2005 TOYOTA AVENSIS manual transmission

C50950
C50205
C50206
C50207
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−121
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Hold the differential case RH by vice. Install the center dif-
ferential pinion and pinion thrust washer to the differential
spider and install them to the differential case RH.
NOTICE:
When holding the differential case RH by vise, be sure to
place an aluminum sheet between them and use a mini-
mum force.
(c) Pressing and holding the differential spider toward the dif-
ferential case RH, measure the pinion’s backlash with a
dial indicator as illustrated.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
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
MA0.80 (0.0313)MH1.15 (0.0453)
MB0.85 (0.0333)MJ1.20 (0.0472)
MC0.90 (0.0353)MK1.25 (0.0492)
MD0.95 (0.0373)ML1.30 (0.0512)
ME1.00 (0.0393)MM1.35 (0.0532)
MF1.05 (0.0413)MN1.40 (0.0552)
MG1.10 (0.0433)−−
(d) Temporarily install the differential side gear thrust washer
No.2 LH, center differential side gear conical spring wash-
er and differential case No.2 to the differential case LH.
HINT:
Ensure that the conical washers is installed correctly.
(e) Install the differential intermediate case to the above and
fix them with 4 bolts.

C50208
C50209
C50210
C51468
Differential
Case No.2
Differential
Case LH
40−122
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(f) Remove the differential spider, 5 center differential pin-
ions and 5 center differential pinion thrust washers from
the differential case RH. Put them in the differential inter-
mediate case and fix the case.
(g) Pressing and holding the differential spider toward the dif-
ferential intermediate case, measure the pinion’s back-
lash with a dial indicator.
Standard backlash:
0.05−0.20 mm (0.0020−0.0079 in.)
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
MA0.80 (0.0313)MH1.15 (0.0453)
MB0.85 (0.0333)MJ1.20 (0.0472)
MC0.90 (0.0353)MK1.25 (0.0492)
MD0.95 (0.0373)ML1.30 (0.0512)
ME1.00 (0.0393)MM1.35 (0.0532)
MF1.05 (0.0413)MN1.40 (0.0552)
MG1.10 (0.0433)−−
(h) Remove the 4 bolts and disconnect the differential case
LH from the differential intermediate case.
(i) Remove the differential case No.2 from the differential
case LH.

C51469
C50188
Differential
Case No.2
Differential
Case LH
C50193
D25612
SST
D25603
SST
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−123
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(j) Install the selected differential side gear thrust washer
No. 2 LH and center differential planetary gear to the dif-
ferential case LH.
(k) Install the differential case No. 2 to the differential case LH
again.
(l) Install the adjusted differential case RH to the intermedi-
ate case and tighten the15 bolts using a torx socket
wrench (T50).
Torque: 63 N
m (642 kgf
cm, 46 ft
lbf)
NOTICE:
Align the matchmarks.
10. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing FR to the differential case.
SST 09950−70010 (09951−07100), 09649−17010
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Using SST, install the outer race of the tapered roller bear-
ing FR.
SST 09527−17011, 09950−60020 (09951−01030)
NOTICE:
Clearance is not allowed between the plate washer and
transaxle housing.

D25613
SST
D25601
SST
C50224
D03568
C
C
C
A
AB
C
40−124
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing RR to the differential case.
SST 09316−20011, 09214−76011
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Install the front differential case shim RR to the transaxle
case.
If the bearing is new, check to select a front differential case
shim RR of proper thickness starting from the thinner ones.
If the bearing is reused, check to select a front differential case
shim RR starting from the same thickness as one installed be-
fore disassembly.
(c) Using SST, install the outer race of the front differential
case tapered roller bearing RR.
SST 09950−60020 (09951−00890), 09950−70010
(09951−07100)
NOTICE:
Clearance is not allowed between the differential case
shim and transaxle case.
12. ADJUST TAPERED POLLER BEARING PRELOAD
(a) Install the intermediate case to the differential case LH
and fix them with 4 bolts.
(b) Install the differential assy to the transaxle case.
(c) Clean the matching surfaces of the transaxle case and
transaxle housing.
(d) Install the transaxle housing to the transaxle case and
tighten them with the16 bolts.
Torque:
Bolt A: 25 N
m (255 kgf
cm,18ft
lbf)
Bolt B 33 N
m (337 kgf
cm, 24 ft
lbf)
Bolt C 29 N
m (295 kgf
cm, 21ft
lbf)
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
HINT:
Usually, bolt A is a non−reusable bolt. In this case, however, it
can be used after cleaning it.

SST
C50227
D25614
C50224
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−125
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST, turn the differential assy right and left 2or 3
times to allow the bearing settle.
SST 09564−32011
(f) Using SST and a torque wrench, measure the turning
torque of the differential case assy.
SST 09564−32011
Turning torque at 60 rpm:
New bearing
0.20−0.69 N
m (2.0−7.0 kgf
cm,1.8−6.1in.
lbf)
Used bearing
0.10−0.35 N
m(1.0−3.6 kgf
cm, 0.9−3.1in.
lbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below and select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(g) Remove the16 bolts and the transaxle housing.
(h) Remove the differential assy.

D25215
90−100_C(194−230_F)
C50186
Match−marks
C50232
C50233
D25605
SST 40−126
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90−110_C. (194.0−230.0_F)
NOTICE:
Do not overheat the ring gear to110_C (230.0_F) or more.
(b) Clean the contact surface of the front differential case.
(c) Set the match−marks, install the front differential ring gear
case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.
(d) Temporarily install the 8 bolts as shown in the illustration.
(e) Remove the 4 bolts shown in the illustration.
(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95.1N
m (970 kgf
cm, 70 ft
lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
14. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09223−15020, 09950−70010 (09951−07100)
(b) Coat the rip of oil seal with a little MP grease.

D03809
Vinyl Tape
SST
D25615
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40−127
U151E, U151F A/T REPAIR MANUAL (RM1021U)
15. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Wind a vinyl tape around SST at the place 6.0 mm (0.236
in.) above from the bottom end until the thickness of the
wound tape is about 5.0 mm (0.197 in.).
SST 09950−60020 (09951−00730)
NOTICE:
Remove foreign matter such as grease on the SST before
winding the tape.
(b) Coat the rip of oil seal with a little MP grease.
(c) Using SST, install a new oil seal.
SST 09950−60020 (09951−00730), 09950−70010
(09951−07150)
Standard press in depth:
5.5−6.5 mm (0.217−0.256 in.)
NOTICE:
Stop pressing when the would vinyl tape is contact with the
transaxle housing.

4006M−03
D26445
Mark
Front
Differential
Ring Gear
D26446
Front
Differential
Ring Gear
C50237Front Differential Ring Gear
D25595
HoldTurn
SST
SST
− AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40−107
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FRONT DIFFERENTIAL ASSY (U151E)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match−marks on the front differential ring gear
and differential case.
(b) Remove the14 bolts.
(c) Using a plastic hammer, tap on the front differential ring
gear to remove it from the case.
2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front differ-
ential tapered roller bearing from the differential case.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00490), 09950−40011(09957−04010)