2005 TOYOTA AVENSIS manual transmission

D03601
SST
D03602
D03603
SST
D03798
D03604
40±36
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
71. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive gear
from the transaxle case.
SST 09950±60010 (09951±00600), 09950±70010
(09951±07100)
(b) As shown in the illustration, tighten 2 bolts evenly and
make clearance of approx. 20.0 mm (0.797 in.) between
the counter drive gear and the inner race.
(c) Using SST, remove the tapered roller bearing.
SST 09950±60010 (09951±00600), 09950±40011
(09951±04010, 09952±04010, 09953±04020,
09954±04010, 09955±04011, 09958±04011)
(d) Using a brass bar and a hammer, remove the 2 counter
drive gear bearing outer races from the transaxle case.
72. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, remove the snap ring from the trans-
axle case.

D03607
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±37
U241E A/T REPAIR MANUAL (RM840U)
73. REMOVE BREATHER PLUG NO.2 (ATM)
74. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, the transaxle apply tube clamp No. 2
and the differential gear loop apply tube from the trans-
axle case.

D03839
AB
CDE
F
G
I
J
H 40±38
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
75. BEARING POSITION

± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±39
U241E A/T REPAIR MANUAL (RM840U)
MarkFront Race Diameter
Inside / Outside mm (in.)Thrust Bearing Diameter
Inside / Outside mm (in.)Rear Race Diameter
Inside / Outside mm (in.)
A±53.0 (2.087) / 78.2 (3.079)52.1 (2.051) / 75.5 (2.972)
B±37.73 (1.4854) / 58.0 (2.283)29.9 (1.177) / 55.5 (2.185)
C±33.85 (1.3327) / 52.2 (2.055)±
D±23.5 (0.925) / 44.0 (1.732)±
E±36.3 (1.429) / 52.2 (2.055)34.5 (1.358) / 48.5 (1.909)
F±34.6 (1.362) / 52.2 (2.055)±
G40.3 (1.587) / 58.0 (2.283)38.6 (1.520) / 60.0 (2.362)38.6 (1.520) / 58.0 (2.283)
H±53.6 (2.110) / 69.6 (2.740)±
I±33.7 (1.327) / 48.2 (1.898)30.3 (1.193) / 46.0 (1.811)
J±53.6 (2.110) / 70.18 (2.763) or 69.6 (2.740)±

D03607
D03604
D03611
Counter Drive Gear Side:
Front Planetary Gear Side:SST
SST
40±40
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
76. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the apply tube, and apply tube clamp No. 2 with the
bolt to the transaxle housing.
Torque: 9.8 N
m (100 kgf
cm, 87 in.
lbf)
NOTICE:
Make sure to insert the tube to the stopper.
77. INSTALL BREATHER PLUG NO.2 (ATM)
78. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, install the hole snap ring to the trans-
axle case.
79. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, instal the 2 counter drive gear
bearings outer races to the transaxle case.
NOTICE:

Press±fit the bearing race until it contacts the snap
ring.

Do not apply excessive pressure to it.
SST 09950±60020 (09951±00890), 09950±70010
(09951±07150)

D03613
SST
D03614
SST
D03913
D03813
D08072
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±41
U241E A/T REPAIR MANUAL (RM840U)
(b) Using SST and a press, install the tapered roller bearing
to the counter drive gear.
SST 09649±17010
NOTICE:

Press±fit the bearing inner race until contacts the
counter drive gear.

Do not apply excessive pressure to it.
(c) Using SST and a press, install the counter drive gear and
bearing to the transaxle case.
SST 09950±60020 (09951±00890), 09950±70010
(09951±07150)
NOTICE:
Do not apply excessive pressure to it.
80. INSTALL 1ST & REVERSE BRAKE PISTON
(a) Coat 2 new O±rings with ATF.
(b) Install the 2 O±ring to the 1st & reverse brake piston.
(c) Coat a 1st & reverse brake piston with ATF, install it to the
transaxle case.
(d) Install the 1st & reverse brake return spring to the 1st &
reverse brake piston.

D03600
SST
D03615
D08063
D03916
SST
Counter Drive
GearTransaxle
Case
2nd Brake Hub
w/ Front Planetary
Gear Assy
40±42
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(e) Using SST, a press and snap ring expander, install the
piston return spring and snap ring to the transaxle case.
SST 09387±00070
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 being de-
form.

Do not expand the snap ring excessively.
81. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear
and brake hub snap ring to the brake hub.
82. INSTALL FRONT PLANETARY GEAR ASSY
(a) Install the front planetary gear assy to the brake hub.
(b) Using SST and a press, press±fit the front planetary gear
assy.
NOTICE:
Do not apply excessive pressure to it.

D03917
D03596
SST
D03918
SST
D08074
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±43
U241E A/T REPAIR MANUAL (RM840U)
(c) Install the front planetary gear washer, as shown in the il-
lustration.
(d) Using SST, install the nut.
SST 09387±00030, 09387±00080
Torque: 268 N
m (2,728 kgf
cm, 197 ft
lbf)
(e) Using SST and a torque wrench, measure the turning
torque of the bearing while rotating SST at 60 rpm. When
the measured value is not within the specified value,
gradually tighten the nut until it reaches the specified val-
ue.
SST 09950±60010 (09951±00400), 09950±70010
(09951±07100), 09387±00030, 09387±00080
Turning torque at 60 rpm:
New Bearing
0.5 ± 1.0 N
m (5.1 ± 10.0 kgf
cm, 4.4 ± 8.7 in.
lbf)
Used Bearing
0.3 ± 0.5 N
m (3.1 ± 5.1 kgf
cm, 2.7 ± 4.4 in.
lbf)
(f) Using a chesel and hammer, stake the front planetary
gear washer.