Piston TOYOTA AVENSIS 2005 Service Manual PDF

C83465
C83465
C83464
C83462
D03796
SST
40±86
± AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
4. REMOVE 2ND BRAKE PISTON O±RING
(a) Remove the 2 O±rings from the 2ND brake piston.
5. INSTALL 2ND BRAKE PISTON O±RING
(a) Coat 2 new O±rings with ATF and install them in the 2ND
brake piston.
6. INSTALL 2ND BRAKE PISTON
(a) Press in the 2ND brake piston into the 2ND brake cylinder
with your hands.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB±ASSY
(a) Install the piston return spring.
(b) Place SST on the piston return spring, and compress the
piston return spring with a press.
SST 09387±00060
(c) Using a screwdriver, install the snap ring.
NOTICE:
Be sure the end gap of the snap ring is not aligned with the
piston return spring claw.

D03677
SST
D08101
D08102
D08103
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
40±81
U241E A/T REPAIR MANUAL (RM840U)

Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE DIRECT CLUTCH RETURN SPRING
SUB±ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09387±00020
(b) Using a snap ring expander, remove the snap ring from
the direct clutch drum.
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the direct clutch drum.
(d) Remove the piston return spring from the direct clutch
drum.
(e) Install direct clutch drum on the transaxle rear cover.
(f) Holding the direct clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch piston.

D09211
D03680
D08102
D08101
D03677
SST
40±82
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. INSPECT DIRECT CLUTCH RETURN SPRING
SUB±ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 22.58 mm (0.8890 in.)
6. INSTALL DIRECT CLUTCH RETURN SPRING
SUB±ASSY
(a) Coat the direct clutch piston with ATF, and install it to the
direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch pis-
ton.
(b) Install the piston return spring to the direct clutch drum.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch ba-
lancer.
(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09387±00020
(e) Using a snap ring expander, install the snap ring to the di-
rect clutch drum.
NOTICE:

Be sure the end gap of the snap ring is not aligned
with the clutch balancer claw.

C83127
C83128
C83129
D03554
D03555
40±18
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
16. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No. 1 from the trans-
axle case.
17. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2ND brake gasket from the
transaxle case.
18. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
19. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the trans-
axle case.
20. REMOVE C±3 ACCUMULATOR PISTON
(a) Remove the compression spring from the C
3 accumulator
piston.

D03556
D03902
D03557
D03903
D03558
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±19
U241E A/T REPAIR MANUAL (RM840U)
(b) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
oil hole and remove the C
3 accumulator piston.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing.
(c) Remove the O±ring from the C
3 accumulator piston.
21. REMOVE C±1 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the C
1 accumulator piston and com-
pression spring.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing.
(b) Remove the 2 O±rings from the C
1 accumulator piston.
22. 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 com-
pression springs.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing.

D03904
D03560
C56727
D03559
D03563
40±20
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(b) Remove the O±ring from the B3 accumulator piston.
23. REMOVE MANUAL DETENT SPRING SUB±ASSY
(a) Remove the 2 bolts, the manual detent spring sub±assy
and spring cover.
24. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and the parking lock pawl bracket.
25. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle±nose pliers, remove the manual valve lever
shaft retainer spring.
26. REMOVE MANUAL VALVE LEVER SUB±ASSY
(a) Using a chisel and hammer, unstake and remove the
manual valve lever spacer.

D03610
SST
D08051
D03806
D03914
C83141
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±27
U241E A/T REPAIR MANUAL (RM840U)
47. REMOVE UNDERDRIVE BRAKE RETURN SPRING
SUB±ASSY
(a) Using SST, a snap ring expander and a press, remove the
snap ring from the transaxle case.
SST 09387±00020
(b) Remove the U/D brake return spring sub±assy from the
U/D brake piston.
48. INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB±ASSY
(a) Using vernier calipers, measure the free length of the U/D
brake return spring sub±assy together with the spring
seat.
Standard free length: 14.04 mm (0.5213 in.)
49. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 U/D clutch drum oilseal rings from the
transaxle case.
50. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove 2 transaxle case No. 1 plugs from the transaxle
rear cover.
(b) Remove 2 O±rings from the 2 transaxle case No. 1 plugs.

D09183
D09184
C83140
D03801
SST
D03799
40±28
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
51. 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.
(c) Remove the 2 outer rear clutch oil seal rings from the
transaxle rear cover.
(d) Using a torx socket wrench T30, remove the 2 screws and
transaxle rear cover plate.
(e) Using SST, remove the needle±roller bearing from the
transaxle rear cover.
SST 09387±00040 (09387±01010, 09387±01030,
09387±01040)
52. REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove the U/D brake piston.

D03794
D25510
D03591
D03586
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±29
U241E A/T REPAIR MANUAL (RM840U)
(b) Remove the 2 O±rings from the U/D brake piston.
53. REMOVE BRAKE APPLY TUBE
(a) Remove a bolt, clamp and 2 brake apply tubes.
(b) Remove the brake apply tube from the clamp.
54. REMOVE FRONT CLUTCH APPLY TUBE
55. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Using a screwdriver, remove the 2 governor apply gasket
No. 1.
56. REMOVE DIRECT CLUTCH ASSY
(a) Remove the thrust bearing and the direct clutch assy from
the transaxle case.

D08058
D08059
D08060
D09189
40±32
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)

Before assembling new discs, soak them in ATF for
at least 15 minutes.
62. REMOVE SECOND BRAKE PISTON ASSY
(a) Using a screwdriver, remove the 2ND brake cylinder hole
snap ring from the transaxle case.
(b) Remove the 2ND brake cylinder from the transaxle case.
63. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 5 discs and 5 plates from the trans-
axle case.
64. INSPECT 1ST & REVERSE BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate, and
flange are worn or burnt.
If necessary, replace them.
NOTICE:

If the lining of the disc is peeling off or discolored, or
even if a part of the groove is defaced, replace all
discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.