2005 TOYOTA AVENSIS brake

− BRAKEBRAKE BOOSTER ASSY (RHD) (2AZ−FSE)
32−7
AVENSIS Supplement (RM1045E)
20. INSTALL ENGINE COVER NO.1
21. INSTALL FRONT WHEEL RH
Torque:103 N
m(1,050 kgf
cm, 76 ft
lbf)
22. FILL RESERVOIR WITH BRAKE FLUID
23. BLEED MASTER CYLINDER
SST 09023−00100
24. BLEED BRAKE LINE
25. CHECK AND ADJUST BRAKE PEDAL HEIGHT
26. CHECK PEDAL FREE PLAY
27. CHECK PEDAL RESERVE DISTANCE
28. CHECK FLUID LEVEL IN RESERVOIR
29. CHECK BRAKE FLUID LEAKAGE

300N6−01
C53220F45751
SST
F13686
Hold
Turn
C80291
F44775
30−4
− DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (2AZ−FSE)
AVENSIS Supplement (RM1045E)
OVERHAUL
HINT:
Overhaul the RH side following the same procedure as for the LH side.
1. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
(a) Remove the drain plug and gasket, and then drain the ATF.
(b) Install a new gasket and drain plug.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER LH
4. SEPARATE FRONT AXLE HUB LH NUT
(a) Using SST and a hammer, unstake the staked part of the
nut.
SST 09930−00010
(b) While applying the brake, remove the axle hub LH nut.
NOTICE:
Loosen the staked part of the lock nut completely, other-
wise the screw of the drive shaft may become damaged.
5. SEPARATE FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and separate the front stabilizer link assy
LH from the shock absorber assy LH.
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
6. DISCONNECT SPEED SENSOR FRONT LH
(a) Remove the bolt, and disconnect the speed sensor wire
and flexible hose from the shock absorber.
(b) Remove the bolt, and disconnect the speed sensor from
the steering knuckle.
NOTICE:
SBe careful not to damage the speed sensor.
SPrevent foreign matter from adhering to the speed
sensor.

4006I−03
D26703
SST
D26704
2nd Brake Piston
Return Spring
C89124
2nd Brake Piston
Return Spring
D26705
− AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
40−91
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SECOND BRAKE PISTON ASSY (U151E/U151F)
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB−ASSY
(a) Place SST on the return spring and compress.
SST 09387−00060
(b) Using a screwdriver, remove the snap ring.
(c) Remove the 2nd brake piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB−ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length:16.61mm (0.6539 in.)
3. REMOVE 2ND BRAKE PISTON
(a) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf/cm
2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.

D26706
O−ring
O−ring
D26706
O−ring
O−ring
D26775
D26704
2nd Brake Piston
Return Spring
40−92
− AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. REMOVE 2ND BRAKE PISTON O−RING
(a) Remove the 2 O−rings from the 2nd brake piston.
5. INSTALL 2ND BRAKE PISTON O−RING
(a) Apply the 2 new O−rings with ATF, install them in the 2nd
brake piston.
NOTICE:
Assemble the O−ring carefully not to have a twist and a
pinching.
6. INSTALL 2ND BRAKE PISTON
(a) Apply the 2nd brake piston with ATF, and install it to the
2nd brake cylinder.
NOTICE:
Be careful not to damage the O−ring.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB−ASSY
(a) Install the 2nd brake piston return spring.
NOTICE:
Installing the spring sub−assembly, check all of the
springs are fit in the piston correctly.

D26703
SST
− AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
40−93
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Place SST on the piston return spring, and compress the
piston return spring with a press.
SST 09387−00060
(c) Using a screwdriver, install the snap ring.
(d) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
SStop the press when the spring sheet is lowered to the
place1−2 mm (0.039−0.078 in.) from the snap ring
groove.
SThis prevents the spring sheet from being deformed.

C91931
Valve Body Oil
Strainer Assy
C91932
O−ring
C91933
C83127
C83128
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−21
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O−ring from the oil strainer.
14. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and
valve body assy.
15. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No.1 from the trans-
axle case.
16. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2nd brake gasket from the
transaxle case.

C83129
D03554
Check Ball
D03555
D03556
D03902
O−ring
C−3 Accumulator Piston 40−22
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
17. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
18. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the trans-
axle case.
19. REMOVE C−3 ACCUMULATOR PISTON
(a) Remove the spring from the C−3 accumulator piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the C−3 accumulator piston.
NOTICE:
SBlowing off the air may cause the piston to jump−out.
When removing the piston, hold it by your hand using
a waste cloth.
STake care not to splash ATF when air−blowing.
(c) Remove the O−ring from the C−3 accumulator piston.

D26450
Differential
Gear Assy
D03573
D03574
Forward Clutch
Assy
D03906
Thrust Needle
Roller Bearing
D26787
Multiple Disc
Clutch Clutch
HubThrust Needle
Roller Bearing
Thrust Needle
Roller Bearing
Thrust
Bearing
Race
No.1
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−27
U151E, U151F A/T REPAIR MANUAL (RM1021U)
34. REMOVE DIFFERENTIAL GEAR ASSEMBLY
(a) Remove the differential gear assy from the transaxle
case.
35. REMOVE OVERDRIVE BRAKE GASKET
(a) Remove the 2 overdrive brake gaskets from the transaxle
case.
36. REMOVE FORWARD CLUTCH ASSY
(a) Remove the forward clutch assy from the transaxle case.
(b) Remove the thrust needle roller bearing from the forward
clutch.
37. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Remove the thrust needle roller bearing, multiple disc
clutch clutch hub, thrust needle roller bearing and thrust
bearing race No.1 from the transaxle case.