Page 3593 of 5135
9808J±01
± COMPONENTS151350
98±1
3501/TRANSAXLE OR TRANSMISSION ASSY & GASKET KIT (ATM)
(0008± )NZE121..ATM U340E
Page 3594 of 5135
4002N±01
D25171
D25172
D25173
C81314
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
40±71
U340E A/T REPAIR MANUAL (RM824E)
FRONNT DIFFERENTIAL ASSY (U34#E Series)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVE (ATM) GEAR
[ 33481X / 4301 ]
(a) Remove the speedometer drive gear from the differential
case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
[ 41221 / 4301 ]
(a) Put match±marks on the front differential ring gear and
differential case.
(b) Using SST and a hammer, unstake the lock plate.
SST 09930±00010
(c) Remove the 8 bolts and lock plate.
Page 3595 of 5135
C81315
C81316
C81317
C81318
C81319
40±72
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
(d) Using a plastic hammer, remove the front differential ring
gear from the differential case.
3. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
[ 41342A / 4301 ]
(a) Using a punch and a hammer, unstake the differential
case.
(b) Using a pin punch and a hammer, remove the straight pin.
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
[ 41342F / 4301 ]
(a) Remove the pinion shaft from the front differential case.
5. REMOVE FRONT DIFFERENTIAL SIDE GEAR
[ 41331F / 4301 ]
(a) Remove the 2 pinions, 2 thrust washers, 2 side gears and
2 thrust washers No.1 from the front differential case.
Page 3596 of 5135

C68188
D25174
SST
D25175
SST
D25176
SST
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
40±73
U340E A/T REPAIR MANUAL (RM824E)
6. REMOVE DIFFERENTIAL DRIVE PINION PLUG
[ 41211E / 4301 ]
(a) Using a brass bar and a hammer, remove the differential
drive pinion plug.
7. REMOVE COUNTER DRIVEN GEAR
[ 35783R / 4301 ]
(a) Using SST and a press, remove the counter driven gear
from the differential drive pinion.
SST 09950±60010 (09951±00350), 09950±70010
(09951±07150)
8. INSTALL COUNTER DRIVEN GEAR
[ 35783R / 4301 ]
(a) Using SST and a press, install the counter driven gear to
the differential drive pinion.
SST 09950±60010 (09951±00350), 09950±70010
(09951±07150)
NOTICE:
When replacing the counter driven gear, replace the count-
er drive gear in the transaxle case, too.
HINT:
The differential drive pinion shall be press±fit until it comes to
contact with the counter driven gear.
9. INSTALL DIFFERENTIAL DRIVE PINION PLUG
[ 41211E / 4301 ]
(a) Using SST and a plastic hammer, install a new differential
drive pinion plug to the differential drive pinion
SST 09221±25026 (09221±00071)
Standard clearance:
2.5 ± 2.6 mm (0.0984 ± 0.1023 in.)
Page 3597 of 5135
![TOYOTA AVENSIS 2005 Service Repair Manual C81320
C81321
C81322
40±74
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL FRONT DIFFERENTIAL SIDE GEAR
[ 41331F / 4301 ]
(a) A TOYOTA AVENSIS 2005 Service Repair Manual C81320
C81321
C81322
40±74
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL FRONT DIFFERENTIAL SIDE GEAR
[ 41331F / 4301 ]
(a) A](/manual-img/14/57441/w960_57441-3596.png)
C81320
C81321
C81322
40±74
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
10. INSTALL FRONT DIFFERENTIAL SIDE GEAR
[ 41331F / 4301 ]
(a) After applying ATF to the 2 front differential side gears, 2
side gear thrust washers No. 1, 2 front differential pinions
and 2 pinion thrust washers, install them to the front differ-
ential case.
HINT:
At the time of installation, set the alignment of the front differen-
tial pinions perpendicular to that of the side gear and rotate
them so that their holes will be aligned with the holes in the dif-
ferential case.
11. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
[ 41342F / 4301 ]
(a) Install the pinion shaft so as to align the lock pin holes on
the pinion shaft and differential case.
12. INSPECT BACKLASH
(a) Measure the side gear backlash while holding 1 pinion
gear toward the case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
If the backlash is out of specification, install the correct thrust
washer to the side gear.
(b) Referring to the table below, select thrust washers which
will ensure that the backlash is within for both sides.
Thrust washer thickness: mm (in.)
ThicknessThickness
0.95 (0.0374)1.10 (0.0433)
1.00 (0.0394)1.15 (0.0453)
1.05 (0.0413)1.20 (0.0472)
If the backlash is not within the specification, install a thrust
washer of a different thickness.
Page 3598 of 5135
C81323
C81324
D25177
C81325
C81326
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
40±75
U340E A/T REPAIR MANUAL (RM824E)
13. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
[ 41342A / 4301 ]
(a) Using a pin punch and a hammer, install the pinion shaft
straight pin.
(b) Using a chisel and a hammer, stake the differential case.
14. INSTALL FRONT DIFFERENTIAL RING GEAR
[ 41221 / 4301 ]
(a) Using ATF and heater, hear the front differential ring gear
to 90 ± 110 C (194.0 ± 230.0 F).
(b) Clean the contact surface of the front differential case.
(c) Install the 4 lock plates and 8 bolts.
Torque: 88 Nm (900 kgfcm, 65 ftlbf)
(d) Using SST, stake the ring gear lock plate.
SST 09930±00010
Page 3599 of 5135
D25171
40±76
± AUTOMATIC TRANSMISSION / TRANSFRONNT DIFFERENTIAL ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
15. INSTALL SPEEDOMETER DRIVE (ATM) GEAR
[ 33481X / 4301 ]
(a) Install the speedometer drive gear to the differential case.
Page 3600 of 5135
4002M±01
C67905
C67904
C82123
C67908
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U34#E Series)
40±67
U340E A/T REPAIR MANUAL (RM824E)
TRANSMISSION VALVE BODY ASSY (U34#E Series)
OVERHAUL
1. REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
[ 35290A / 3512 ]
(a) Remove the bolt, and pull out the line pressure control so-
lenoid assy.
2. REMOVE TRANSMISSION 3WAY SOLENOID ASSY
NO.3
[ 35250A / 3512 ]
(a) Remove the bolt, and pull out the transmission 3 way so-
lenoid assy No. 3.
3. REMOVE LOCK UP CONTROL SOLENOID ASSY
[ 35280 / 3512 ]
(a) Remove the bolt, and pull out the lock up control solenoid
assy.
4. REMOVE TRANSMISSION 3WAY SOLENOID ASSY
NO.2
[ 35230 / 3512 ]
(a) Remove the bolt, and pull out the transmission 3 way so-
lenoid assy No. 2.