2005 TOYOTA AVENSIS manual transmission

4002K±01
C67867
C67868
C67869
C67870
40±58
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
INTERMEDIATE SHAFT ASSY (U34#E Series)
OVERHAUL
1. REMOVE FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 2 discs and 2 plates.
2. INSPECT FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed mark is defaced, replace
all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
3. REMOVE DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Using a screwdriver, remove the snap ring.
(b) Remove the 3 plates, flange and 3 discs.
4. INSPECT DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.




C67871
C67872
C67873
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±59
U340E A/T REPAIR MANUAL (RM824E)
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed mark is defaced, replace
all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
5. REMOVE DIRECT CLUTCH RETURN SPRING
SUB±ASSY
[ 35604 / 3507 ]
(a) Using SST and a press, remove the snap ring and direct
clutch return spring from the intermediate shaft.
SST 09387±00020
6. INSPECT DIRECT CLUTCH RETURN SPRING
SUB±ASSY
[ 35604 / 3507 ]
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 32.9 mm (1.2953 in.)
7. REMOVE DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Install the direct and reverse clutch on the transaxle rear
cover.
(b) Apply compressed air (392kPa, 4.0 kgf
cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch drum and
direct clutch piston.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing
HINT:
When the piston can not be removed as it is slanted, either blow
the air again with the protruding side pushed or removed the
piston using a needle nose pliers with vinyl tape on the tip.

C68212
D25110
C68213
C67875
C67876
40±60
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
8. INSPECT DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
9. REMOVE DIRECT CLUTCH DRUM SUB±ASSY
[ 35605A / 3507 ]
(a) Put a match±mark on the direct clutch drum at the same
position with the cutout of the intermediate shaft assy.
(b) Apply compressed air into the oil hole shown in the il-
lustration and remove the direct clutch drum from the in-
termediate shaft.
10. INSPECT INTERMEDIATE SHAFT SUB±ASSY
[ 35708G / 3507 ]
(a) Shake the direct clutch pin and check that a check ball is
not stuck.
(b) Apply low pressure air to the check ball with compressed
air and check that no air leak is identified.
11. REMOVE DIRECT CLUTCH PISTON O±RING
[ 35606C / 3507 ]
(a) Using a screwdriver, remove the 2 O±rings.
12. REMOVE DIRECT CLUTCH DRUM O±RING
[ 35605D / 3507 ]
(a) Using a screwdriver, remove the O±ring.

C67876
C67875
D25111
C68200





C67871
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±61
U340E A/T REPAIR MANUAL (RM824E)
13. INSTALL DIRECT CLUTCH DRUM O±RING
[ 35605D / 3507 ]
(a) Coat the O±ring with ATF, install it to the direct clutch
drum.
NOTICE:
Be careful not to damage the O±ring.
14. INSTALL DIRECT CLUTCH PISTON O±RING
[ 35606C / 3507 ]
(a) Coat the 2 O±rings with ATF, install them to the direct
clutch piston.
NOTICE:
Be careful not to damage the O±ring.
15. INSTALL DIRECT CLUTCH DRUM SUB±ASSY
[ 35605A / 3507 ]
(a) Coat the direct clutch drum with ATF.
(b) Aligning the cutout in the intermediate shaft assy with the
match±mark on the direct clutch drum, install the direct
clutch drum to the intermediate shaft assy.
NOTICE:
Be careful not to damage the O±ring and clutch drum's lip.
16. INSTALL DIRECT CLUTCH PISTON SUB±ASSY
[ 35606A / 3507 ]
(a) Coat the direct clutch piston with ATF, install it to the inter-
mediate shaft.
NOTICE:

Do not damage the O±ring the direct clutch piston's.
17. INSTALL DIRECT CLUTCH RETURN SPRING
SUB±ASSY
[ 35604 / 3507 ]
(a) Install the direct clutch return spring on the direct clutch
piston.
(b) Place SST on the piston return spring and compress the
springs with a press.
SST 09387±00020
(c) Using a snap ring expander , install the snap ring from the
direct clutch drum.

D25112
Disc
Flange
Plate
D25113
Disc
Flange
Plate
D25114
40±62
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
U340E A/T REPAIR MANUAL (RM824E)
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
groove, preventing the spring sheet from the deform-
ing.

Do not expand the snap ring excessively.
18. INSTALL DIRECT CLUTCH DISK
[ 35667A / 3507 ]
(a) Coat the 3 plates, 3 discs and flange with ATF, install them
to the intermediate shaft.
(b) Install the snap ring.
19. INSTALL FORWARD CLUTCH DISC
[ 35677H / 3507 ]
(a) Install the 2 plates, 2 discs and a flange.
(b) Install the snap ring.
20. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the forward and reverse clutch and thrust needle
roller bearing on the transaxle rear cover.
(b) Using a dial indicator, measure the reverse clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf
cm
2, 57 psi)
Pack clearance:
0.86 ± 1.26 mm (0.0339 ± 0.0496 in.)
If the pack clearance is less than the limit of pack clearance,
parts may have been assembled incorrectly, so check and reas-
semble again.
If the pack clearance is non±standard, select another flange.
HINT:
There are 4 flanges in different thickness.
Flange Thickness: mm (in.)
No.ThicknessNo.Thickness
±3.0 (0.118)23.4 (0.134)
13.2 (0.126)33.6 (0.142)

D25115
± AUTOMATIC TRANSMISSION / TRANSINTERMEDIATE SHAFT ASSY (U34#E Series)
40±63
U340E A/T REPAIR MANUAL (RM824E)
21. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct and reverse clutch and thrust needle roll-
er bearing on the transaxle rear cover.
(b) Using a dial indicator and measuring terminal (SST),
measure the forward clutch pack clearance while apply-
ing and releasing compressed air (392 kPa, 4.0 kgf
cm
2,
57 psi)
SST 09350±36010 (09350±06110)
HINT:
The direct and reverse clutch will come out as you apply the
compressed air. Therefore, while the checking is being done,
press on the input shaft of the direct and reverse clutch using
stamping machine or alike so that the pressure is not applied
on the direct and reverse clutch.
Pack clearance:
0.62 ± 1.02 mm (0.0244 ± 0.0402 in.)
If the pack clearance is less than the limit of pack clearance,
parts may have been assembled incorrectly, so check and reas-
semble again..
If the pack clearance is non±standard, select another flange.
HINT:
There are 4 flanges in different thickness.
Selected flange thickness: mm (in.)
No.ThicknessNo.Thickness
±3.0 (0.118)23.4 (0.134)
13.2 (0.126)33.6 (0.142)

4006V±01
C83194
C83195
C83196
C83197
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
40±97
U241E A/T REPAIR MANUAL (RM840U)
TRANSMISSION VALVE BODY ASSY (U241E)
OVERHAUL
1. REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Remove the bolt and line pressure control solenoid assy.
2. REMOVE SHIFT SOLENOID VALVE SL1
(a) Remove the bolt and shift solenoid valve SL1.
3. REMOVE SHIFT SOLENOID VALVE DSL
(a) Remove the bolt and shift solenoid valve DSL.
4. REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt and shift solenoid valve SL2.

C83198
C83198
C83197
C83196
40±98
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
5. REMOVE SHIFT SOLENOID VALVE S4
(a) Remove the bolt and shift solenoid valve S4.
6. REMOVE MANUAL VALVE
(a) Remove the manual valve from the valve body assy.
7. INSTALL MANUAL VALVE
(a) Coat the manual valve with ATF, install it to the valve body assy.
8. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the bolt and shift solenoid valve S4.
9. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the bolt and shift solenoid valve SL2.
10. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the bolt and shift solenoid valve DSL.