2005 TOYOTA AVENSIS clutch

D03794
D03609
D08071
D03610
SST
D09197
40±52
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(c) Coat 2 new O±rings with ATF, install them to the U/D
brake piston.
(d) Install the U/D brake piston to the transaxle case.
101. INSTALL UNDERDRIVE BRAKE RETURN SPRING
SUB±ASSY
(a) Install the U/D brake return spring to the U/D brake piston.
(b) Using SST, a snap ring expander and a press, install the
snap ring to the transaxle case.
SST 09387±00020
NOTICE:
Do not apply excessive pressure to it.
102. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Install the 3 discs and 3 plates to the transaxle case.

D08050
D08082
D03907
D03925
Free
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±53
U241E A/T REPAIR MANUAL (RM840U)
(b) Using a screwdriver, install the snap ring.
(c) Using a dial indicator, measure the U/D brake piston
stroke while applying and releasing compressed air (392
kPa, 4.0 kgf/cm
2, 57 psi).
Piston stroke: 1.81 ± 2.20 mm (0.0713 ± 0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will
meet the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)33.4 (0.134)
23.2 (0.126)±±
(d) Temporally remove the snap ring and attach the flange.
Restore the snap ring.
103. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Install the outer race retainer to the 1±way clutch.
(b) Install the U/D clutch assy to the 1±way clutch. Rotate the
U/D clutch assy to check the rotating direction for the lock
or free operation.

C50158
D03581
D03580
D09691
D09692
40±54
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(c) Install the 1±way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the 1±way clutch outer race is
visible.
(d) Using screwdriver, install the snap ring to the transaxle
case.
104. INSTALL UNDERDRIVE CLUTCH ASSY
(a) Coat the bearing and bearing race with petroleum jelly,
install them onto the U/D clutch.
Race diameter: mm (in.)
InsideOutside
Bearing37.73 (1.4854)58.0 (2.283)
Race29.9 (1.177)55.5 (2.185)
(b) Install the U/D clutch assy to the transaxle case.
105. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Install the parking lock pawl pin and torsion spring to the
parking lock pawl.
(b) Temporarily install the parking lock pawl, shaft and spring
to the transaxle case as shown in the illustration.

D03579
D09693
D03576
D03875
D
D25511
Dimension (1)
Dimension (2)
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±55
U241E A/T REPAIR MANUAL (RM840U)
(c) Install the U/D planetary gear assy to the transaxle case.
NOTICE:
Engage all the discs of U/D clutch and hub splines of the
U/D planetary gear assy firmly and assemble them secure-
ly.
(d) Install the parking lock pawl shaft.
(e) Install the pawl shaft clamp with the bolt.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
(f) Using a straight edge and vernier calipers as shown in the
illustration, measure the gap between the top of the differ-
ential drive pinion in the U/D planetary gear and contact
surface of the transaxle case and housing. (Dimension D)
NOTICE:
Note down the dimension D as it is necessary for the fol-
lowing process.
(g) As shown in the illustration, measure the 2 places of the
transaxle housing, Calculate the dimension E using the
formula.
NOTICE:
NOte down the dimension E as it is necessary for the fol-
lowing process.
HINT:
Dimension E = Dimension (1) ± Dimension (2)

C51677
D08087
D03628
D03929
40±56
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
106. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Using a dial indicator, measure the inside diameter of the
forward clutch hub bushing
Standard inside diameter:
23.025 ± 23.045 mm (0.9065 ± 0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091 in.)
NOTICE:

When the diameter is over the maximum, replace the
multiple disc clutch hub with new one.

Check the contact surface of the bush in the direct
clutch shaft. If any scratch or discolor is identified, re-
place the direct clutch sub±assy with new one.
If the inside diameter is greater than the maximum, replace the
forward clutch hub.
107. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the bearing race to the transaxle while checking its
direction.
Bearing race diameter: mm (in.)
InsideOutside
Bearing race34.5 (1.358)48.5 (1.909)
(b) Coat the thrust needle roller bearing and race with petro-
leum jelly, install them onto the multiple disc clutch hub.
Thrust bearing and race diameter: mm (in.)
InsideOutside
Bearing36.3 (1.429)52.2 (2.055)
(c) Install the input shaft thrust bearing to the multiple clutch
hub.
Bearing diameter: mm (in.)
InsideOutside
Bearing23.5 (0.925)44.0 (1.732)
(d) Install the forward clutch hub to the transaxle case.

D11358
Race ”B”
Race ”A”
Forward Clutch Side
D03574
D03573
C50035
D03569
−
AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSAXLE ASSY (U24
1E)
40− 57
Correction to R/M Pub. No. RM840U (Bulletin No. OB −1123)
108. INSTALL FORWARD CLUTCH ASSY
(a) Install the input shaft thrust bearing to the forward clutch.
Bearing diameter: mm (in.)
InsideOutside
Bearing33.85 ( 1.3327)52.2 (2.055)
NOTICE:
Install the thrust bearing properly so that the race ”B” will
be visible.
(b) Install the forward clutch to the multiple clutch hub.
NOTICE:
Align the splines of all discs in the forward clutch with
those of multiple clutch hub to assemble them securely.
109. INSTALL OVERDRIVE BRAKE GASKET
[35179 / 98− 3]
(a) Install 2 new O/D brake gaskets to the transaxle case.
11 0. INSTALL FRONNT DIFFERENTIAL ASSY
(a) Install the differential assy to the transaxle case.
111 . INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump assy and 7 bolts to the transaxle case.
Torque: 22 N ⋅m (226 kgf⋅cm, 16ft⋅lbf)

C69643
C69644
C69641
C69646
C83814
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
41±63
E355,E356 M/T REPAIR MANUAL (RM867E)
8. REMOVE SYNCHRONIZER RING SET NO.2
(a) Remove the synchronizer ring set No.2 from the transmis-
sion clutch hub No.1.
9. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing from the out-
put shaft.
10. REMOVE 2ND GEAR BEARING SPACER
(a) Remove the 2nd gear bearing spacer from the output
shaft.
11. REMOVE 2ND GEAR BUSH
(a) Remove the 2nd gear bush from the output shaft.
12. REMOVE 2ND GEAR BUSH BALL
(a) Using a magnetic finger, remove the 2nd gear bush ball
from the output shaft.

SST
C69648
C69649
C69650
SST
C69651
C69652
41±64
± MANUAL TRANSMISSION/TRANSAXLEOUTPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
13. REMOVE 1ST GEAR
(a) Using SST and a press, remove the transmission clutch
hub No.1 and 1st gear from the output shaft.
SST 09950±00020
14. REMOVE SYNCHRONIZER RING SET NO.1
(a) Remove the synchronizer ring set No.1 from the 1st gear.
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output
shaft.
16. REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the output shaft front
bearing (inner race) from the output shaft.
SST 09950±00020, 09950±60010 (09951±00320),
09950±70010 (09951±07150)
NOTICE:
Do not tighten SST excessively.
17. REMOVE REVERSE GEAR
(a) Remove the reverse gear, 3 synchromesh shifting keys
and 3 synchromesh shifting key springs from the trans-
mission clutch hub No.1.