2005 TOYOTA AVENSIS manual transmission

05JL7−01
G23405Transmission Wire
05 −540−
DIAGNOSTICS ELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U 151E)
AVENSIS Supplement (RM 1045E)
MANUAL SHIFTING TEST
1. PERFORM MANUAL SHIFTING TEST
HINT:
S With this test, it can be determined whether the trouble oc-
curs in the electrical circuit or is a mechanical problem in
the transaxle.
S If any abnormalities are found in the following test, the
problem is in the transaxle itself.
(a) Disconnect the transmission wire connector.
(b) Drive with the transmission wire disconnected. Shifting the shift lever to the D position to check whether
the shifting condition changes the table below.
Shift PositionShifting Condition
DNo Shift (Not Change)
HINT:
When driving with the transmission wire disconnected, the gear
position will be as follows:
S When the shift lever is in the D position, the gear is held
in the 4th position.
S When the shift lever is in the R or the P position, the gear
is also in the R or the P position respectively.
(c) Connect the transmission wire connector.
(d) Clear the DTC (see page 05 −557).

C91933
A
B
CB
B
B
A
CCC
L
L
C
B
C91932
C91931
C91927
40−22
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
AVENSIS Supplement (RM1045E)
(c) Align the groove of the manual valve with the pin of the
lever.
(d) Install the 17 bolts.
Torque:11N
m(110 kgf
cm, 8 ft
lbf)
NOTICE:
SPush the valve body against the accumulator piston
spring and the check ball body to install it.
SFirst, temporarily tighten those bolts marked byLin
the illustration because they are positioning bolts.
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 41mm (1.614 in.)
8. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O−ring with ATF.
(b) Install the O−ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque:11N
m(110 kgf
cm, 8 ft
lbf)
9. INSTALL TRANSMISSION WIRE
(a) Coat an O−ring with ATF.
(b) Install the ATF temperature sensor with the lock plate and
bolt.
Torque: 6.6 N
m (67 kgf
cm, 58 in.
lbf)
(c) Connect the 7 shift solenoid valve connectors.

4006N−02
C50182
Match−marks
Front Differential Ring Gear
C50183
Front Differential
Ring Gear
C50184Front Differential Ring Gear
C50187
Differential
Case Assy
Differential
LH Case
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−115
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FRONT DIFFERENTIAL ASSY (U151F)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match−marks on the ring gear and differential
case.
(b) Remove the16 bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the case.
2. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the differential LH case from the differential case
assy.

C50188
Differential
Case No.2
Differential
Case LH
C50189
Differential
Case LH
Center
Differential
Side Gear
Thrust Washer
No.2Conical Spring
Front
Differential
Side Gear
Thrust WasherFront
Differential
Side Gear
D25610
C50190
C50191
40−116
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Remove the differential case No.2 from the differential
case LH.
(c) Remove the front differential side gear, front differential
side gear thrust washer, conical spring and center differ-
ential side gear thrust washer No.2 from the differential
case LH.
(d) Using a snap ring expander, remove the pinion shaft
spacer snap ring.
(e) Using a pin punch and a hammer, remove 3 straight pins.
(f) Remove the center differential pinion shaft and 2 differen-
tial pinion shafts.

C50943
D25597
SST
SST HoldTurn
D25598
SST
C50193
C50230
Differential
RH Case
Differential
Intermediate Case
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−117
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Remove 4 front differential pinions, 4 front differential pin-
ion thrust washers, front differential pinion shaft holder,
front differential planetary ring gear and differential side
gear thrust washer No.1.
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00480)
(b) Using SST, remove the front differential case rear tapered
roller bearing outer race and differential case washer.
SST 09308−00010
4. REMOVE CENTER DIFFERENTIAL PINION
(a) Using torx socket (T50), remove the15 bolts.
(b) Place the matchmarks on the differential intermediate
case and differential case.
(c) Remove the differential intermediate case from the differ-
ential case RH.

C50196
Differential Case RH
Center Differential
Side Gear
C50194
D25611
SSTSST Hold
Turn
D25596
SST
D25599
SST
40−118
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the center differential side gear, conical spring
washer and center differential side gear thrust washer No.
1RH from the differential case RH.
(e) Remove the differential spider, 5 center differential pin-
ions and 5 center differential pinion thrust washers from
the differential intermediate case.
5. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front ta-
pered roller bearing from the differential case.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00600)
(b) Using SST, remove the front differential case front ta-
pered roller bearing outer race and differential case wash-
er.
SST 09308−00010
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950−70010 (09951−07100), 09649−17010

D25600
SST
C50943
C50216
C50213
Differential
Case LH
Differential
Case No.2
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−119
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950−70010 (09951−07100), 09608−10010
8. INSTALL DIFFERENTIAL CASE SUB−ASSY NO.2
(a) Coat the front differential side gear thrust washer No.1,
front differential planetary ring gear, front differential pin-
ion No.2, front differential pinion thrust washer No.2, front
differential pinion shaft holder, front differential pinion
shaft and 2 differential pinion shafts with ATF, install them
to the differential case No.2.
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
(c) Engage the front differential side gear to the above men-
tioned front differential case.
(d) Install the differential case LH to the front differential case
and measure its center.
(e) After that, remove the differential case LH.

C50214
C50217
D25610
C51252
Differential Case RH
Center Differential
Side Gear
40−120
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(f) Using a straight edge and feeler gauge, measure the
clearance between the front differential case and the front
differential side gear.
t= Thrust washer thickness
L= Clearance
t= L−0.162−0.265 mm (0.0064−0.0104 in.)
If the clearance is not within the specified value, refer to the
table below and select a thrust washer which will ensure that the
clearance is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
If the clearance is not within the specified value, parts may have
been assembled incorrectly, so check and reassemble it.
(g) Using a pin punch and a hammer, install 3 straight pins.
(h) Using a snap ring expander, install the pinion shaft spacer
snap ring.
9. INSTALL CTR DIFFERENTIAL PLANETARY GEAR
ASSY
(a) Install the center differential side gear, conical spring
washer and center differential side gear thrust washer
No.2 RH from the differential case RH.
HINT:
Ensure that the conical washers is installed correctly.