2005 TOYOTA AVENSIS transmission

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.

D30865
C91925
−
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION VALVE BODY ASSY (U151E)
40−23
AVENSIS Supplement (RM1045E)
10. I NSTALL AUTO M AT I C TRANSAXLE O I L PAN
SUB −ASSY
(a) Install the 2 magnets to the oil pan.
(b) Apply seal packing to the 18 bolts. Seal packing:
THREE BOND 1344 or equivalent
(c) Install a new gasket, the oil pan and 18 bolts to the trans- axle case.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
NOTICE:
Apply seal packing to the bolts and tighten them within 10
minutes of application.
11 . ADD AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
1 2. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
1 3. RESET MEMORY (SEE PAGE 05 −54 1)

40187−01
C91925
D30865
AT0103
C91927
40−16
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
AVENSIS Supplement (RM1045E)
TRANSMISSION WIRE (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug and gasket, and drain ATF.
(b) Install a new gasket and the drain plug.
Torque: 47 N
m (479 kgf
cm, 35 ft
lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all of the oil
pan bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine the particles in the oil pan.
(1) Collect any steel chips with the removed magnets.
Look at the chips and particles in the pan and on the
magnets carefully to see the type of wear which
might be found in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.

D30866
D30867
D30866
C91927
D30865
− AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
40−17
AVENSIS Supplement (RM1045E)
5. REMOVE TRANSMISSION WIRE
(a) Disconnect the transmission wire connectors.
(b) Remove the bolt and transmission wire.
6. INSTALL TRANSMISSION WIRE
(a) Coat an O−ring of the transmission wire connector with
AT F.
(b) Install the transmission wire and bolt.
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
7. CONNECT TRANSMISSION WIRE
(a) Coat an O−ring of the ATF temperature sensor 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.
8. INSTALL AUTOMATIC TRANSAXLE OIL PAN
SUB−ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing to the 18 bolts.
Seal packing:
THREE BOND1344 or equivalent

C91925
40−1 8
−
AUTOMATIC TRANSMISSION / TRANS TRANSMISSION WIRE (U151E)
AVENSIS Supplement (RM1045E)
(c) Install a new gasket, the oil pan and 18 bolts to the trans- axle case.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
NOTICE:
Apply seal packing to the bolts and tighten them within 10
minutes of application.
9. ADD AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
1 0. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PUB. NO. RM 1018E, PAGE 40 −2)
11 . RESET MEMORY (SEE PAGE 05 −54 1)

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.