2005 TOYOTA AVENSIS manual transmission

D09183
D09184
C83140
D03801
SST
D03799
40±28
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
51. REMOVE TRANSAXLE REAR COVER SUB±ASSY
(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic
hammer to remove the transaxle rear cover from the
transaxle case.
(c) Remove the 2 outer rear clutch oil seal rings from the
transaxle rear cover.
(d) Using a torx socket wrench T30, remove the 2 screws and
transaxle rear cover plate.
(e) Using SST, remove the needle±roller bearing from the
transaxle rear cover.
SST 09387±00040 (09387±01010, 09387±01030,
09387±01040)
52. REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove the U/D brake piston.

D03794
D25510
D03591
D03586
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±29
U241E A/T REPAIR MANUAL (RM840U)
(b) Remove the 2 O±rings from the U/D brake piston.
53. REMOVE BRAKE APPLY TUBE
(a) Remove a bolt, clamp and 2 brake apply tubes.
(b) Remove the brake apply tube from the clamp.
54. REMOVE FRONT CLUTCH APPLY TUBE
55. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Using a screwdriver, remove the 2 governor apply gasket
No. 1.
56. REMOVE DIRECT CLUTCH ASSY
(a) Remove the thrust bearing and the direct clutch assy from
the transaxle case.

D08053
D03587
D03791
D08054
D08055
40±30
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(b) Remove the bearing race from the direct clutch.
57. REMOVE REAR PLANETARY SUN GEAR ASSY
(a) Remove the rear planetary sun gear assy from the trans-
axle case.
(b) Remove the rear planetary sun gear thrust bearing from
the rear planetary sun gear.
(c) Remove the thrust washer No. 1 and 1±way clutch thrust
bearing from the rear planetary sun gear.
58. REMOVE 1 WAY CLUTCH ASSY
(a) Remove the 1±way clutch assy from the transaxle case.

D03909
D03589
D08056
D08057
D04083
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±31
U241E A/T REPAIR MANUAL (RM840U)
(b) Remove the 1±way clutch inner race from the 1±way
clutch assy.
59. REMOVE 1WAY CLUTCH SLEEVE OUTER
(a) Remove the 1±way clutch sleeve outer.
60. REMOVE 2ND BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the 2ND brake hole snap
ring from the transaxle case.
(b) Remove the flange, 3 discs and 3 plates from the trans-
axle case.
61. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed number is defaced, re-
place all discs.

D08058
D08059
D08060
D09189
40±32
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)

Before assembling new discs, soak them in ATF for
at least 15 minutes.
62. REMOVE SECOND BRAKE PISTON ASSY
(a) Using a screwdriver, remove the 2ND brake cylinder hole
snap ring from the transaxle case.
(b) Remove the 2ND brake cylinder from the transaxle case.
63. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 5 discs and 5 plates from the trans-
axle case.
64. INSPECT 1ST & REVERSE BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate, and
flange are worn or burnt.
If necessary, replace them.
NOTICE:

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

Before assembling new discs, soak them in ATF for
at least 15 minutes.

D03616
D08062
D03910
D03593
D03873
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±33
U241E A/T REPAIR MANUAL (RM840U)
65. REMOVE REAR PLANETARY GEAR ASSY
(a) Using a screwdriver, remove the snap ring from the brake
hub.
(b) Remove the rear planetary gear assy from the transaxle
case.
(c) Remove the thrust washer No. 2 from the rear planetary
gear assy.
(d) Remove the thrust bearing race No. 3 from the rear plane-
tary gear assy.
66. REMOVE INPUT SUN GEAR
(a) Remove the 2 thrust bearings, the bearing race and the
input sun gear from the transaxle case.

D03595
D03596
SST
D03597
SST
D08063
D03615
40±34
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
67. REMOVE FRONT PLANETARY GEAR ASSY
(a) Using a chisel and a hammer, unstake the lock washer.
NOTICE:
Push down all claws of the washer. Otherwise SST can not
be fully pressed against the nut and can not loosen the nut.
(b) Using SST, remove the nut.
SST 09387±00030, 09387±00080
(c) Using SST and a press, remove the front planetary gear
assy from the counter drive gear.
SST 09950±60010 (09951±00450)
(d) Remove front planetary gear assy from the brake hub.
68. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the brake hub snap ring and
front planetary ring gear from the brake hub.

D03600
SST
D08061
D03800
D03913
D03811
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±35
U241E A/T REPAIR MANUAL (RM840U)
69. REMOVE 1ST & REVERSE BRAKE PISTON
(a) Using SST, a press and a snap ring expander, remove
snap ring and the piston return spring.
SST 09387±00070
NOTICE:

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

Do not expand the snap ring excessively.
(b) Remove the1ST & reverse brake return spring from the
1ST & reverse brake piston.
(c) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove 1ST & reverse brake piston.
NOTICE:

Blowing off the air may cause the piston 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.
(d) Remove 2 O±rings from the 1ST & reverse brake piston.
70. INSPECT 1ST & REVERSE BRAKE RETURN SPRING
SUB±ASSY
(a) Using vernier calipers, measure the free length of the 1ST
& reverse brake return spring together with the spring
seat.
Standard free length: 15.51 mm (0.6106 in.)