2005 TOYOTA AVENSIS manual transmission

D26419
Snap Ring
D26420
D26718
D26422
D26719
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40−85
U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.
(b) Remove the flange, 3 discs,, 3 plates and cushion plate
from the intermediate shaft.
4. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
SIf the lining of the disc comes off or discolors, or even if a
part of the groove is defaced, replace all discs.
SBefore assembling new discs, soak them in ATF for at
least15 minutes.
5. REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.
(b) Remove the flange, 4 discs and 4 plates from the inter-
mediate shaft.
6. INSPECT OVERDRIVE DIRECT CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
SIf the lining of the disc comes off or discolors, or even if a
part of the groove is defaced, replace all discs.
SBefore assembling new discs, soak them in ATF for at
least15 minutes.

D03677
SST
D26424
Clutch
Balancer
Direct Clutch
Drum
D26423
Direct Clutch
Drum
Overdrive
Clutch Return
Spring
D09211
Overdrive Clutch
Return Spring
40−86
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE OVERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09387−00020
(b) Using a snap ring expander, remove the snap ring from
the direct clutch drum.
NOTICE:
SStop the press when the spring sheet is lowered to the
place1−2 mm (0.039−0.078 in.) from the snap ring
groove.
SThis prevents the spring sheet from being deformed.
SDo not expand the snap ring excessively.
(c) Remove the clutch balancer from the direct clutch drum.
(d) Remove the overdrive clutch return spring from the direct
clutch drum.
8. INSPECT OVERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 25.91mm (1.0201in.)

D26463
D26425
D26464
O−ring
D26464
O−ring
D26462
Intermediate
ShaftDirect Clutch
Drum
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40−87
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a) Install intermediate shaft on the transaxle rear cover.
(b) Holding the direct clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2,57psi)tothe
transaxle rear cover to remove the direct clutch piston.
10. REMOVE OVERDRIVE DIRECT CLUTCH DRUM
SUB−ASSY
(a) Holding the direct clutch drum by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
rear cover to remove the direct clutch drum.
11. REMOVE OVERDRIVE DIRECT CLUCH O−RING
(a) Using a screwdriver, remove the O−ring from the direct
clutch drum.
12. INSTALL OVERDRIVE DIRECT CLUCH O−RING
(a) Coat a O−ring with ATF, and install it to the direct clutch
drum.
NOTICE:
Assemble the O−ring carefully not to have a twist and a
pinching.
13. INSTALL OVERDRIVE DIRECT CLUTCH DRUM
SUB−ASSY
(a) Coat the direct clutch drum with ATF, and install it to the
intermediate shaft.
NOTICE:
SBe careful not to damage the O−ring.
SBe careful not to damage the lip seal of the direct
clutch drum.

D26461
Overdrive Direct
Clutch Piston
D26423
Overdrive
Clutch Return
Spring
D26424
Clutch
BalancerDirect Clutch
Drum
D03677
SST
40−88
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
14. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
(a) Apply the overdrive direct clutch piston with ATF, and
install it to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch pis-
ton.
15. INSTALL OVERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Install the piston return spring to the direct clutch drum.
NOTICE:
Installing the spring sub−assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
SBe careful not to damage the lip seal of the direct
clutch balancer.
SInstall the clutch balancer carefully not to have a
pinching and any other defects at the sealing lip.
SApply enough ATF to the sealing lip prior to assem-
bling.
(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09387−00020
(e) Using a snap ring expander, install the snap ring to the di-
rect clutch drum.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
SStop the press when the spring sheet is lowered to the
place1−2 mm (0.039−0.078 in.) from the snap ring
grove.
SThis prevents the spring sheet from being deformed.
SDo not expand the snap ring excessively.

D25588
Stopper
Stopper
D26417
Disc Flange
Plate
D26421
Snap Ring
D26416
Disc Flange
Plate
Cushion
Plate
D26419
Snap Ring
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40−89
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the piston shown in the
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.
16. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the intermediate
shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
17. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Apply the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the
intermediate shaft.
NOTICE:
SInstall the cushion plate with the mark on the white
surface facing to plate.
SBe careful about the order of discs, plates and flange
assembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.

D26426
D26427
D26428
40−90
− AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
18. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.60−0.82 mm (0.02362−0.03228 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.0 (0.118)53.4 (0.134)
23.1(0.122)63.5 (0.138)
33.2 (0.126)73.6 (0.142)
43.3 (0.130)−−
19. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.61−0.83 mm (0.02401−0.03268 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
02.5 (0.098)42.9 (0.114)
12.6 (0.102)53.0 (0.118)
22.7 (0.106)63.1(0.122)
32.8 (0.110)−−
(b) Check that the disc rotates when rotating the disc after in-
serting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

400H1−02
D26715
D26753
Snap Ring
D26754
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40−79
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:1.00−1.25 mm (0.0394−0.4921in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.

D09189
D26418
SST
Snap Ring
D26709
Clutch
Balancer
Input Shaft
D26708
Forward Clutch
Return SpringInput Shaft
40−80
− AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
SIf the lining of the disc comes off or discolors, or even if
replace all discs.
SBefore assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB−ASSY
(a) Place SST on the spring retainer and compress the return
spring with a press.
SST 09387−00020
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
SStop the press when the spring sheet is lowered1−
2 mm (0.039−0.078 in.) from the snap ring groove,
preventing the spring sheet from deforming.
SDo not expand the snap ring excessively.
(c) Remove the clutch balancer from the input shaft.
(d) Remove the forward clutch return spring from the input
shaft.