2005 TOYOTA AVENSIS transmission

D25506
D25505
D03915
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± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
112. INSTALL THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Install the thrust bearing race to the U/D planetary gear
assy.
113. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Calculate the end play value using the following formula
and values of Dimension D and E that ware measured
when installing cylindrical roller bearing and U/D plane-
tary gear, Select an appropriate U/D planetary gear thrust
bearing race No. 2 which satisfies the specified end play
value, and install it.
End play: 0.20 ± 0.69 mm (0.0079 ± 0.0272 in.)
HINT:
End play = Dimension E ± Dimension D ± thrust bearing thick-
ness 3.28 mm (0.1291 in.) ± U/D thrust bearing race No. 2 thick-
ness.
Race thickness: mm (in.)
E ± DThickness
Less than 7.34 (0.2890)3.5 (0.138)
7.34 (0.2890)3.8 (0.150)
Bearing and bearing race diameter: mm (in.)
InsideOutside
Bearing53.0 (2.087)78.2 (3.079)
Bearing race52.1 (2.051)75.5 (2.972)
114. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Install new oil seal ring to the transaxle housing.

D03807
SST
D03630Seal Bend Width 1.2 mm (0.047 in.) FIPG
C50259
C
C
C
CA
AA B
BB
C83145
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
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U241E A/T REPAIR MANUAL (RM840U)
115. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST and a press, install the U/D cylindrical roller
bearing.
SST 09950±60020 (09951±00810), 09950±70010
(09951±07100)
NOTICE:
Do not apply excessive pressure to it.
116. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil
on the contacting surfaces of the transaxle case or trans-
axle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826±00090, THREE BOND 1281 or equiva-
lent
(c) Install the transaxle housing and 16 bolts to the transaxle
case.
Torque:
Bolt A: 22 N
m (226 kgf
cm, 16 ft
lbf)
Bolt B and C: 29 N
m (300 kgf
cm, 22 ft
lbf)
HINT:
Apply seal packing or equivalent to the bolt A.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to
new bolts and tighten them within 10 minutes after applica-
tion.
117. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install 2 new O±rings to the 2 transaxle case No. 1 plugs.
(b) Install the 2 transaxle case No. 1 plugs to the transaxle
housing.
Torque: 7.4 N
m (75 kgf
cm, 65 in.
lbf)

D08091
D03631
D03632
D03905
D03565
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± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
118. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
End play: 0.26 ± 1.25 mm (0.0103 ± 0.0492 in.)
119. FIX AUTOMATIC TRANSAXLE ASSY
120. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with ATF, install it to the transaxle
case.
(b) Install the oil seal to the transaxle case.
121. INSTALL PARKING LOCK ROD SUB±ASSY
(a) Install the parking lock rod to the manual valve lever.
122. INSTALL MANUAL VALVE LEVER SUB±ASSY
(a) Install a new spacer and manual valve lever shaft to the
transaxle case.

D03564
D03930
D03559
D03561
D03560
B
A
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±61
U241E A/T REPAIR MANUAL (RM840U)
(b) Using a pin punch and a hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small hole
for locating the staking position in the spacer with the
staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small
hole.
(e) Check that the spacer does not turn.
123. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle±nose pliers, install the retainer spring.
124. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N
m (205 kgf
cm, 15 ft
lbf)
Bolt length: 25 mm (0.984 in.)
125. INSTALL MANUAL DETENT SPRING SUB±ASSY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring and cover in
this order.
Torque:
Bolt A: 20 N
m (205 kgf
cm, 15 ft
lbf)
Bolt B: 12 N
m (120 kgf
cm, 9 ft
lbf)

D03904
D25512
D03903
D03557
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± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
Bolt length:
Bolt A: 27 mm (1.063 in.)
Bolt B: 16 mm (0.630 in.)
126. INSTALL B±3 ACCUMULATOR PISTON
(a) Coat a new O±ring with ATF, install it to the B
3 accumula-
tor piston.
(b) Coat the accumulator B
3 piston and spring with ATF,
install them to the transaxle case.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
Inner 60.24 (2.3716) /
15.9 (0.626)Yellowish green
Outer 74.61 (2.9374) /
21.7 (0.854)Blue
127. INSTALL C±1 ACCUMULATOR PISTON
(a) Coat 2 new O±rings with ATF, install them to the C
1 accu-
mulator piston.
(b) Coat accumulator C
1 piston with ATF, install it to the trans-
axle case.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
81.53 (3.2098) /
18.5 (0.728)Pink

D03902
C83146
D03555
D03554
C50156
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
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U241E A/T REPAIR MANUAL (RM840U)
128. INSTALL C±3 ACCUMULATOR PISTON
(a) Coat a new O±ring with ATF, install it to the C
3 accumula-
tor piston.
(b) Coat the C
3 accumulator piston with ATF, install it to the
transaxle case.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
90.49 (3.5626) /
19.2 (0.756)White
(c) Install the compression spring from the C3 accumulator
piston.
129. INSTALL CHECK BALL BODY
(a) Install the check ball body and spring.
130. INSTALL TRANSMISSION WIRE
(a) Coat a new O±ring with ATF, install it to the transaxle sole-
noid wire.

C50009
C83129
C83128
C83127
D03553
A
C
A
C

A
BB B

C 40±64
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
(b) Install the solenoid wire retaining bolt
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
131. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to the
transaxle case.
132. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF,
install it to the transaxle case.
133. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No. 1 with ATF, install
it to the transaxle case.
134. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the
valve body with 17 bolts to the transaxle case.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 41 mm (1.614 in.)
Bolt C: 45 mm (1.771 in.)

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± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
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U241E A/T REPAIR MANUAL (RM840U)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
When installing the valve body to the transaxle case,
do not hold the solenoids.
Tighten those bolts marked by
in the illustration
first temporarily because they are positioning bolts.
(b) Connect the 5 solenoid connectors.
(c) Install the ATF temperature sensor, clamp and bolt.
Torque: 6.6 N
m (67 kgf
cm, 58 in
lbf)
135. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O±ring with ATF, install it to the oil strainer.
(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 N
m (110 kgf
cm, 8 ft
lbf)
136. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET
(a) Install a new oil pan gasket to the oil pan.