2005 TOYOTA AVENSIS drive shaft

D25588
Stopper
Stopper
D26417
Disc Flange
Plate
D26421
Snap Ring
D26416
Disc Flange
Plate
Cushion
Plate
D26419
Snap Ring
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40−89
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the piston shown in the
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.
16. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the intermediate
shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
17. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Apply the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the
intermediate shaft.
NOTICE:
SInstall the cushion plate with the mark on the white
surface facing to plate.
SBe careful about the order of discs, plates and flange
assembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.

D26426
D26427
D26428
40−90
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
18. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.60−0.82 mm (0.02362−0.03228 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.0 (0.118)53.4 (0.134)
23.1(0.122)63.5 (0.138)
33.2 (0.126)73.6 (0.142)
43.3 (0.130)−−
19. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.61−0.83 mm (0.02401−0.03268 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
02.5 (0.098)42.9 (0.114)
12.6 (0.102)53.0 (0.118)
22.7 (0.106)63.1(0.122)
32.8 (0.110)−−
(b) Check that the disc rotates when rotating the disc after in-
serting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

400H1−02
D26715
D26753
Snap Ring
D26754
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−79
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:1.00−1.25 mm (0.0394−0.4921in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.

D26415
Flange
Plate Disc
D26753
Snap Ring
D26715
D03672
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−83
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
12. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kgf
cm
2, 4.0 kPa, 57 psi).
Pack clearance:1.00−1.25 mm (0.0394−0.4921in.)
If the piston stroke is less than the minimum, parts may have
been assembled incorrectly. Check and reassemble again.
If the clearance is not standard, select another flange.
HINT:
There are 5 different flanges in thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.00 (0.1181)43.45 (0.1358)
23.15 (0.1240)53.60 (0.1417)
33.30 (0.1299)−−
13. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the forward
clutch assy after inserting the multiple disc clutch into it.
NOTICE:
Do not place the forward clutch assy in a vise.

4010K−01
D09644
Control Shaft Lever
D09643
Lock Nut
Nut Stopper
D09639
Park/neutral Position Switch
40−18
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB−ASSY
(a) Remove the bolt and speedometer driven hole cover sub−assy from the transaxle assy.
(b) Remove the O−ring from the speedometer driven hole cover.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Remove the nut, washer and control shaft lever.
(b) Using a screwdriver, unstake the nut stopper, and re-
move the lock nut and nut stopper.
(c) Remove the 2 bolts and pull out the park/neutral position
switch.
3. REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the transaxle case.

D03560
C56727
D03563
D03564
D03565
40−24
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
23. REMOVE MANUAL DETENT SPRING SUB−ASSY
(a) Remove the 2 bolts, the manual detent spring sub−assy
and cover.
24. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
25. REMOVE MANUAL VALVE LEVER SUB−ASSY
(a) Using a chisel and hammer, cut off and remove the
spacer.
(b) Using a pin punch (
35 mm) and hammer, drive out the
pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.
(c) Remove the manual valve lever shaft and manual valve
lever.

D26382
Parking Lock Rod Sub−assy
D03566
D08046Oil Pump Assy
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−25
U151E, U151F A/T REPAIR MANUAL (RM1021U)
26. REMOVE PARKING LOCK ROD SUB−ASSY
(a) Remove the parking lock rod from the manual valve lever.
27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the trans-
axle case.
28. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle case with the oil pump side facing up.
29. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft endplay.
Endplay: 0.262−1.244 mm (0.01−0.049 in.)

D03829
Dial Indicator
Forward Clutch Hub
D03576
Pawl Shaft Clamp
D09652
D09689
40−28
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
38. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Using a dial indicator, measure the inside diameter of the
forward clutch hub bushing
Standard inside diameter:
23.025−23.046 mm (0.9065−0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091in.)
NOTICE:
SWhen the diameter is over the maximum, replace the
multiple disc clutch hub with new one.
SCheck 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.
39. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Remove the bolt and pawl shaft clamp.
(b) Remove the parking lock pawl shaft.
(c) Push the parking lock pawl.
HINT:
Failure to do so will cause interference when the underdrive
planetary gear is removed.