2005 TOYOTA AVENSIS transmission oil plug manual

C83143
C83144
C83142
D03900
D03900
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±15
U241E A/T REPAIR MANUAL (RM840U)
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 TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove 4 O±rings from the 4 transaxle case No. 1 plugs.
7. REMOVE SPEED SENSOR(TMC ±MADE)
(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
(b) Remove the 2 O±rings from the sensors.
8. REMOVE TRANSMISSION REVOLUTION
SENSOR(AISIN ±MADE)
(a) Remove the 2 bolts and the 2 transmission revolution
sensors from the transaxle assy.
(b) Remove the 2 O±rings from the sensors.

D08046
C83145
D09182
D03606
SST
D03915
40±22
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
30. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
END Play: 0.26 ± 1.25 mm (0.0103 ± 0.0492 in.)
31. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 2 transaxle case No 1 plugs.
(b) Remove the 2 O±rings from the transaxle case plug.
32. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing with a
plastic hammer to remove the transaxle housing from the
transaxle case.
NOTICE:
Differential may be accidentally removed when the trans-
axle housing is removed.
33. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the cylindrical roller bearing from the
transaxle case.
SST 09514±35011
34. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.

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.

C83141
D09193
C83140
D09194
40±50
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
97. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install 2 new O±rings to the 2 transaxle case No. 1 plugs.
(b) Install 2 transaxle case No. 1 plugs to the transaxle rear
cover.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
98. INSTALL TRANSAXLE REAR COVER SUB±ASSY
(a) Using SST and a press, install the bearing.
SST 09950±60010 (09951±00230, 09951±00350)
Press fit depth: 12.05 ± 12.75 mm (0.4744 ± 0.5020 in.)
NOTICE:

Face the inscribed mark side of the bearing race up.

Repeat the press fit until the specified value is ob-
tained.
(b) Apply liquid sealer to the 2 screws.
Sealant:
Part No. 08833±00080, THREE BOND 2430 or equiva-
lent.
(c) Using a torx socket wrench T30, install the transaxle rear
cover plate with the 2 screws.
Torque: 7.5 N
m (76 kgf
cm, 66 in.
lbf)
(d) Coat 2 new oil seal rings with ATF, install them to the
transaxle rear cover.

D03807
SST
D03630Seal Bend Width 1.2 mm (0.047 in.) FIPG
C50259
C
C
C
CA
AA B
BB
C83145
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±59
U241E A/T REPAIR MANUAL (RM840U)
115. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST and a press, install the U/D cylindrical roller
bearing.
SST 09950±60020 (09951±00810), 09950±70010
(09951±07100)
NOTICE:
Do not apply excessive pressure to it.
116. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil
on the contacting surfaces of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or equiva-
lent
(c) Install the transaxle housing and 16 bolts to the transaxle
case.
Torque:
Bolt A: 22 N
m (226 kgf
cm, 16 ft
lbf)
Bolt B and C: 29 N
m (300 kgf
cm, 22 ft
lbf)
HINT:
Apply seal packing or equivalent to the bolt A.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to
new bolts and tighten them within 10 minutes after applica-
tion.
117. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install 2 new O±rings to the 2 transaxle case No. 1 plugs.
(b) Install the 2 transaxle case No. 1 plugs to the transaxle
housing.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

C83143
C83142
D08034
D08093
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±67
U241E A/T REPAIR MANUAL (RM840U)
141. INSTALL OIL COOLER TUBE UNION
(a) Coat a new O±ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 27 N
m (280 kgf
cm, 20 ft
lbf)
142. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat 4 new O±rings with ATF, install them to the 4 trans-
axle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)
143. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the breather No. 2 plug.
144. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch onto the manual
valve lever shaft and temporarily install the 2 adjusting
bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 N
m (70 kgf
cm, 61 in.
lbf)
(c) Temporarily install control shaft lever.

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.

D26388
Rear Clutch
Oil Seal
Ring Outer
D26389
D26472
SST
D26390
D26391
Brake Apply Tube
Clutch Apply Tube
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−31
U151E, U151F A/T REPAIR MANUAL (RM1021U)
46. REMOVE TRANSAXLE CASE NO.1PLUG
(a) Remove the 4 transaxle case No.1 plugs from the trans-
axle rear cover.
(b) Remove the 4 O−rings from the 4 transaxle case No.1
plugs.
47. REMOVE REAR CLUTCH OIL SEAL RING OUTER
(a) Remove the 3 rear clutch oil seal rings from the transaxle
rear cover.
48. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle−roller bearing from the
transaxle rear cover.
SST 09387−00041 (09387−01021, 09387−01030,
09387−01040)
49. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Using a screwdriver, remove the 3 apply gaskets.
50. REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and brake apply tube.
(b) Remove the clutch apply tube.
(c) Remove the brake apply tube from the clamp.