2005 TOYOTA AVENSIS transmission oil plug manual

D03605
SSTHold
Turn
D03914
Underdrive
Clutch Drum
Oil Seal Ring
D26383
D03606
SST
Hold
Turn
D03915
Underdrive
Output
Shaft Oil
Seal Ring
40−40
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
76. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle−roller bearing from the
transaxle case.
SST 09387−00041 (09387−01010, 09387−01030,
09387−01040)
77. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 oil seal rings from the transaxle case.
78. REMOVE TRANSAXLE CASE NO.1PLUG
(a) Remove the 2 transaxle case No. 1 plugs.
(b) Remove the 2 O−rings from the 2 transaxle case No. 1
plugs.
79. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the underdrive cylindrical roller bear-
ing from the transaxle case.
SST 09514−35011
80. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.

D26400
Transaxle Apply
Tube Clamp
Differential Gear Lube Apply Tube
D26383
Underdrive
Output Shaft
Oil Seal Ring
D03915
AT F
D03807
SST
D03914
Underdrive
Clutch Drum
Oil Seal Ring
AT F 40−44
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
83. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube and transaxle
apply tube clamp with the bolt to the transaxle housing.
Torque: 9.8 Nm(100 kgfcm, 87 in.lbf)
NOTICE:
Make sure to insert the pipe to the stopper.
84. INSTALL TRANSAXLE CASE NO.1PLUG
(a) Install the 2 new O−rings to the 2 transaxle case No.1
plugs.
(b) Install the 2 transaxle case No.1 plugs to the transaxle
rear cover.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
85. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Coat the new oil seal ring with ATF and install it to the
transaxle housing.
86. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical
roller bearing.
SST 09950−60020 (09951−00810), 09950−70010
(09951−07100)
NOTICE:
Do not apply excessive pressure to it.
87. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Coat the 2 new oil seal rings with ATF, install them to the
transaxle rear cover.
NOTICE:
SDo not expand the gap of the oil seal ring too much.
SFix the hooks certainly. Confirm the smooth rotation.

D26766
SST
D26389
Rear Clutch
Oil Seal
Ring Outer
D26388
D26454
FIPG
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−57
U151E, U151F A/T REPAIR MANUAL (RM1021U)
113. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing
to the transaxle rear cover.
SST 09950−60010 (09951−00230, 09952−06010)
Press fit depth: 20.55−21.25 mm (0.8091−0.8366 in.)
NOTICE:
SFace the inscribed mark side of the bearing race up.
SRepeat the press fit until the specified value is ob-
tained.
(b) Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install
them to the transaxle rear cover.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
115. INSTALL TRANSAXLE CASE NO.1PLUG
(a) Install the 4 new O−ring to the 4 transaxle case No. 1
plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
rear cover.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
116. INSTALL TRANSAXLE REAR COVER SUB−ASSY
(a) Remove any packing material and be careful not to get oil
on the contacting surfaces of the transaxle rear cover or
the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826−00090, THREE BOND1281or equiva-
lent.
NOTICE:
Concerning about the amount of the FIPG application, the
amount should be controlled to from even sealing film on
entire flange surface and have slight protrusion of the FIPG
all around of the connecting area. The FIPG shall be ap-
plied continuously on the flange. (Reference value of the
section diameter:
1.2)

C91931
Valve Body Oil
Strainer Assy.
C86316
Magnet
C91925
D26716
D03900D30672
Speed Sensor
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−71
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Install the oil strainer and 3 bolts to the valve body.
Torque:11Nm(110 kgfcm, 8 ftlbf)
NOTICE:
Apply ATF to the bolts.
151. INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install the new oil pan gasket with the 18 bolts to the trans-
axle case.
Torque: 7.8 Nm (80 kgfcm, 69 in.lbf)
NOTICE:
SBecause the bolts should be seal bolts, apply seal
packing to new bolts and tighten them within10 min-
utes after application.
SRemove any oil or grease from the contacting surface
of the transaxle case and the oil pan with the gasket
completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO.1PLUG
(a) Coat the 4 new O−rings with ATF, install them to the 4
transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
153. INSTALL SPEED SENSOR
(a) Install them to the 2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Torque:11.0 Nm(115 kgfcm, 8 ftlbf)

C83144
Elbow
O−ring
C83143
Union
O−ring
D09639
D09640Control Shaft Lever
40−72
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Coat a new O−ring with ATF, install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 Nm (276 kgfcm, 20 ftlbf)
155. INSTALL OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Coat a new O−ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 25 Nm (255 kgfcm,18ftlbf)
156. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose into the transaxle case certainly.
157. 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 Nm (70 kgfcm, 61in.lbf)
(c) Temporarily install control shaft lever.

05KAQ–02
G24063
SST
SST
– DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U341E) (From February, 2004)05–223
AVENSIS REPAIR MANUAL SUPPLEMENT
(RM1098E)
HYDRAULIC TEST
1. PERFORM HYDRAULIC TEST
(a) Measure the line pressure.
NOTICE:

Perform the test at the normal operating ATF (Automatic Transmission Fluid) 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.

This check must be conducted after checking and adjusting engine.

Perform under condition that A/C is OFF.

When conducting stall test, do not continue more than 10 seconds.
(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 an Intelligent Tester II to the 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 position.
(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 position.
Specified line pressure:
ConditionD position kPa (kgf / cm2, psi)R position kPa (kgf / cm2, psi)
Idling372 to 412 kPa
(3.8 to 4.2 kgf/cm2, 54 to 60 psi)
553 to 623 kPa
(5.6 to 6.4 kgf/cm2, 80 to 90 psi)
Stall test1,126 to 1,226 kPa
(11.5 to 12.5 kgf/cm2, 163 to 178 psi)
1,664 to 1,864 kPa
(17.0 to 19.0 kgf/cm2, 241 to 270 psi)
Evaluation:
ProblemPossible cause
If the measured values at all positions are higher
Shift solenoid valve SLT defective

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

Shift solenoid valve SLT defective

Regulator valve detective

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

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

R position circuit fluid leak

Reverse clutch defective

1st and reverse brake defective