2005 TOYOTA AVENSIS oil

D26446
D26451
SST
D25606
SST
40−114
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tighten the14 bolts.
Torque: 95.0 N
m (970 kgf
cm, 70 ft
lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
17. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
(b) Apply the rip of oil seal with a little MP grease.
SST 09223−15020, 09950−70010 (09951−07150)
Oil seal drive in depth: 0á0.5 mm (0á0.0197 in.)
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive into a new oil seal.
(b) Apply the lip of the oil seal with a little MP grease.
SST 09710−30050, 09950−70010 (09951−07150)
Oil seal drive in depth: 0á0.5 mm (0á0.0197 in.)

400H3−02
D26429
D03701
Snap Ring
D26430
Underdrive
Clutch Drum
40−94
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while ap-
plying and releasing compressed air (392 kPa, 4.0 kgf/
cm
2, 57 psi).
Pack clearance:1.51−1.71mm (0.0594−0.0673 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the under-
drive clutch drum.

C56360
D03824
D03705
D26465
O−ring
D26465
O−ring
40−96
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the return spring from the underdrive clutch
drum.
7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length:17.14 mm (0.6752 in.)
8. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the underdrive clutch piston.
9. REMOVE UNDERDRIVE CLUTCH DRUM O−RING
(a) Using a screwdriver, remove the O−ring from the under-
drive clutch drum.
10. INSTALL UNDERDRIVE CLUTCH DRUM O−RING
(a) Apply the new O−ring with ATF, install it to the underdrive
clutch drum.
NOTICE:
Assemble the O−ring carefully not to have a twist and a
pinching.

D25592
StopperStopper
D26431
Disc
Flange
Plate
D03701
D26429
40−98
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the underdrive clutch
drum shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stopper.
13. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Apply the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the underdrive
clutch drum.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
14. INSTALL UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, install the underdrive clutch flange
No.2 hole snap ring.
(b) Check that the end gap of snap ring is not aligned with one
of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
15. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch piston stroke while apply-
ing and releasing compressed air (392 kPa, 4.0 kgf/cm
2,
57 psi).
Park clearance:1.51−1.71mm (0.0594−0.0673 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another
flange.
HINT:
There are 5 flanges in different thickness.
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)−−

400H1−02
D26715
D26753
Snap Ring
D26754
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−79
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:1.00−1.25 mm (0.0394−0.4921in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.

D09211
ForwardClutchRe-
turn Spring
D03664
C56374
D25587
A
D26707Forward Clutch Piston
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−81
U151E, U151F A/T REPAIR MANUAL (RM1021U)
5. INSPECT FORWARD CLUTCH RETURN SPRING
SUB−ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 26.74 mm (1.0528 in.)
6. REMOVE FORWARD CLUTCH PISTON SUB−ASSY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the oil pump
to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted, either blow
the air again with the protruding side pushed, or remove the pis-
ton using the needle nose plier with vinyl tape on the tip.
7. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring to the input shaft.
8. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the new input shaft oil seal ring from both sides
to reduce dimension A.
Dimension A: 5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input
shaft.
NOTICE:
Do not expand the gap of the oil seal ring too much. Fix the
hooks certainly.
9. INSTALL FORWARD CLUTCH PISTON SUB−ASSY
(a) Coat the forward clutch piston with ATF, and install it to the
input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward clutch
piston.

C83143
Union
O−ring
C83144
Elbow
O−ring
D03900D30672
Speed Sensor
D26716
D09176
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−19
U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. REMOVE OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Remove the union.
(b) Remove the O−ring from the union.
5. REMOVE OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Remove the elbow.
(b) Remove the O−ring from the elbow.
6. REMOVE SPEED SENSOR
(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
7. REMOVE TRANSAXLE CASE NO.1PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove the 4 O−rings from the 4 transaxle case No.1
plugs.
8. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.

C91925
C86316
Magnet
AT0103
Magnet
C91927
Temperature
Sensor
D03547
Transmission Wire
40−20
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Remove the 18 bolts, oil pan and gasket.
(b) Remove the 2 magnets from the oil pan.
10. INSPECT TRANSMISSION OIL CLEANER MAGNET
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non−magnetic).... bushing wear
11. DISCONNECT TRANSMISSION WIRE
(a) Remove the 7 connectors from the shift solenoid valves.
(b) Remove the bolt, lock plate and ATF temperature sensor.
12. REMOVE TRANSMISSION WIRE
(a) Remove the bolt and transmission wire from the transaxle
case.