2005 TOYOTA AVENSIS clutch

C69553
C69552
C69551
C69633
SST
C69634
41±58
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
26. INSTALL 4TH GEAR BEARING SPACER
(a) Coat the 4th gear bearing spacer with gear oil,install it to
the input shaft.
27. INSTALL 2ND SYNCHRONIZER OUTER RING
(a) Coat the 2nd synchronizer outer ring with gear oil, install
it to the transmission the transmission clutch clutch hub
No.2.
NOTICE:
Align the claw of the clutch hub No.2 with the noch of the
2nd synchronizer outer ring and assemble.
28. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing with gear oil, install
it to the input shaft.
29. INSTALL 4TH GEAR
(a) Coat the 4th gear with gear oil, install it to the input shaft.
30. INSTALL INPUT SHAFT REAR RADIAL BALL
BEARING
(a) Using SST and a press, install the input shaft rear radial
ball bearing to the input shaft.
SST 09608±06041
NOTICE:

Make the groove on the bearing face to the rear and
install.

Make sure that the 3rd gear should rotate.

190AI±01
A62720
Drive End Frame Assy Generator w/ Clutch Pulley
Alternator Pulley CapGenerator Rotor Assy
Rear End Cover
Sub±Assy Rear Seal Plate
Generator Brush
Holder Assy
Front Seal
Plate
Alternator Coil Assy
N´m (kgf´cm, ft´lbf)
: Specified torque
5.8 (59, 51 in.´lbf)
1.8 (18, 16 in.´lbf)
4.6 (47, 41 in.´lbf)
± STARTING & CHARGINGGENERATOR ASSY(130A) (1CD±FTV)
19±31
1CD±FTV ENGINE REPAIR MANUAL (RM927E)
GENERATOR ASSY(130A) (1CD±FTV)
COMPONENTS

D25148
TA CDLC3 12345 768
9 1 0111 21 3 1 514 16
± DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E)05±991
AVENSIS REPAIR MANUAL (RM1018E)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R ranges.
NOTICE:

Do the test at normal operating ATF temperature 50 to 80
C (122 to 176
F).

Do not continuously run this test for longer than 5 seconds.

To ensure safety, do this test in a wide, clear level area which provides good traction.

The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect the hand±held tester to DLC3 or tachome-
ter to terminal TAC of DLC3 with SST.
SST 09843±18030
(3) Fully apply the parking brake.
(4) Keep your left foot pressing firmly on the brake ped-
al.
(5) Start the engine.
(6) Shift into the D range. Press all the way down on the
accelerator pedal with your right foot.
(7) Quickly read the stall speed at this time.
Stall speed: 2,400
150 rpm
(8) Do the same test in the R range.
Stall speed: 2,400
150 rpm
Evaluation:
ProblemPossible cause
(a) Stall speed low in D and R ranges

Engine output may be insufficient

Stator one±way clutch not operating properly
HINT: If the value is larger or smaller than the specified value by
600 rpm or more, the torque converter could be faulty.
(b) Stall speed high in D range

Line pressure too low

Forward clutch slipping

One±way clutch No.2 not operating properly
(c) Stall speed high in R range

Line pressure too low

Reverse clutch slipping

1st and reverse brake slipping
(d) Stall speed high in D and R ranges
Line pressure too low

Improper fluid level

D25148
TA C
12345 768
9 1 0111 21 3 1 514 16 05±992
± DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Measure the time lag.
(1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag
before the shock can be felt. This is used for checking the condition of the reverse clutch, forward
clutch, and 1st and reverse brake.
NOTICE:

Do the test at normal operating ATF temperature 50 to 80
C (122 to 176
F).

Be sure to allow 1 minute interval between tests.

Take 3 measurements and take the average value.
(2) Chock the 4 wheels.
(3) Connect the hand±held tester to DLC3 or tachome-
ter to terminal TAC of DLC3 with SST.
SST 09843±18030
(4) Start engine and check idle speed.
Idle speed: 650  50 rpm (In N range and A/C OFF)
(5) Shift the lever from N to D range. Using a stop
watch, measure the time from when the lever is
shifted until the shock is felt.
Time lag: N
D less than 1.2 seconds
(6) In the same way, measure the time lag for N
R.
Time lag: N
R less than 1.5 seconds
Evaluation (If N
D or N
R time lag is longer than the specified):
ProblemPossible cause
N
D time lag is longer

Line pressure too low

Forward clutch worn

One±way clutch No.2 not operating properly
N
R time lag is longer

Line pressure too low

Reverse clutch worn

1st and reverse brake worn

G24063
SST
SST
± DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E)05±993
AVENSIS REPAIR MANUAL (RM1018E)
9. HYDRAULIC TEST
(a) Measure the line pressure.
NOTICE:

Do the test at normal operation ATF temperature 50 to 80
C (122 to 176
F).

The line pressure test should always be carried out in pairs. One technician should observe
the conditions of wheels or wheel stopper outside the vehicle while the other is doing the test.

Be careful to prevent SST's hose from interfering with the exhaust pipe.
(1) Warm up the ATF.
(2) Remove the test plug on the left side of the trans-
axle case and connect SST.
SST 09992±00095 (09992± 00231, 09992±00271)
(3) Fully apply the parking brake and chock the 4
wheels.
(4) Connect the hand±held tester to DLC3.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressing firmly on the brake ped-
al and shift into D range.
(7) Measure the line pressure when the engine is idling.
(8) Depress the accelerator pedal all the way down.
Quickly read the highest line pressure when engine
speed reaches stall speed.
(9) In the same way, do the test in R range.
Specified line pressure:
ConditionD range kPa (kgf / cm2, psi)R range kPa (kgf / cm2, psi)
Idling370 to 410 (3.8 to 4.2, 54 to 60)540 to 640 (5.5 to 6.5, 78 to 92)
Stall1,110 to 1,230 (11.3 to 12.5, 161 to 178)1,700 to 1,810 (17.3 to 18.5, 246 to 263)
Evaluation:
ProblemPossible cause
If the measured values at all ranges are higher
Shift solenoid valve SLT defective

Regulator valve detective
If the measured values at all ranges are lower

Shift solenoid valve SLT defective

Regulator valve detective

Oil pump defective
If pressure is low in the D range only
D range circuit fluid leak

Forward clutch defective
If pressure is low in the R range only

R range circuit fluid leak

Reverse clutch defective

1st and reverse brake defective

190VD−01
A55650
SST (A)
SST (B)
A92421
Rotor Shaft
SST (A)
A57794
SST (B)
Turn
A81164
− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)19−11
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
OVERHAUL
1. REMOVE GENERATOR W/CLUTCH PULLEY
(a) Remove the generator pulley cap.
(b) Set SST (A) and (B).
SST 09820−63020
(c) Clamp SST (A) in a vise.
(d) Set the generator to SST.
NOTICE:
At this time, make sure that the generator and SST are per-
pendicular to one another.
(e) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(f) To loosen the pulley, turn SST (B) in the direction shown
in the illustration.
(g) Remove the generator from SST.
(h) Remove the pulley from the rotor shaft.
2. REMOVE GENERATOR REAR END COVER
(a) Remove the 3 nuts and end cover.
(b) Remove the terminal insulator.

A81147
A81148
SST
A92425
A81902
Lock Turn
B12264
Ohmmeter 19−12
− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
3. REMOVE GENERATOR BRUSH HOLDER ASSY
(a) Remove the 2 screws, then remove the generator brush
holder.
4. REMOVE GENERATOR COIL ASSY
(a) Remove the 4 bolts.
(b) Using SST, remove the coil assembly.
SST 09950−40011 (09951−04020, 09952−04010,
09953−04020, 09954−04010, 09955−04071,
09957−04010, 09958−04011)
5. REMOVE GENERATOR ROTOR ASSY
6. INSPECT GENERATOR W/CLUTCH PULLEY
(a) Check that the pulley is locked when it is turned clock-
wise, and that the pulley rotates smoothly when it is
turned counterclockwise.
7. INSPECT GENERATOR ROTOR ASSY
(a) Inspect the resistance.
(1) Using an ohmmeter, measure the resistance be-
tween the slip rings.
Standard resistance: 2.3 to 2.7
at 20˚C (68˚F)
If the resistance is not as specified, replace the rotor.

A55650
SST (A)
SST (B)
A92421
Rotor Shaft
SST (A)
A57803
SST (B)
Turn
19−16− STARTING & CHARGINGGENERATOR ASSY (1CD−FTV)(From September,
2003)
1CD−FTV ENGINE REPAIR MANUAL (RM1046E)
17. INSTALL GENERATOR W/CLUTCH PULLEY
(a) Temporarily install the pulley to the rotor shaft.
(b) Set SST (A) and (B).
SST 09820−63020
(c) Clamp SST (A) in a vise.
(d) Set the generator to SST.
NOTICE:
At this time, make sure that the generator and SST are per-
pendicular to one another.
(e) Insert the 3 tabs of SST (B) into the 3 holes on the pulley.
(f) To torque the pulley, turn SST (B) in the direction shown
in the illustration.
Torque: 111 Nm (1,132 kgfcm, 82 ftlbf)
HINT:
Use a torque wrench with the fulcrum length of 50 cm (19.69
in.).
(g) Remove the generator from SST.
(h) Check that the generator pulley rotates smoothly.
(i) Install the generator pulley cap.