TOYOTA AVENSIS 2005 Service Repair Manual

D09693
D03576Pawl Shaft Clamp
D03875
E
D25511
Dimension (1)
Dimension (2)
D08087
Thrust Bearing Race No.1
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−61
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the parking lock pawl shaft.
(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
(d) Using a straight edge and vernier calipers as shown in the
illustration, measure the gap between the top of the differ-
ential drive pinion in the underdrive planetary gear and
contact surface of the transaxle case and housing (Di-
mension E).
NOTICE:
Note down the dimension E as it is necessary for the follow-
ing process.
(e) As shown in the illustration, measure the 2 places of the
transaxle housing, calculate the dimension F using the
formula.
NOTICE:
Note down the dimension F as it is necessary for the follow-
ing process.
HINT:
Dimension F = Dimension (1)−Dimension (2)
124. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust bearing race No.1 to the transaxle case
while checking its direction.
Bearing race diameter: mm (in.)
InsideOutside
Bearing race39.5 (1.555)45.8 (1.803)

D26710
Thrust Needle
Roller BearingMultiple Disc
Clutch Clutch
Hub
D26711
Thrust Needle
Roller BearingMultiple Disc
Clutch Clutch
Hub
D03820
Thrust Needle
Roller Bearing
D03574
Forward Clutch Assy
40−62
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Coat the thrust needle roller bearing and race with yellow
petrolatum, install them onto the multiple disc clutch hub.
Thrust bearing and race diameter: mm (in.)
InsideOutside
Thrust Bearing36.4 (1.433)52.2 (2.055)
(c) Coat the needle roller bearing with ATF.
(d) Install the needle roller bearing to the multiple clutch hub.
Bearing diameter: mm (in.)
InsideOutside
Bearing23.6 (0.929)44 (1.732)
(e) Install the multiple clutch hub to the transaxle case.
125. INSTALL FORWARD CLUTCH ASSY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward
clutch.
Thrust bearing diameter: mm (in.)
InsideOutside
Thrust Bearing33.58 (1.3220)51.9 (2.043)
NOTICE:
Install the thrust bearing properly so that the no colored
race or blue ink jet race will be visible.
(c) Install the forward clutch to the forward clutch assy.
NOTICE:
SAlign the splines of all discs in the forward clutch with
those of multiple clutch hub to assemble them se-
curely.
SBe careful not to damage the bush inside of the for-
ward clutch hub during installing.

D03573
D26450
Differential
Gear Assy
D25506
Thrust Bearing
Underdrive
Race No.2Underdrive Planetary
Gear Assy
Forward Clutch
Assy
Differential Gear Assy
Forward Clutch
Assy
D25505
Thrust
Needle
Roller Bearing
Differential Gear Assy
Underdrive Planetary
Gear Assy
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−63
U151E, U151F A/T REPAIR MANUAL (RM1021U)
126. INSTALL OVERDRIVE BRAKE GASKET
(a) Install the 2 new overdrive brake gaskets.
127. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assy to the transaxle case.
128. INSTALL THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Install the thrust bearing underdrive race No.2 to the un-
derdrive planetary gear assy.
129. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula
and values of Dimension E and F that ware measured
when installing cylindrical roller bearing and underdrive
planetary gear. Select an appropriate underdrive plane-
tary gear thrust bearing race No. 2 which satisfies the spe-
cified end play value, and install it.
End play: 0.498−0.993 mm (0.01961−0.03909 in.)
HINT:
End play = Dimension F−Dimension E−thrust bearing thick-
ness 2.5 mm (0.0984 in.)−underdrive thrust bearing race No.
2 thickness.
Race thickness: mm (in.)
F−EThickness
Less than 7.72 (0.3039)3.5 (0.138)
7.72 (0.3039)3.8 (0.150)

D03569
D03629
O−ring
D03630Seal Bend Width 1.2 mm (0.047 in.) FIPG
40−64
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Bearing and bearing race diameter: mm (in.)
InsideOutside
Bearing57.2 (2.252)84.96 (3.345)
Bearing race56.4 (2.22)83 (3.268)
130. INSTALL OIL PUMP ASSY
(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.0 Nm (226 kgfcm,16ftlbf)
(b) Coat the O−ring of oil pump with ATF.
NOTICE:
Confirm the input shaft rotates smoothly with the manual
operation after assembling the oil pump.
131. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil
on the contacting surface of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826−00090, THREE BOND1281or equiva-
lent

D25608
C
C
CAB2WD:
4WD:
B
D
C CC
CB
B
A
A
D08091
D03631
D26468
SST
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−65
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Install the transaxle housing and 16 bolts to the transaxle
case.
Torque:
Bolt A: 25 Nm (255 kgfcm,18ftlbf)
Bolt B: 33 Nm (337 kgfcm, 24 ftlbf)
Bolt C: 29 Nm (295 kgfcm, 21ftlbf)
Bolt D: 22 Nm (226 kgfcm,16.0 ftlbf)
HINT:
Apply seal packing or equivalent to the bolt A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to
new bolts and tighten them within10 minutes after applica-
tion.
132. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
End play: 0.262−1.249 mm (0.0100−0.0494 in.)
133. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.
134. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950−60010 (09951−00230), 09950−70010
(09951−07100)
Oil seal drive in depth: 0á0.5 mm (0á0.0197 in.)

D26382
Parking Lock Rod Sub−assy
D03565
Spacer
D03564
D26765
D03559
40−66
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
135. INSTALL PARKING LOCK ROD SUB−ASSY
(a) Install the parking lock rod to the manual valve lever.
136. INSTALL MANUAL VALVE LEVER SUB−ASSY
(a) Install a new spacer and manual valve lever shaft to the
transaxle case.
NOTICE:
Do not damage on the oil seal during assembling the shaft
to the transaxle case.
(b) Using a pin punch and hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small hole
for locating the staking position in the spacer with the
staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small
hole.
(e) Check that the spacer does not turn.
137. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle−nose pliers, install the retainer spring.
NOTICE:
Hang the spring on the shaft certainly.

D03561
D03560
B
A
D03904
O−ring
B−3 Accumulator Piston
D25512
AT F
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−67
U151E, U151F A/T REPAIR MANUAL (RM1021U)
138. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgfcm,15ftlbf)
Bolt length: 25 mm (0.984 in.)
NOTICE:
Be sure the parking rod is placed between the parking pawl
and the guide of the parking bracket when the parking
bracket is assembled.
139. INSTALL MANUAL DETENT SPRING SUB−ASSY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring and cover in
this order.
HINT:
Tighten them in the order, A and B.
Torque:
Bolt A: 20 Nm (205 kgfcm,15ftlbf)
Bolt B:12Nm(120 kgfcm, 9 ftlbf)
Bolt length:
Bolt A: 27 mm (1.063 in.)
Bolt B:16 mm (0.630 in.)
140. INSTALL B−3 ACCUMULATOR PISTON
(a) Coat a new O−ring with ATF, install it to the B−3 accumula-
tor piston.
NOTICE:
Install the O−ring to the accumulator piston and the accu-
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
Inner 62.00 (2.4409) /
15.50 (0.610)Purple
Outer 74.23 (2.9224) /
21.70 (0.854)Purple

D26402
O−ring
O−ring Reverse clutch Accumulator Piston
C92978
AT F
D03902
O−ring
C−3 Accumulator Piston
C83146
D03555
40−68
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
141. INSTALL REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Coat the 2 new O−rings with ATF, install them to the re-
verse accumulator piston.
NOTICE:
Install the O−ring to the accumulator piston and the accu-
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
60.96 (2.3999) /
14.10 (0.555)Yellow
142. INSTALL C−3 ACCUMULATOR PISTON
(a) Coat a new O−ring with ATF, install it to the C−3 accumu-
lator piston.
NOTICE:
Install the O−ring to the accumulator piston and the accu-
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
72.20 (2.8425) /
19.0 (0.748)Colorless
(c) Install the spring from the C−3 accumulator piston.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.

D03554
Check Ball
C83129
C83128
C83127
D03636AT F
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−69
U151E, U151F A/T REPAIR MANUAL (RM1021U)
143. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Regarding the installation of the spring for the check ball
body, be sure to place the spring in the hole in the ball body.
Be careful about the parts orientation.
144. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to the
transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
145. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF,
install it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
146. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No. 1 with ATF, install
it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
147. INSTALL TRANSMISSION WIRE
(a) Coat a new O−ring with ATF, install it to the transmission
wire.
NOTICE:
Be careful about the O−ring not to have a twist, a protrusion
and a pinching during installing the wire transmission to
the transaxle case. Moreover, apply enough ATF to the O−
ring prior to assembling.

D03547
Transmission Wire
C91927
GFE
A
B
C
D
C91933
A
CB
B
A
C
L
L
C91932
O−ring
40−70
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the transmission wire retaining bolt.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
148. CONNECT TRANSMISSION WIRE
(a) Coat a O−ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor, with the lock plate and
bolt.
Torque: 6.6 Nm (67 kgfcm, 58 in.lbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
SConnect the connector to A, B, C, D, E, F, G, from
shorter one.
SApply ATF to the bolt.
149. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the
valve body with 17 bolts to the transaxle case.
Torque:11Nm(110 kgfcm, 8 ftlbf)
Bolt length:
Bolt A: 41mm (1.614 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 25 mm (0.984 in.)
NOTICE:
SPush the valve body against the accumulator piston
spring and the check ball body to install it.
SWhen installing the valve body to the transaxle case,
do not hold the solenoids.
STighten temporarily those bolts marked byLin the il-
lustration first because they are positioning bolts.
150. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O−ring with ATF, install it to the oil strainer.
NOTICE:
Assemble the O−ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O−ring prior
to assembling.