TOYOTA AVENSIS 2005 Service Repair Manual

D25588
Stopper
Stopper
D26417
Disc Flange
Plate
D26421
Snap Ring
D26416
Disc Flange
Plate
Cushion
Plate
D26419
Snap Ring
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40−89
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the piston shown in the
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.
16. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the intermediate
shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
17. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Apply the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the
intermediate shaft.
NOTICE:
SInstall the cushion plate with the mark on the white
surface facing to plate.
SBe careful about the order of discs, plates and flange
assembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.

D26426
D26427
D26428
40−90
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
18. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft 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:0.60−0.82 mm (0.02362−0.03228 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 not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
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)−−
19. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.61−0.83 mm (0.02401−0.03268 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 not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
02.5 (0.098)42.9 (0.114)
12.6 (0.102)53.0 (0.118)
22.7 (0.106)63.1(0.122)
32.8 (0.110)−−
(b) Check that the disc rotates when rotating the disc after in-
serting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

400H1−02
D26715
D26753
Snap Ring
D26754
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−79
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:1.00−1.25 mm (0.0394−0.4921in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.

D09189
D26418
SST
Snap Ring
D26709
Clutch
Balancer
Input Shaft
D26708
Forward Clutch
Return SpringInput Shaft
40−80
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. INSPECT FORWARD 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:
SIf the lining of the disc comes off or discolors, or even if
replace all discs.
SBefore assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB−ASSY
(a) Place SST on the spring retainer and compress the return
spring with a press.
SST 09387−00020
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
SStop the press when the spring sheet is lowered1−
2 mm (0.039−0.078 in.) from the snap ring groove,
preventing the spring sheet from deforming.
SDo not expand the snap ring excessively.
(c) Remove the clutch balancer from the input shaft.
(d) Remove the forward clutch return spring from the input
shaft.

D09211
ForwardClutchRe-
turn Spring
D03664
C56374
D25587
A
D26707Forward Clutch Piston
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−81
U151E, U151F A/T REPAIR MANUAL (RM1021U)
5. INSPECT FORWARD CLUTCH RETURN SPRING
SUB−ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 26.74 mm (1.0528 in.)
6. REMOVE FORWARD CLUTCH PISTON SUB−ASSY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the oil pump
to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted, either blow
the air again with the protruding side pushed, or remove the pis-
ton using the needle nose plier with vinyl tape on the tip.
7. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring to the input shaft.
8. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the new input shaft oil seal ring from both sides
to reduce dimension A.
Dimension A: 5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input
shaft.
NOTICE:
Do not expand the gap of the oil seal ring too much. Fix the
hooks certainly.
9. INSTALL FORWARD CLUTCH PISTON SUB−ASSY
(a) Coat the forward clutch piston with ATF, and install it to the
input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward clutch
piston.

D26708
Forward Clutch
Return SpringInput Shaft
D26709
Clutch BalancerInput Shaft
D26418
SST
Snap Ring
D26788
Stopper
Stopper
40−82
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
10. INSTALL FORWARD CLUTCH RETURN SPRING
SUB−ASSY
(a) Install the return spring to the input shaft.
NOTICE:
Installing the spring sub−assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the input shaft.
NOTICE:
SBe careful not to damage the lip seal of the forward
clutch balancer.
SInstall the clutch balancer carefully not to have a
pinching and any other defects at the sealing lip.
SApply enough ATF to the sealing lip prior to assem-
bling.
(d) Place SST on the clutch balancer, and compress the
clutch balancer with a press.
SST 09387−00020
(e) Install the snap ring with a snap ring expander.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
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.
(g) Set the end gap of the snap ring in the piston shown in the
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.

D26415
Flange
Plate Disc
D26753
Snap Ring
D26715
D03672
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−83
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
12. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kgf
cm
2, 4.0 kPa, 57 psi).
Pack clearance:1.00−1.25 mm (0.0394−0.4921in.)
If the piston stroke is less than the minimum, parts may have
been assembled incorrectly. Check and reassemble again.
If the clearance is not standard, select another flange.
HINT:
There are 5 different flanges in thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.00 (0.1181)43.45 (0.1358)
23.15 (0.1240)53.60 (0.1417)
33.30 (0.1299)−−
13. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the forward
clutch assy after inserting the multiple disc clutch into it.
NOTICE:
Do not place the forward clutch assy in a vise.

4010K−01
D09644
Control Shaft Lever
D09643
Lock Nut
Nut Stopper
D09639
Park/neutral Position Switch
40−18
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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 re-
move the lock nut and nut 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 transaxle case.

C83143
Union
O−ring
C83144
Elbow
O−ring
D03900D30672
Speed Sensor
D26716
D09176
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−19
U151E, U151F A/T REPAIR MANUAL (RM1021U)
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 SPEED SENSOR
(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
7. REMOVE TRANSAXLE CASE NO.1PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove the 4 O−rings from the 4 transaxle case No.1
plugs.
8. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.

C91925
C86316
Magnet
AT0103
Magnet
C91927
Temperature
Sensor
D03547
Transmission Wire
40−20
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Remove the 18 bolts, oil pan and gasket.
(b) Remove the 2 magnets from the oil pan.
10. INSPECT TRANSMISSION OIL CLEANER MAGNET
(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
11. DISCONNECT TRANSMISSION WIRE
(a) Remove the 7 connectors from the shift solenoid valves.
(b) Remove the bolt, lock plate and ATF temperature sensor.
12. REMOVE TRANSMISSION WIRE
(a) Remove the bolt and transmission wire from the transaxle
case.