2005 TOYOTA AVENSIS manual transmission

C89122
SST
SST
Counter Drive
GearBearing
D26713
O−ringO−ring
D26593
1st & Reverse
Brake Piston
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−47
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Using SST and a press, install the counter drive gear and
bearing to the transaxle case.
SST 09223−15030, 09527−17011, 09950−60020
(09951−00750), 09950−70010 (09951−07150)
NOTICE:
Do not apply excessive pressure to it.
94. INSTALL1ST & REVERSE BRAKE PISTON
(a) Coat the 2 new O−rings with ATF.
(b) Install the 2 O−rings to the 1st & reverse brake piston.
NOTICE:
SAssemble the O−ring carefully not to have a twist and
a pinching.
SApply enough ATF to the O−ring prior to assembling.
(c) Coat a 1st & reverse brake piston with ATF, install it to the
transaxle case.
NOTICE:
Be careful not to damage the O−ring.

D03600
SST
D03615
Front Planetary Ring Gear
Brake Hub
Snap Ring
D26763
Front Planetary
Gear Assy
Brake Hub
40−48
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
95. INSTALL1ST & REVERSE BRAKE RETURN SPRING
SUB−ASSY
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387−00070
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
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, preventing the spring sheet from being de-
formed.
SDo not expand the snap ring excessively.
SInstalling the spring sub−assembly, check all of the
springs are fit in the piston correctly.
SThe snap ring should be fixed surely in the groove of
the cylinder.
SFix the snap ring to the inside of the claw of the spring
seat surely.
96. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear
and snap ring to the brake hub.
NOTICE:
Confirm the snap ring is fixed in the groove of the brake hub
correctly.
97. INSTALL FRONT PLANETARY GEAR ASSY
(a) Install the front planetary gear assy to the brake hub.

D03916
SST
Counter Drive
GearTransaxle
Case
2nd Brake Hub
w/ Front Planetary
Gear Assy
SST
D03917
D03596
SST
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−49
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST and a press, press−fit the front planetary gear
assy.
SST 09950−60010 (09951−00500), 09950−70010
(09951−07100)
NOTICE:
SDo not apply excessive pressure to it.
SPress the inner race of LH tapered roller bearing,
counter gear and front planetary gear assembly to the
position where no pre−load should be applied to one
pair of tapered roller bearings (left and right).
(c) Install the new washer, as shown in the illustration.
(d) Using SST, install the nut.
SST 09387−00030, 09387−00080
Torque: 210−350 Nm
(2,141kgfcm,155 ftlbf−3,569 kgfcm, 258 ftlbf)
NOTICE:
Assemble the washer after pressing each part, then tighten
the nut to minimum tightening torque.

D03918
SST
D08074
Lock Washer
C89123
C
BA
Input Sun Gear
D
40−50
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST and a torque wrench, measure the turning
torque of the bearing while rotating SST at 60 rpm. When
the measured value is not within the specified value,
gradually tighten the nut until it reaches the specified val-
ue.
SST 09387−00080
Turning torque at 60 rpm:
New Bearing
0.51−1.02 Nm (5.1−10.0 kgfcm, 4.4−8.7 in.lbf)
Used Bearing
0.26−0.51Nm (2.7−5.2 kgfcm, 2.3−4.5 in.lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation
torque of tapered roller bearing is measured.
Torque: 350 Nm (3,569 kgfcm, 258 ftlbf) (a limit)
(g) Using a chisel and hammer, stake the front lock washer.
98. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
NOTICE:
SInstall the bearing race on the side of the front plane-
tary carrier. Be careful about the orientation of the
race.
SInstalling thrust bearing and front sun gears, be care-
ful about the orientation of the parts.
SInstall the bearing race on the side of the front sun
gear. Be careful about the orientation of the race.
SInstall the thrust bearing and the race after holding
the parts on the rear planetary carrier by applying
grease. Be sure the assembling order.

D26591Rear Planetary Gear Assy
D03616
Snap Ring
D26413
Disc
Plate
D26452
A
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−51
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Thrust bearing and bearing race diameter: mm (in.)
insideoutside
Thrust Bearing, A32.5 (1.28)56.5 (2.224)
Bearing Race, B40.2 (1.583)59.3 (2.335)
Thrust Bearing, C38.6 (1.520)59.7 (2.35)
Bearing Race, D38.6 (1.520)59.3 (2.335)
99. INSTALL REAR PLANETARY GEAR ASSY
(a) Install the rear planetary gear assy to the rear planetary
ring gear.
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm the snap ring is fixed in the groove of the1st & re-
verse brake hub correctly.
100. INSTALL1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case(Dimension A).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance:1.16−1.35 mm (0.0457−0.0531in.)
HINT:
Piston stroke = Dimension A−Flange thickness

D03815
D26396Second Brake Piston Assy
D08058
Snap Ring
C929771−Way Clutch Sleeve Outer
40−52
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
11.8 (0.071)52.2 (0.087)
21.9 (0.075)62.3 (0.091)
32.0 (0.079)72.4 (0.094)
42.1 (0.083)82.5 (0.098)
(c) Install the flange.
102. INSTALL SECOND BRAKE PISTON ASSY
(a) Install the second brake piston assy to the transaxle case.
(b) Install the snap ring and measure the inside diameter.
Inside diameter: More than167 mm (6.57 in.)
NOTICE:
SBecause the taper snap ring has the positioning
direction, check it when installing.
SWhen the diameter does not meet the specified value,
replace the snap ring with new one.
SAfter assembling, confirm that there is no clearance
between the second brake cylinder and the fitting sur-
face of the cylinder in the transaxle case.
103. INSTALL1WAY CLUTCH SLEEVE OUTER
(a) Install the 1−way clutch sleeve outer to the 2nd brake cyl-
inder assy.
NOTICE:
Check the positioning direction of the outer sleeve.

D03909
1−Way Clutch
Inner Race
D09638
Free
D03588
Thrust Needle
Roller Bearing
1−Way Clutch Assy
D26394
Planetary Carrier
Thrust Washer No.1
D26393
Planetary Carrier Thrust Washer No.2
Rear Planetary Sun Gear
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40−53
U151E, U151F A/T REPAIR MANUAL (RM1021U)
104. INSTALL1WAY CLUTCH ASSY
(a) Install the 1−way clutch inner race to the 1−way clutch.
NOTICE:
SCheck the direction of the inner race.
SConfirm that the discrimination mark can be seen by
the worker.
(b) Check the rotating direction of 1−way clutch for the lock
or free operation, as shown in the illustration.
(c) Install the 1−way clutch and thrust needle roller bearing
to the 1−way clutch sleeve outer.
Bearing diameter: mm (in.)
InsideOutside
Bearing53.6 (2.110)69.4 (2.732)
NOTICE:
Install the thrust bearing properly so that no−colored race
will be visible.
105. INSTALL PLANETARY CARRIER THRUST WASHER
NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow
petrolatum, install it onto the planetary sun gear assy.
NOTICE:
After assembling, confirm that the projection should be
fixed surely in the hole of the planetary sun gear assembly.
106. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 2 with yellow
petrolatum, install it onto the rear planetary sun gear.

D26404
BA
D26714Rear Planetary Sun Gear Assy
D26412
Plate Disc
D26453
B 40−54
− AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Coat the bearing with yellow petrolatum, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Race, A33.0 (1.299)45.4 (1.787)
Bearing, B31.85 (1.254)45.2 (1.78)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
NOTICE:
Installing the rear planetary sun gear assembly, confirm
that the B1discs engage.
107. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
108. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between
the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 0.62−0.91mm (0.0244−0.0358 in.)
HINT:
Piston stroke = Dimension B−Flange thickness−Snap ring
thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
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)8−