TOYOTA AVENSIS 2005 Service Repair Manual

D26400
Differential
Gear Lube
Apply TubeTransaxle Apply
Tube Clamp
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−41
U151E, U151F A/T REPAIR MANUAL (RM1021U)
81. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, transaxle apply tube clamp and differen-
tial gear lube apply tube from the transaxle housing.

C89118
AB
CDE
F
HIJ
KG 40−42
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
82. BEARING POSITION

− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−43
U151E, U151F A/T REPAIR MANUAL (RM1021U)
MarkFront Race Diameter
Inside / Outside mm (in.)Thrust Bearing Diameter
Inside / Outside mm (in.)Rear Race Diameter
Inside / Outside mm (in.)
A−57.2 (2.252) / 84.96 (3.3449)56.4 (2.220) / 83.0 (3.268)
B−37.73 (1.4854) / 58.0 (2.283)−
C−33.85 (1.3327) / 52.2 (2.055)−
D24.94 (0.982)23.5 (0.925) / 44.0(1.732)−
E−36.3 (1.429) / 51.93 (2.044)34.5 (1.358) / 48.35 (1.904)
F34.35 (1.352) / 56.57 (2.227)32.45 (1.278) / 56.48 (2.223)−
G40.15 (1.581) / 59.25 (2.333)38.65 (1.522) / 59.79 (2.354)38.65 (1.522) / 59.25 (2.332)
H−53.6 (2.110) / 69.6 (2.740)−
I33.02 (1.3) / 45.8 (1.803)31.85 (1.254) / 57.3 (2.256)−
J−24.79 (0.976) / 39.5 (1.555)23.6 (0.929) / 37.95 (1.494)
K−56.3 (2.216) / 75.96 (2.991)−

D26400
Transaxle Apply
Tube Clamp
Differential Gear Lube Apply Tube
D26383
Underdrive
Output Shaft
Oil Seal Ring
D03915
AT F
D03807
SST
D03914
Underdrive
Clutch Drum
Oil Seal Ring
AT F 40−44
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
83. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube and transaxle
apply tube clamp with the bolt to the transaxle housing.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
NOTICE:
Make sure to insert the pipe to the stopper.
84. INSTALL TRANSAXLE CASE NO.1PLUG
(a) Install the 2 new O−rings to the 2 transaxle case No.1
plugs.
(b) Install the 2 transaxle case No.1 plugs to the transaxle
rear cover.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
85. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Coat the new oil seal ring with ATF and install it to the
transaxle housing.
86. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical
roller bearing.
SST 09950−60020 (09951−00810), 09950−70010
(09951−07100)
NOTICE:
Do not apply excessive pressure to it.
87. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Coat the 2 new oil seal rings with ATF, install them to the
transaxle rear cover.
NOTICE:
SDo not expand the gap of the oil seal ring too much.
SFix the hooks certainly. Confirm the smooth rotation.

D03809
Vinyl Tape
SST
D03810
SST
D03794
O−ringO−ring
D26764
Underdrive
Brake Piston
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−45
U151E, U151F A/T REPAIR MANUAL (RM1021U)
88. INSTALL NEEDLE ROLLER BEARING
(a) Wind a vinyl tape around SST at the place 4.0 mm (0.157
in.) above from the bottom end until the thickness of the
wound tape is about 5.0 mm (0.197 in.).
NOTICE:
Clean SST to remove deposited oil, before winding a vinyl
tape.
(b) Coat the needle roller bearing with ATF.
(c) Using SST and a press, install the needle−roller bearing
to the transaxle case.
SST 09950−60010 (09951−00320), 09950−70010
(09951−07100)
NOTICE:
When the wound vinyl tape contacts the transaxle case,
stop press−fitting.
89. INSTALL UNDERDRIVE BRAKE PISTON
(a) Coat the 2 new O−rings with ATF, install them to the un-
derdrive brake piston.
NOTICE:
SAssemble the O−ring carefully not to have a twist and
a pinching.
SApply enough ATF to the O−ring prior to assembling.
(b) Coat the underdrive brake piston with ATF.
(c) Install the underdrive brake piston to the transaxle case.
NOTICE:
Be careful not to damage the O−ring.

D26407
SST
Snap Ring
C89126
SST
D26467
Snap Ring
D26410
SST
40−46
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
90. INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387−00020
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
NOTICE:
SStop the press when the spring sheet is lowered1−
2 mm (0.039−0.078 in.) from the snap ring groove, to
prevent the spring sheet from deforming.
SDo not expand the snap ring excessively.
SInstalling the spring sub−assembly, check all of the
springs are fit in the piston correctly.
SThe snap ring should be fixed surely in the groove of
the transaxle case.
91. INSTALL BREATHER PLUG NO.2 (ATM)
92. INSTALL COUNTER DRIVE GEAR BEARING
(a) Coat the counterdrive gear bearing with ATF.
(b) Using SST and a press, install the bearing outer race.
SST 09950−60020 (09951−01030), 09950−70010
(09951−07150), 09649−17010
NOTICE:
SDo not apply excessive pressure to it.
SPress−fit the bearing outer race until it contacts the
transaxle case.
(c) Using a snap ring expander, install the snap ring.
NOTICE:
Face the white mark side of the snap ring up.
93. INSTALL COUNTER DRIVE GEAR
(a) Coat the couterdrive gear with ATF.
(b) Using SST and a press, install the tapered roller bearing
to the counter drive gear.
SST 09950−70010 (09951−07150), 09649−17010
NOTICE:
Do not apply excessive pressure to it.

C89122
SST
SST
Counter Drive
GearBearing
D26713
O−ringO−ring
D26593
1st & Reverse
Brake Piston
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−47
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Using SST and a press, install the counter drive gear and
bearing to the transaxle case.
SST 09223−15030, 09527−17011, 09950−60020
(09951−00750), 09950−70010 (09951−07150)
NOTICE:
Do not apply excessive pressure to it.
94. INSTALL1ST & REVERSE BRAKE PISTON
(a) Coat the 2 new O−rings with ATF.
(b) Install the 2 O−rings to the 1st & reverse brake piston.
NOTICE:
SAssemble the O−ring carefully not to have a twist and
a pinching.
SApply enough ATF to the O−ring prior to assembling.
(c) Coat a 1st & reverse brake piston with ATF, install it to the
transaxle case.
NOTICE:
Be careful not to damage the O−ring.

D03600
SST
D03615
Front Planetary Ring Gear
Brake Hub
Snap Ring
D26763
Front Planetary
Gear Assy
Brake Hub
40−48
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
95. INSTALL1ST & REVERSE BRAKE RETURN SPRING
SUB−ASSY
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387−00070
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
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, preventing the spring sheet from being de-
formed.
SDo not expand the snap ring excessively.
SInstalling the spring sub−assembly, check all of the
springs are fit in the piston correctly.
SThe snap ring should be fixed surely in the groove of
the cylinder.
SFix the snap ring to the inside of the claw of the spring
seat surely.
96. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear
and snap ring to the brake hub.
NOTICE:
Confirm the snap ring is fixed in the groove of the brake hub
correctly.
97. INSTALL FRONT PLANETARY GEAR ASSY
(a) Install the front planetary gear assy to the brake hub.

D03916
SST
Counter Drive
GearTransaxle
Case
2nd Brake Hub
w/ Front Planetary
Gear Assy
SST
D03917
D03596
SST
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−49
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST and a press, press−fit the front planetary gear
assy.
SST 09950−60010 (09951−00500), 09950−70010
(09951−07100)
NOTICE:
SDo not apply excessive pressure to it.
SPress the inner race of LH tapered roller bearing,
counter gear and front planetary gear assembly to the
position where no pre−load should be applied to one
pair of tapered roller bearings (left and right).
(c) Install the new washer, as shown in the illustration.
(d) Using SST, install the nut.
SST 09387−00030, 09387−00080
Torque: 210−350 Nm
(2,141kgfcm,155 ftlbf−3,569 kgfcm, 258 ftlbf)
NOTICE:
Assemble the washer after pressing each part, then tighten
the nut to minimum tightening torque.

D03918
SST
D08074
Lock Washer
C89123
C
BA
Input Sun Gear
D
40−50
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(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 09387−00080
Turning torque at 60 rpm:
New Bearing
0.51−1.02 Nm (5.1−10.0 kgfcm, 4.4−8.7 in.lbf)
Used Bearing
0.26−0.51Nm (2.7−5.2 kgfcm, 2.3−4.5 in.lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation
torque of tapered roller bearing is measured.
Torque: 350 Nm (3,569 kgfcm, 258 ftlbf) (a limit)
(g) Using a chisel and hammer, stake the front lock washer.
98. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
NOTICE:
SInstall the bearing race on the side of the front plane-
tary carrier. Be careful about the orientation of the
race.
SInstalling thrust bearing and front sun gears, be care-
ful about the orientation of the parts.
SInstall the bearing race on the side of the front sun
gear. Be careful about the orientation of the race.
SInstall the thrust bearing and the race after holding
the parts on the rear planetary carrier by applying
grease. Be sure the assembling order.