2005 TOYOTA AVENSIS clutch

D04077
D03703
SST
D03704
D08127
40±88
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
3. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
HINT:

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

Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09350±32014 (09351±32070)
(b) Using a snap ring expander, remove the snap ring.
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 and piston return spring from
the U/D clutch drum.
(d) Install the U/D clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.

D08128
D09214
D04078
D08129
D04078
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
40±89
U241E A/T REPAIR MANUAL (RM840U)
(e) Holding the U/D clutch piston with your hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the U/D clutch piston.
5. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB±ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.14 mm (0.6748 in.)
6. REMOVE UNDERDRIVE CLUTCH DRUM O±RING
7. INSPECT UNDERDRIVE CLUTCH DRUM SUB±ASSY
(a) Using a dial indicator, measure the inside diameter of the
U/D clutch drum bushing.
Standard drum bushing:
32.56 ± 32.58 mm (1.2818 ± 1.2826 in.)
Maximum drum bushing: 32.63 mm (1.2846 in.)
If the inside diameter is greater than the maximum, replace the
U/D clutch drum.
8. INSTALL UNDERDRIVE CLUTCH DRUM O±RING
(a) Coat a new O±ring with ATF and install it to the U/D clutch
drum.

D03860
D03704
D03703
SST
D08130
Flange
Disc
Plate 40±90
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the U/D clutch piston with ATF, and install it to the
U/D clutch piston drum.
NOTICE:
Be careful not to damage the O±ring.
(b) Install the piston return spring and clutch balancer to the
U/D clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
(c) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09350±32014 (09351±32070)
(d) Using a snap ring expander, install the snap ring to U/D
clutch drum.
NOTICE:

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

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

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
10. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Install the 3 plates, 3 discs and flange.

D08125
D08123
D08124
± AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U241E)
40±91
U241E A/T REPAIR MANUAL (RM840U)
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
11. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the U/D clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the U/D clutch piston stroke while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Park clearance: 1.51 ± 1.90 mm (0.0594 ± 0.0748 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the park clearance is non±standard, select another flange.
HINT:
There are 3 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
A3.0 (0.118)C3.4 (0.134)
B3.2 (0.126)±±

4006R±01
D09210
D08099
D08100
D04079
40±80
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
DIRECT CLUTCH ASSY (U241E)
OVERHAUL
1. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch and needle roller bearing on the
transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
0.605 ± 0.825 mm (0.02382 ± 0.03248 in.)
If the pack clearance is non±standard, inspect the discs, plates
and flange.
2. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Using a screwdriver, remove the snap ring from the direct
clutch drum.
(b) Remove the flange, 3 discs and 3 plates from the direct
clutch drum.
3. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:

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

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.

D08104
Flange
Disc
Plate
D08099
D09210
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
40±83
U241E A/T REPAIR MANUAL (RM840U)

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.
7. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Install the 3 plates, 3 discs and flange.
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
8. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Park clearance:
0.605 ± 0.825 mm (0.02382 ± 0.03248 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is non±standard, select another flange.
HINT:
There are 6 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.0 (0.118)43.3 (0.130)
23.1 (0.122)53.4 (0.134)
33.2 (0.126)63.5 (0.138)