TOYOTA AVENSIS 2005 Service Repair Manual

C91931
Valve Body Oil
Strainer Assy
C91932
O−ring
C91933
C83127
C83128
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−21
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O−ring from the oil strainer.
14. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and
valve body assy.
15. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No.1 from the trans-
axle case.
16. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2nd brake gasket from the
transaxle case.

C83129
D03554
Check Ball
D03555
D03556
D03902
O−ring
C−3 Accumulator Piston 40−22
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
17. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
18. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the trans-
axle case.
19. REMOVE C−3 ACCUMULATOR PISTON
(a) Remove the spring from the C−3 accumulator piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the C−3 accumulator piston.
NOTICE:
SBlowing off the air may cause the piston to jump−out.
When removing the piston, hold it by your hand using
a waste cloth.
STake care not to splash ATF when air−blowing.
(c) Remove the O−ring from the C−3 accumulator piston.

D26401
D26402
O−ring
O−ring Reverse clutch Accumulator Piston
D03558
D03904
O−ring
B−3 Accumulator Piston
D03559
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−23
U151E, U151F A/T REPAIR MANUAL (RM1021U)
20. REMOVE REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the reverse accumulator piston and
spring.
NOTICE:
SBlowing off the air may cause the piston to jump−out.
When removing the piston, hold it by your hand using
a waste cloth.
STake care not to splash ATF when air−blowing.
(b) Remove the 2 O−rings from the reverse clutch accumula-
tor piston.
21. REMOVE B−3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the B−3 accumulator piston and 2
springs.
NOTICE:
SBlowing off the air may cause the piston to jump−out.
When removing the piston, hold it by your hand using
a waste cloth.
STake care not to splash ATF when air−blowing.
(b) Remove the O−ring from the B−3 accumulator piston.
22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using a needle−nose pliers, remove the manual valve le-
ver shaft retainer spring.

D03560
C56727
D03563
D03564
D03565
40−24
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
23. REMOVE MANUAL DETENT SPRING SUB−ASSY
(a) Remove the 2 bolts, the manual detent spring sub−assy
and cover.
24. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
25. REMOVE MANUAL VALVE LEVER SUB−ASSY
(a) Using a chisel and hammer, cut off and remove the
spacer.
(b) Using a pin punch (
35 mm) and hammer, drive out the
pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.
(c) Remove the manual valve lever shaft and manual valve
lever.

D26382
Parking Lock Rod Sub−assy
D03566
D08046Oil Pump Assy
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−25
U151E, U151F A/T REPAIR MANUAL (RM1021U)
26. REMOVE PARKING LOCK ROD SUB−ASSY
(a) Remove the parking lock rod from the manual valve lever.
27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the trans-
axle case.
28. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle case with the oil pump side facing up.
29. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft endplay.
Endplay: 0.262−1.244 mm (0.01−0.049 in.)

D25608
U151E:
U151F:
D03569
Oil Pump Assy
D25505
Thrust Needle
Roller Bearing
Differential Gear Assy Forward Clutch Assy
D25506
Thrust Bearing Underdrive Race No.2
Differential
Gear Assy Forward Clutch Assy
Underdrive Planetary Gear Assy
40−26
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
30. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing with a
plastic hammer to remove the transaxle housing from the
transaxle case.
NOTICE:
Differential may be accidentally removed when the trans-
axle housing is removed.
31. REMOVE OIL PUMP ASSY
(a) Remove the 7 bolts and oil pump from the transaxle case.
32. REMOVE THRUST NEEDLE ROLLER BEARING
(a) Remove the thrust needle roller bearing from the under-
drive planetary gear assy.
33. REMOVE THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Remove the thrust bearing underdrive race No. 2 from the
underdrive planetary gear assy.

D26450
Differential
Gear Assy
D03573
D03574
Forward Clutch
Assy
D03906
Thrust Needle
Roller Bearing
D26787
Multiple Disc
Clutch Clutch
HubThrust Needle
Roller Bearing
Thrust Needle
Roller Bearing
Thrust
Bearing
Race
No.1
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−27
U151E, U151F A/T REPAIR MANUAL (RM1021U)
34. REMOVE DIFFERENTIAL GEAR ASSEMBLY
(a) Remove the differential gear assy from the transaxle
case.
35. REMOVE OVERDRIVE BRAKE GASKET
(a) Remove the 2 overdrive brake gaskets from the transaxle
case.
36. REMOVE FORWARD CLUTCH ASSY
(a) Remove the forward clutch assy from the transaxle case.
(b) Remove the thrust needle roller bearing from the forward
clutch.
37. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Remove the thrust needle roller bearing, multiple disc
clutch clutch hub, thrust needle roller bearing and thrust
bearing race No.1 from the transaxle case.

D03829
Dial Indicator
Forward Clutch Hub
D03576
Pawl Shaft Clamp
D09652
D09689
40−28
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
38. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Using a dial indicator, measure the inside diameter of the
forward clutch hub bushing
Standard inside diameter:
23.025−23.046 mm (0.9065−0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091in.)
NOTICE:
SWhen the diameter is over the maximum, replace the
multiple disc clutch hub with new one.
SCheck the contact surface of the bush in the direct
clutch shaft. If any scratch or discolor is identified, re-
place the direct clutch sub−assy with new one.
If the inside diameter is greater than the maximum, replace the
forward clutch hub.
39. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Remove the bolt and pawl shaft clamp.
(b) Remove the parking lock pawl shaft.
(c) Push the parking lock pawl.
HINT:
Failure to do so will cause interference when the underdrive
planetary gear is removed.

D03579
Underdrive
Planetary
Gear Assy
D26386
D03580
Thrust Bearing
Bearing Race
D03581Snap Ring
D03627
Underdrive
1−Wa y
Clutch
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−29
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the underdrive planetary gear assy from the
transaxle case.
NOTICE:
Be careful so that the underdrive planetary gear assy will
not fall out.
40. REMOVE PARKING LOCK PAWL
(a) Remove the spring, pawl pin and parking lock pawl.
41. REMOVE UNDERDRIVE CLUTCH ASSY
(a) Remove the underdrive clutch assy, thrust bearing and
bearing race from the transaxle case.
42. REMOVE UNDERDRIVE1WAY CLUTCH ASSY
(a) Using a screwdriver, remove the snap ring from the trans-
axle case.
(b) Remove the underdrive 1−way clutch from the transaxle
case.

D03907
Outer Race
Retainer
D26466
Snap
Ring
D26385
Flange
D09196
D26387
40−30
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Remove the outer race retainer from the 1−way clutch.
43. REMOVE UNDERDRIVE CLUTCH DISC NO.2
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.
44. INSPECT UNDERDRIVE CLUTCH DISC NO.2
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
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.
45. REMOVE TRANSAXLE REAR COVER SUB−ASSY
(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic
hammer to remove the transaxle rear cover from the
transaxle case.