2005 TOYOTA AVENSIS brake

D03600
SST
D03615
Front Planetary Ring Gear
Brake Hub
Snap Ring
D26763
Front Planetary
Gear Assy
Brake Hub
40−48
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
95. INSTALL1ST & REVERSE BRAKE RETURN SPRING
SUB−ASSY
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387−00070
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
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, preventing the spring sheet from being de-
formed.
SDo not expand the snap ring excessively.
SInstalling the spring sub−assembly, check all of the
springs are fit in the piston correctly.
SThe snap ring should be fixed surely in the groove of
the cylinder.
SFix the snap ring to the inside of the claw of the spring
seat surely.
96. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear
and snap ring to the brake hub.
NOTICE:
Confirm the snap ring is fixed in the groove of the brake hub
correctly.
97. INSTALL FRONT PLANETARY GEAR ASSY
(a) Install the front planetary gear assy to the brake hub.

D03916
SST
Counter Drive
GearTransaxle
Case
2nd Brake Hub
w/ Front Planetary
Gear Assy
SST
D03917
D03596
SST
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−49
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST and a press, press−fit the front planetary gear
assy.
SST 09950−60010 (09951−00500), 09950−70010
(09951−07100)
NOTICE:
SDo not apply excessive pressure to it.
SPress the inner race of LH tapered roller bearing,
counter gear and front planetary gear assembly to the
position where no pre−load should be applied to one
pair of tapered roller bearings (left and right).
(c) Install the new washer, as shown in the illustration.
(d) Using SST, install the nut.
SST 09387−00030, 09387−00080
Torque: 210−350 Nm
(2,141kgfcm,155 ftlbf−3,569 kgfcm, 258 ftlbf)
NOTICE:
Assemble the washer after pressing each part, then tighten
the nut to minimum tightening torque.

D26591Rear Planetary Gear Assy
D03616
Snap Ring
D26413
Disc
Plate
D26452
A
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−51
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Thrust bearing and bearing race diameter: mm (in.)
insideoutside
Thrust Bearing, A32.5 (1.28)56.5 (2.224)
Bearing Race, B40.2 (1.583)59.3 (2.335)
Thrust Bearing, C38.6 (1.520)59.7 (2.35)
Bearing Race, D38.6 (1.520)59.3 (2.335)
99. INSTALL REAR PLANETARY GEAR ASSY
(a) Install the rear planetary gear assy to the rear planetary
ring gear.
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm the snap ring is fixed in the groove of the1st & re-
verse brake hub correctly.
100. INSTALL1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case(Dimension A).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance:1.16−1.35 mm (0.0457−0.0531in.)
HINT:
Piston stroke = Dimension A−Flange thickness

D03815
D26396Second Brake Piston Assy
D08058
Snap Ring
C929771−Way Clutch Sleeve Outer
40−52
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
11.8 (0.071)52.2 (0.087)
21.9 (0.075)62.3 (0.091)
32.0 (0.079)72.4 (0.094)
42.1 (0.083)82.5 (0.098)
(c) Install the flange.
102. INSTALL SECOND BRAKE PISTON ASSY
(a) Install the second brake piston assy to the transaxle case.
(b) Install the snap ring and measure the inside diameter.
Inside diameter: More than167 mm (6.57 in.)
NOTICE:
SBecause the taper snap ring has the positioning
direction, check it when installing.
SWhen the diameter does not meet the specified value,
replace the snap ring with new one.
SAfter assembling, confirm that there is no clearance
between the second brake cylinder and the fitting sur-
face of the cylinder in the transaxle case.
103. INSTALL1WAY CLUTCH SLEEVE OUTER
(a) Install the 1−way clutch sleeve outer to the 2nd brake cyl-
inder assy.
NOTICE:
Check the positioning direction of the outer sleeve.

D26404
BA
D26714Rear Planetary Sun Gear Assy
D26412
Plate Disc
D26453
B 40−54
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Coat the bearing with yellow petrolatum, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Race, A33.0 (1.299)45.4 (1.787)
Bearing, B31.85 (1.254)45.2 (1.78)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
NOTICE:
Installing the rear planetary sun gear assembly, confirm
that the B1discs engage.
107. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
108. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between
the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 0.62−0.91mm (0.0244−0.0358 in.)
HINT:
Piston stroke = Dimension B−Flange thickness−Snap ring
thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
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)8−

D26470
D
D26390
D03923
D26391
Brake Apply
Tube
Clutch Apply Tube
40−56
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using vernier calipers and a simple straightedge, mea-
sure the position shown in the illustration.
(f) Calculate the end play value using the following formula.
Select a thrust bearing which satisfies the end play value
and install it.
End play: 0.244−0.901mm (0.0096−0.0355 in.)
NOTICE:
Make sure that the no colored race side is facing the direct
clutch assy.
HINT:
End play = Dimension D−Dimension C
Bearing thickness and diameter : mm (in.)
ThicknessInsideOutside
3.6 (0.1417)56.3 (2.217)75.7 (2.980)
3.8 (0.1496)56.3 (2.217)75.7 (2.980)
111. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install the 3 new governor apply gaskets No. 1 to the
transaxle case.
112. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube before
installing the apply tube to the transaxle case. This pre-
vents the apply tube from being deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube and a bolt to the transaxle
case.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
NOTICE:
Each pipe should be securely inserted until it reaches the
stopper.

D26387AA
D26414
Flange
Plate Disc
D26466
Snap Ring
D08082
40−58
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Apply liquid sealer to the ”A” bolt threads.
Sealant:
Part No. 08833−00080, THREE BOND1344, LOCTITE
242 or equivalent.
(d) Install the 11 bolts.
Torque:
Bolt A:19.0 Nm(190 kgfcm,14ftlbf)
Other bolt: 25.0 Nm (250 kgfcm,18ftlbf)
117. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle
case.
NOTICE:
Be careful about the order of discs, plate and flange assem-
bly.
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
118. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:1.81−2.20 mm (0.0713−0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will
meet the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)43.1 (0.122)
23.2 (0.126)53.3 (0.130)
33.4 (0.134)−−
(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.

D03573
D26450
Differential
Gear Assy
D25506
Thrust Bearing
Underdrive
Race No.2Underdrive Planetary
Gear Assy
Forward Clutch
Assy
Differential Gear Assy
Forward Clutch
Assy
D25505
Thrust
Needle
Roller Bearing
Differential Gear Assy
Underdrive Planetary
Gear Assy
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−63
U151E, U151F A/T REPAIR MANUAL (RM1021U)
126. INSTALL OVERDRIVE BRAKE GASKET
(a) Install the 2 new overdrive brake gaskets.
127. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assy to the transaxle case.
128. INSTALL THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Install the thrust bearing underdrive race No.2 to the un-
derdrive planetary gear assy.
129. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula
and values of Dimension E and F that ware measured
when installing cylindrical roller bearing and underdrive
planetary gear. Select an appropriate underdrive plane-
tary gear thrust bearing race No. 2 which satisfies the spe-
cified end play value, and install it.
End play: 0.498−0.993 mm (0.01961−0.03909 in.)
HINT:
End play = Dimension F−Dimension E−thrust bearing thick-
ness 2.5 mm (0.0984 in.)−underdrive thrust bearing race No.
2 thickness.
Race thickness: mm (in.)
F−EThickness
Less than 7.72 (0.3039)3.5 (0.138)
7.72 (0.3039)3.8 (0.150)