TOYOTA AVENSIS 2005 Service Repair Manual

D26591Rear Planetary Gear Assy
D03616
Snap Ring
D26413
Disc
Plate
D26452
A
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
Thrust bearing and bearing race diameter: mm (in.)
insideoutside
Thrust Bearing, A32.5 (1.28)56.5 (2.224)
Bearing Race, B40.2 (1.583)59.3 (2.335)
Thrust Bearing, C38.6 (1.520)59.7 (2.35)
Bearing Race, D38.6 (1.520)59.3 (2.335)
99. INSTALL REAR PLANETARY GEAR ASSY
(a) Install the rear planetary gear assy to the rear planetary
ring gear.
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm the snap ring is fixed in the groove of the1st & re-
verse brake hub correctly.
100. INSTALL1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case(Dimension A).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance:1.16−1.35 mm (0.0457−0.0531in.)
HINT:
Piston stroke = Dimension A−Flange thickness

D03815
D26396Second Brake Piston Assy
D08058
Snap Ring
C929771−Way Clutch Sleeve Outer
40−52
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
11.8 (0.071)52.2 (0.087)
21.9 (0.075)62.3 (0.091)
32.0 (0.079)72.4 (0.094)
42.1 (0.083)82.5 (0.098)
(c) Install the flange.
102. INSTALL SECOND BRAKE PISTON ASSY
(a) Install the second brake piston assy to the transaxle case.
(b) Install the snap ring and measure the inside diameter.
Inside diameter: More than167 mm (6.57 in.)
NOTICE:
SBecause the taper snap ring has the positioning
direction, check it when installing.
SWhen the diameter does not meet the specified value,
replace the snap ring with new one.
SAfter assembling, confirm that there is no clearance
between the second brake cylinder and the fitting sur-
face of the cylinder in the transaxle case.
103. INSTALL1WAY CLUTCH SLEEVE OUTER
(a) Install the 1−way clutch sleeve outer to the 2nd brake cyl-
inder assy.
NOTICE:
Check the positioning direction of the outer sleeve.

D03909
1−Way Clutch
Inner Race
D09638
Free
D03588
Thrust Needle
Roller Bearing
1−Way Clutch Assy
D26394
Planetary Carrier
Thrust Washer No.1
D26393
Planetary Carrier Thrust Washer No.2
Rear Planetary Sun Gear
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−53
U151E, U151F A/T REPAIR MANUAL (RM1021U)
104. INSTALL1WAY CLUTCH ASSY
(a) Install the 1−way clutch inner race to the 1−way clutch.
NOTICE:
SCheck the direction of the inner race.
SConfirm that the discrimination mark can be seen by
the worker.
(b) Check the rotating direction of 1−way clutch for the lock
or free operation, as shown in the illustration.
(c) Install the 1−way clutch and thrust needle roller bearing
to the 1−way clutch sleeve outer.
Bearing diameter: mm (in.)
InsideOutside
Bearing53.6 (2.110)69.4 (2.732)
NOTICE:
Install the thrust bearing properly so that no−colored race
will be visible.
105. INSTALL PLANETARY CARRIER THRUST WASHER
NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow
petrolatum, install it onto the planetary sun gear assy.
NOTICE:
After assembling, confirm that the projection should be
fixed surely in the hole of the planetary sun gear assembly.
106. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 2 with yellow
petrolatum, install it onto the rear planetary sun gear.

D26404
BA
D26714Rear Planetary Sun Gear Assy
D26412
Plate Disc
D26453
B 40−54
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Coat the bearing with yellow petrolatum, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Race, A33.0 (1.299)45.4 (1.787)
Bearing, B31.85 (1.254)45.2 (1.78)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
NOTICE:
Installing the rear planetary sun gear assembly, confirm
that the B1discs engage.
107. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
108. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between
the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 0.62−0.91mm (0.0244−0.0358 in.)
HINT:
Piston stroke = Dimension B−Flange thickness−Snap ring
thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
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)8−

D03623
Snap Ring
D26392
BA
Overdrive Direct
Clutch Hub
D26403
Thrust Bearing
Direct Clutch Assy
D26469
C
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−55
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Temporarily remove the snap ring, attach the selected
flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible through the
groove of the transaxle case.
109. INSTALL OVERDREVE DIRECT CLUTCH HUB
SUB−ASSY
(a) Install the direct clutch hub to the planetary gear assy.
NOTICE:
Be careful not to damage the bush inside of the overdrive
clutch hub during instaling.
(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the direct
clutch hub.
NOTICE:
Installing the bearing, hold the part on the side of the over-
drive clutch hub.
Bearing and race diameter: mm (in.)
InsideOutside
Bearing, A24.7 (0.972)39.5 (1.555)
Race, B23.6 (0.929)38.0 (1.496)
110. INSTALL DIRECT CLUTCH ASSY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assy and thrust bearing to the rear
planetary sun gear assy.
NOTICE:
The disc in the direct clutch should completely match with
the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.
(c) Clean the connecter part of the transaxle case and the
rear cover.
(d) As shown in the illustration, place a straight edge on the
direct clutch drum and measure the distance between
transaxle case and the straight edge using vernier cali-
pers (Dimension C).

D26470
D
D26390
D03923
D26391
Brake Apply
Tube
Clutch Apply Tube
40−56
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using vernier calipers and a simple straightedge, mea-
sure the position shown in the illustration.
(f) Calculate the end play value using the following formula.
Select a thrust bearing which satisfies the end play value
and install it.
End play: 0.244−0.901mm (0.0096−0.0355 in.)
NOTICE:
Make sure that the no colored race side is facing the direct
clutch assy.
HINT:
End play = Dimension D−Dimension C
Bearing thickness and diameter : mm (in.)
ThicknessInsideOutside
3.6 (0.1417)56.3 (2.217)75.7 (2.980)
3.8 (0.1496)56.3 (2.217)75.7 (2.980)
111. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install the 3 new governor apply gaskets No. 1 to the
transaxle case.
112. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube before
installing the apply tube to the transaxle case. This pre-
vents the apply tube from being deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube and a bolt to the transaxle
case.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
NOTICE:
Each pipe should be securely inserted until it reaches the
stopper.

D26766
SST
D26389
Rear Clutch
Oil Seal
Ring Outer
D26388
D26454
FIPG
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−57
U151E, U151F A/T REPAIR MANUAL (RM1021U)
113. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing
to the transaxle rear cover.
SST 09950−60010 (09951−00230, 09952−06010)
Press fit depth: 20.55−21.25 mm (0.8091−0.8366 in.)
NOTICE:
SFace the inscribed mark side of the bearing race up.
SRepeat the press fit until the specified value is ob-
tained.
(b) Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install
them to the transaxle rear cover.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
115. INSTALL TRANSAXLE CASE NO.1PLUG
(a) Install the 4 new O−ring to the 4 transaxle case No. 1
plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
rear cover.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
116. INSTALL TRANSAXLE REAR COVER SUB−ASSY
(a) Remove any packing material and be careful not to get oil
on the contacting surfaces of the transaxle rear cover or
the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826−00090, THREE BOND1281or equiva-
lent.
NOTICE:
Concerning about the amount of the FIPG application, the
amount should be controlled to from even sealing film on
entire flange surface and have slight protrusion of the FIPG
all around of the connecting area. The FIPG shall be ap-
plied continuously on the flange. (Reference value of the
section diameter:
1.2)

D26387AA
D26414
Flange
Plate Disc
D26466
Snap Ring
D08082
40−58
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Apply liquid sealer to the ”A” bolt threads.
Sealant:
Part No. 08833−00080, THREE BOND1344, LOCTITE
242 or equivalent.
(d) Install the 11 bolts.
Torque:
Bolt A:19.0 Nm(190 kgfcm,14ftlbf)
Other bolt: 25.0 Nm (250 kgfcm,18ftlbf)
117. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle
case.
NOTICE:
Be careful about the order of discs, plate and flange assem-
bly.
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
118. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:1.81−2.20 mm (0.0713−0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will
meet the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)43.1 (0.122)
23.2 (0.126)53.3 (0.130)
33.4 (0.134)−−
(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.

D03925
Free
Free
D03907
Outer Race
Retainer
D03627
Mark
Mark
D03581Snap Ring
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
119. INSPECT UNDERDRIVE1WAY CLUTCH ASSY
(a) Install the underdrive clutch assy to the 1−way clutch.
(b) Rotate the underdrive clutch assy to check the rotating
direction for the lock or free operation.
120. INSTALL UNDERDRIVE1WAY CLUTCH ASSY
(a) Install the outer race retainer to the 1−way clutch.
NOTICE:
Fix the outer race retainer to the external tooth of the one
way clutch surely.
(b) Install the 1−way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the1−way clutch outer race is
visible.
(c) Using a screwdriver, install the snap ring to the transaxle
case.
NOTICE:
The snap ring should be fixed certainly in the groove of the
transaxle case as the gap exists except in the lock of teeth.

D03580
D09691
Parking Lock Pawl
Spring
Pawl Pin
D26386
D03579
Underdrive
Planetary
Gear Assy
40−60
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
121. INSTALL UNDERDRIVE CLUTCH ASSY
(a) Coat the bearing and bearing race with petroleum jelly,
install them onto the underdrive clutch.
Bearing and bearing race diameter: mm (in.)
InsideOutside
Bearing37.73 (1.4854)58.0 (2.2835)
Race29.9 (1.1772)55.5 (2.185)
(b) Install the underdrive clutch assy to the transaxle case.
NOTICE:
Installing the underdrive clutch drum sub−assy, be sure
not to damage the oil seal ring.
122. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock pawl.
(b) Temporarily install the parking lock pawl, shaft and spring
to the transaxle case, as shown in the illustration.
123. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Install the underdrive planetary gear assy to the transaxle
case.
NOTICE:
Engage all the discs of underdrive clutch and hub splines
of the underdrive planetary gear assy firmly and assemble
them securely.