nut.
3. REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using SST, remove the cylindrical roller bearing race in-
ner.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00320), 09950−40011(09957−04010)
4. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Using SST and a press, remove the differential drive pin-
ion, parking lock gear, counter driven gear with under-
drive planetary ring gear and front tapered roller bearing.
SST 09950−60010 (09951−00320), 09387−00050
(b) Clamp the underdrive planetary gear in soft jaw vise.
(c) Using SST, remove the rear tapered roller bearing form
the underdrive planetary gear.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00320), 09950−40011(09957−04010)
5. REMOVE UNDERDRIVE PLANETARY RING GEAR
(a) Using a snap ring pliers, remove the snap ring.

D03827Counter Driven Gear
Underdrive
Planetary Ring Gear
D08112Snap Ring
D08113
D08114
SST
SST
D03827Counter Driven Gear
Underdrive
Planetary Ring Gear
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40−101
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Remove the underdrive planetary ring gear from the
counter driven gear.
6. INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install a new snap ring to the outer race of the tapered roll-
er bearing.
HINT:
When replacing the bearing, also replace the counter driven
gear with a new one.
(b) Using a piston ring compressor, squeeze the snap ring.
(c) Using SST and a press, press in the outer race of the ta-
pered roller bearing.
SST 09950−60020 (09951−00890), 09950−70010
(09951−07100)
NOTICE:
Be sure not to damage on the snap ring during the outer
race installation.
(d) Install the underdrive planetary ring gear to the counter
driven gear.

D08115
Snap Ring
D26435
SST
D08117
D26436
SST
D26433
SST
40−102− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using a snap ring pliers, install the snap ring.
7. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Using a press, press the rear tapered roller bearing to the
underdrive planetary gear.
SST 09502−12010, 09950−60010 (09951−00260),
09950−70010 (09951−07100), 09316−20011
NOTICE:
Press the bearing until it becomes flat at the bottom.
(b) Install the counter driven gear with planetary ring gear to
the underdrive planetary gear.
(c) Using SST and a press, press in the front tapered roller
bearing.
SST 09502−12010, 09950−60010 (09951−00260),
09950−70010 (09951−07100), 09316−20011
NOTICE:
Press the counter driven gear while rotating it.
(d) Using a press, press in the parking lock gear.
SST 09502−12010, 09950−60010 (09951−00260),
09950−70010 (09951−07100), 09316−20011
NOTICE:
Press the counter driven gear while rotating it.

D26434
SST
Differential
Drive Pinion
D26432
SST
D25609
Underdrive
Planetary Gear
D25594
SST Underdrive
Planetary Gear
C56809
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40−103
U151E, U151F A/T REPAIR MANUAL (RM1021U)
8. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using a press, press the differential drive pinion.
SST 09726−40010, 09950−60010 (09951−00260),
09950−70010 (09951−07100)
NOTICE:
Press the counter driven gear while rotating it.
9. INSTALL CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using a press, press the cylindrical roller bearing race in-
ner.
SST 09506−35010, 09950−60010 (09951−00260),
09950−70010 (09951−07100)
NOTICE:
Press the counter driven gear while rotating it.
10. INSTALL FRONT PLANETARY GEAR NUT
(a) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 N
m (2,855 kgf
cm, 207 in.
lbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
11. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387−00050
Turning torque at 60 rpm.:
0.5−1.42 N
m (5.1−14.5 kgf
cm, 0.06−0.17 in.
lbf)
HINT:
Use a torque wrench with a fulcrum length of160 mm (6.30 in.).
(b) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.

400H3−02
D26429
D03701
Snap Ring
D26430
Underdrive
Clutch Drum
40−94
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while ap-
plying and releasing compressed air (392 kPa, 4.0 kgf/
cm
2, 57 psi).
Pack clearance:1.51−1.71mm (0.0594−0.0673 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the under-
drive clutch drum.

D04077
D08129
D03703
SST
Snap Ring
C56359
Clutch
Balancer
Underdrive
Clutch Drum
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
40−95
U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
HINT:
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.
5. INSPECT UNDERDRIVE CLUTCH DRUM SUB−ASSY
(a) Using a dial indicator, measure the inside diameter of the
underdrive clutch drum bushing.
Standard drum bushing:
37.06−37.08 mm (1.4591−1.4598 in.)
Maximum drum bushing: 37.13mm(1.4618 in.)
If the inside diameter is greater than the maximum, replace the
underdrive clutch drum.
6. REMOVE UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09350−32014 (09351−32070)
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
SStop the press when the spring sheet is lowered to the
place1−2 mm (0.039−0.078 in.) from the snap ring
groove.
SThis prevents the spring sheet from being deformed.
SDo not expand the snap ring excessively.
(c) Remove the clutch balancer from the underdrive clutch
drum.

C56360
D03824
D03705
D26465
O−ring
D26465
O−ring
40−96
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the return spring from the underdrive clutch
drum.
7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length:17.14 mm (0.6752 in.)
8. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the underdrive clutch piston.
9. REMOVE UNDERDRIVE CLUTCH DRUM O−RING
(a) Using a screwdriver, remove the O−ring from the under-
drive clutch drum.
10. INSTALL UNDERDRIVE CLUTCH DRUM O−RING
(a) Apply the new O−ring with ATF, install it to the underdrive
clutch drum.
NOTICE:
Assemble the O−ring carefully not to have a twist and a
pinching.