2005 TOYOTA AVENSIS manual transmission

D08104
Flange
Disc
Plate
D08099
D09210
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
40±83
U241E A/T REPAIR MANUAL (RM840U)

Stop the press when the spring sheet is lowered to the
place 1 ± 2 mm (0.039 ± 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
7. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Install the 3 plates, 3 discs and flange.
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
8. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch 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).
Park clearance:
0.605 ± 0.825 mm (0.02382 ± 0.03248 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 non±standard, select another flange.
HINT:
There are 6 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.0 (0.118)43.3 (0.130)
23.1 (0.122)53.4 (0.134)
33.2 (0.126)63.5 (0.138)

D03682
40±84
± AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Inspect the clutch disc rotation.
(1) Check that the disc rotates when rotating the disc
after inserting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

4006Z±01
D08032
D08033
D08034
40±14
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
AUTOMATIC TRANSAXLE ASSY (U241E)
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 remove
the lock nut and 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 breather No. 2 plug.

C83143
C83144
C83142
D03900
D03900
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±15
U241E A/T REPAIR MANUAL (RM840U)
4. REMOVE OIL COOLER TUBE UNION(INLET OIL
COOLER UNION)
(a) Remove the union.
(b) Remove the O±ring from the union.
5. REMOVE OIL COOLER TUBE UNION(OUTLET OIL
COOLER UNION)
(a) Remove the elbow.
(b) Remove the O±ring from the elbow.
6. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove 4 O±rings from the 4 transaxle case No. 1 plugs.
7. REMOVE SPEED SENSOR(TMC ±MADE)
(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
(b) Remove the 2 O±rings from the sensors.
8. REMOVE TRANSMISSION REVOLUTION
SENSOR(AISIN ±MADE)
(a) Remove the 2 bolts and the 2 transmission revolution
sensors from the transaxle assy.
(b) Remove the 2 O±rings from the sensors.

D09176
D09177
AT0103
D09637
40±16
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. FIX AUTOMATIC TRANSAXLE ASSY
10. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the 18 bolts.
(b) Remove the oil pan and 2 magnets.
11. REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET
(a) Remove the gasket from the oil pan.
12. INSPECT AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non±magnetic).... bushing wear
13. REMOVE TRANSMISSION WIRE
(a) Remove the 5 connectors from the shift solenoid valves.
(b) Remove the bolt, clamp and ATF temperature sensor.

D03547
D03636
D09179
D09180
D03553
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±17
U241E A/T REPAIR MANUAL (RM840U)
(c) Remove the bolt and transaxle solenoid wire from the
transaxle case.
(d) Remove the O±ring from the transaxle solenoid wire.
14. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O±ring from the oil strainer.
15. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and
the valve body assy.

C83127
C83128
C83129
D03554
D03555
40±18
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
16. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No. 1 from the trans-
axle case.
17. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2ND brake gasket from the
transaxle case.
18. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
19. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the trans-
axle case.
20. REMOVE C±3 ACCUMULATOR PISTON
(a) Remove the compression spring from the C
3 accumulator
piston.

D03556
D03902
D03557
D03903
D03558
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±19
U241E A/T REPAIR MANUAL (RM840U)
(b) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
oil hole and remove the C
3 accumulator 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.
(c) Remove the O±ring from the C
3 accumulator piston.
21. REMOVE C±1 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the C
1 accumulator piston and com-
pression spring.
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.
(b) Remove the 2 O±rings from the C
1 accumulator piston.
22. REMOVE B±3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the B
3 accumulator piston and 2 com-
pression springs.
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.