2005 TOYOTA AVENSIS transmission oil plug

40123±01
C62684
AT0103
D30631
D05904O±Ring
40±42
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION VALVE BODY ASSY (U341E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket, and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the 19 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all of the pan
bolts, and carefully remove the oil pan assembly. Discard
the gasket.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Remove the magnets and use them to collect any
steel chips. Look at the chips and particles in the oil
pan and on the magnet carefully to see the type of
wear which might be found in the tranaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non±magnetic): bearing wear
4. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
NOTICE:
Be careful as some fluid will come out with the oil strainer.
(b) Remove the O±ring from the oil strainer.

D30342
D30343
D30346
D30344
40±26
±
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U241E)
AVENSIS REPAIR MANUAL (RM1018E)
11. SEPARATE CONNECTOR
(a) Separate the 2 wire harnesse clamps from the oil filler tube.
(b) Separate the transmission wire connector.
(c) Separate the park/neutral position switch connector.
(d) Separate the 2 speed sensor connectors.
12. REMOVE TRANSMISSION CONTROL CABLE CLAMP
(a) Remove the bolt and transmission control cable clamp from the automatic transaxle.
13. REMOVE TRANSMISSION OIL FILLER TUBE SUB±ASSY
(a) Remove the ATF level gauge.
(b) Remove the bolt and oil filler tube.
(c) Remove the O±ring from the oil filler tube.
14. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
(a) Remove the 3 bolts and control cable bracket No.1.
15. REMOVE FRONT WHEELS
16. REMOVE ENGINE UNDER COVER RH
17. REMOVE ENGINE UNDER COVER LH
18. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug gasket and drain ATF.
(b) Install a new gasket and drain plug. Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
19. DRAIN COOLANT
(a)1AZ±FE (See pege 16±19)
(b)1AZ±FSE (See pege 16±31)

4100Z±05
D25304
0 to 5 mm
(0 to 0.20 in.) 41±2
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE OIL (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
MANUAL TRANSAXLE OIL (MTM)
ON±VEHICLE INSPECTION
1. INSPECT TRANSAXLE OIL
(a) Stop the vehicle on the level place.
(b) Remove the transmission filler plug and gasket.
(c) Check that the oil surface is within 5 mm (0.20 in.) from the
lowest position of the inner surface of the transmission fill-
er plug opening.
NOTICE:

Excessively large or small amount of oil may cause
troubles.

After replacing oil, drive the vehicle and check the oil
level.
(d) Check for oil leakage when the oil level is low.
(e) Install the transmission filler plug and new gasket.
Torque:
C50, C250: 39 N
m (400 kgf
cm, 29 ft
lbf)
E354, E357: 49 N
m (500 kgf
cm, 36 ft
lbf)

400DE±02
D25827
SST
D25828
SST
D25829
SST
0
0.5mm
±
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U241E)
40±57
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (U241E)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER RH
3. REMOVE ENGINE UNDER COVER LH
4. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
5.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
6.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, pull out the oil seal.SST 09308±00010
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Using SST, pull out the oil seal. SST 09308±00010
9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09316±60011 (09316±00011)
Oil seal drive in depth:
0
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.

40124±01
\bD31071
SST
\bD31072SST
\b
D31073SST
±
AUTOMATIC TRANSMISSION / TRANS FRONT DIFFERENTIAL OIL SEAL (U341E)
40±55
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DIFFERENTIAL OIL SEAL (U341E)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE FRONT FENDER APRON SUB±ASSY LH
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
5. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
6.REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30±6)
7.REMOVE FRONT DRIVE SHAFT ASSY RH (See page 30±6)
8. REMOVE FRONT TRANSAXLE CASE OIL SEAL
(a) Using SST, pull out the oil seal.
9. REMOVE TRANSAXLE CASE OIL SEAL
(a) Using SST, pull out the oil seal.
10. INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.SST 09726±27012 (09726±02041), 09950±70010
(09951±07200)
Oil seal drive in depth:
2.7
0.5 mm (0
0.020 in.)
(b) Coat the lip of the oil seal with MP grease.

C67656
C67657
D30546
D30547
C67644
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
41±15
C250 M/T REPAIR MANUAL (RM1020E)
38. REMOVE DIFFERENTIAL CASE ASSY
(a) Remove the differential case assy from the front transaxle
case.
39. REMOVE MANUAL TRANSAXLE CASE RECEIVER
(a) Remove the bolt and manual transaxle case receiver from
the front transaxle case.
40. REMOVE REVERSE RESTRICT PIN ASSY
(a) Using a hexagon wrench, remove the reverse restrict pin
plug from the manual transmission case.
(b) Using a pin punch (
5 mm) and hammer, drive out the
slotted spring pin and reverse restrict pin assy from the
manual transmission case.
41. REMOVE OIL RECEIVER PIPE NO.1 (MTM)
(a) Remove the bolt and oil receiver pipe No.1 from the
manual transmission case.
NOTICE:
Be careful not to damage the oil receiver pipe No.1.

C68380
C80432
C80383
C80384
D30549
41±24
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
70. INSTALL OIL RECEIVER PIPE NO.1 (MTM)
(a) Install the oil receiver pipe No.1 with bolt to the manual
transmission case.
Torque: 17 N
m (175 kgf
cm, 13 ft
lbf)
71. INSTALL OIL RECEIVER PIPE NO.2 (MTM)
(a) Install the oil receiver pipe No.2 with bolt to the manual
transmission case.
Torque: 17 N
m (175 kgf
cm, 13 ft
lbf)
72. INSTALL REVERSE RESTRICT PIN ASSY
(a) Install the reverse restrict pin assy to the manual trans-
mission case.
HINT:
Do not set the reverse restrict pin assy in incorrect orientation.
(b) Using a pin punch (
5 mm) and hammer, install the
slotted pin to the restrict pin assy.
Drive in depth: 15.5 ± 16.5 mm (0.6102 ± 0.6496 in.)
(c) Apply sealant to the reverse restrict pin plug.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Using a hexagon wrench and torque wrench install the re-
verse restrict pin plug to the manual transmission case.
Torque: 13 N
m (130 kgf
cm, 9.3 ft
lbf)

C67884
C67889
D08358
C67881
40±66
± AUTOMATIC TRANSMISSION / TRANSTRANSAXLE REAR COVER ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL 2ND COAST & OVERDRIVE O±RING
[ 34622C / 3509 ]
(a) Coat the 2 new O±rings with ATF, install them to the trans-
axle rear cover.
NOTICE:
Be careful not to damage the oil seal lip.
11. INSTALL 2ND COAST & OVERDRIVE BRAKE PISTON
[ 34622B / 3509 ]
(a) Coat the piston with ATF, install it to the transaxle rear cov-
er.
NOTICE:
Be careful not to damage the oil seal lip.
12. INSTALL OVERDRIVE BRAKE RETURN SPRING
SUB±ASSY
[ 34603B / 3509 ]
(a) Using SST and a press, install the O/D brake return spring
and snap ring to the transaxle rear cover.
SST 09387±00070
NOTICE:
Stop the press when the O/D brake piston is lowered 1 ± 2
mm (0.039 ± 0.078 in.) from the snap ring groove, prevent-
ing the O/D brake piston from being deformed.
13. INSTALL TRANSAXLE REAR COVER PLUG
[ 35102B / 3503 ]
(a) Install 4 new O±rings and the 4 screw plugs to the trans-
axle rear cover.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
NOTICE:
Be careful not to damage the oil seal lip.