2005 TOYOTA AVENSIS clutch

D03682
40±84
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Inspect the clutch disc rotation.
(1) Check that the disc rotates when rotating the disc
after inserting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

D03574
D03575
D03576
D09201
D08048
40±24
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
40. REMOVE FORWARD CLUTCH ASSY
(a) Remove the forward clutch from the transaxle case.
41. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Remove the thrust bearing, multiple clutch hub, needle
roller bearing and bearing race from the transaxle case.
42. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Remove the bolt and parking pawl shaft clamp.
(b) Remove the parking lock pawl shaft.
(c) Push the parking lock pawn.
HINT:
Failure to do so will cause interference when the U/D planetary
gear is removed.

D03579
D08049
D03580
D03581
D03627
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±25
U241E A/T REPAIR MANUAL (RM840U)
(d) Remove the U/D planetary gear assy from the transaxle
case.
NOTICE:
Be careful so that the U/D planetary gear assy will not fall
out.
(e) Remove the spring, pawl pin and parking lock pawl.
43. REMOVE UNDERDRIVE CLUTCH ASSY
(a) Remove the U/D clutch assy, needle roller bearing, thrust
bearing U/D race No. 3 from the transaxle case.
44. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Using a screwdriver, remove the snap ring from the trans-
axle case.
(b) Remove the 1±way clutch from the transaxle case.

D09198
D08050
D09197
D09196
40±26
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(c) Remove the outer race retainer from the 1±way clutch.
45. REMOVE UNDERDRIVE CLUTCH DISC NO.2
(a) Using a screwdriver, remove the snap ring from the trans-
axle case.
(b) Remove the flange, 3 discs and 3 plates from the trans-
axle case.
46. INSPECT UNDERDRIVE CLUTCH DISC NO.2
(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.

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.

D08053
D03587
D03791
D08054
D08055
40±30
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(b) Remove the bearing race from the direct clutch.
57. REMOVE REAR PLANETARY SUN GEAR ASSY
(a) Remove the rear planetary sun gear assy from the trans-
axle case.
(b) Remove the rear planetary sun gear thrust bearing from
the rear planetary sun gear.
(c) Remove the thrust washer No. 1 and 1±way clutch thrust
bearing from the rear planetary sun gear.
58. REMOVE 1 WAY CLUTCH ASSY
(a) Remove the 1±way clutch assy from the transaxle case.