2005 TOYOTA AVENSIS transmission

D08115
Snap Ring
D26435
SST
D08117
D26436
SST
D26433
SST
40−102− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using a snap ring pliers, install the snap ring.
7. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Using a press, press the rear tapered roller bearing to the
underdrive planetary gear.
SST 09502−12010, 09950−60010 (09951−00260),
09950−70010 (09951−07100), 09316−20011
NOTICE:
Press the bearing until it becomes flat at the bottom.
(b) Install the counter driven gear with planetary ring gear to
the underdrive planetary gear.
(c) Using SST and a press, press in the front tapered roller
bearing.
SST 09502−12010, 09950−60010 (09951−00260),
09950−70010 (09951−07100), 09316−20011
NOTICE:
Press the counter driven gear while rotating it.
(d) Using a press, press in the parking lock gear.
SST 09502−12010, 09950−60010 (09951−00260),
09950−70010 (09951−07100), 09316−20011
NOTICE:
Press the counter driven gear while rotating it.

D26434
SST
Differential
Drive Pinion
D26432
SST
D25609
Underdrive
Planetary Gear
D25594
SST Underdrive
Planetary Gear
C56809
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40−103
U151E, U151F A/T REPAIR MANUAL (RM1021U)
8. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using a press, press the differential drive pinion.
SST 09726−40010, 09950−60010 (09951−00260),
09950−70010 (09951−07100)
NOTICE:
Press the counter driven gear while rotating it.
9. INSTALL CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using a press, press the cylindrical roller bearing race in-
ner.
SST 09506−35010, 09950−60010 (09951−00260),
09950−70010 (09951−07100)
NOTICE:
Press the counter driven gear while rotating it.
10. INSTALL FRONT PLANETARY GEAR NUT
(a) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 N
m (2,855 kgf
cm, 207 in.
lbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
11. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387−00050
Turning torque at 60 rpm.:
0.5−1.42 N
m (5.1−14.5 kgf
cm, 0.06−0.17 in.
lbf)
HINT:
Use a torque wrench with a fulcrum length of160 mm (6.30 in.).
(b) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.

400H3−02
D26429
D03701
Snap Ring
D26430
Underdrive
Clutch Drum
40−94
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while ap-
plying and releasing compressed air (392 kPa, 4.0 kgf/
cm
2, 57 psi).
Pack clearance:1.51−1.71mm (0.0594−0.0673 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the under-
drive clutch drum.

D04077
D08129
D03703
SST
Snap Ring
C56359
Clutch
Balancer
Underdrive
Clutch Drum
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
40−95
U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(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. INSPECT UNDERDRIVE CLUTCH DRUM SUB−ASSY
(a) Using a dial indicator, measure the inside diameter of the
underdrive clutch drum bushing.
Standard drum bushing:
37.06−37.08 mm (1.4591−1.4598 in.)
Maximum drum bushing: 37.13mm(1.4618 in.)
If the inside diameter is greater than the maximum, replace the
underdrive clutch drum.
6. REMOVE UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09350−32014 (09351−32070)
(b) Using a snap ring expander, remove the snap ring.
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 underdrive clutch
drum.

C56360
D03824
D03705
D26465
O−ring
D26465
O−ring
40−96
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the return spring from the underdrive clutch
drum.
7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length:17.14 mm (0.6752 in.)
8. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the underdrive clutch piston.
9. REMOVE UNDERDRIVE CLUTCH DRUM O−RING
(a) Using a screwdriver, remove the O−ring from the under-
drive clutch drum.
10. INSTALL UNDERDRIVE CLUTCH DRUM O−RING
(a) Apply the new O−ring with ATF, install it to the underdrive
clutch drum.
NOTICE:
Assemble the O−ring carefully not to have a twist and a
pinching.

D03860
C56360
Underdrive
Clutch
Return
Spring
Underdrive
Clutch Drum
C56359
Clutch
Balancer
Underdrive
Clutch Drum
D03703
SST
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
40−97
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, install it to the
underdrive clutch piston drum.
NOTICE:
SBe careful not to damage the O−ring.
SBe careful not to damage the lip seal of the piston.
12. INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB−ASSY
(a) Install the return spring to the underdrive 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 underdrive clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09350−32014 (09351−32070)
(e) Using a snap ring expander, install the snap ring to the un-
derdrive 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.

D25592
StopperStopper
D26431
Disc
Flange
Plate
D03701
D26429
40−98
− AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the underdrive clutch
drum shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stopper.
13. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Apply the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the underdrive
clutch drum.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
14. INSTALL UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, install the underdrive clutch flange
No.2 hole snap ring.
(b) Check that the end gap of snap ring is not aligned with one
of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
15. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch piston stroke while apply-
ing and releasing compressed air (392 kPa, 4.0 kgf/cm
2,
57 psi).
Park clearance:1.51−1.71mm (0.0594−0.0673 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another
flange.
HINT:
There are 5 flanges in different thickness.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)43.1(0.122)
23.2 (0.126)53.3 (0.130)
33.4 (0.134)−−

4006I−03
D26703
SST
D26704
2nd Brake Piston
Return Spring
C89124
2nd Brake Piston
Return Spring
D26705
− AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
40−91
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SECOND BRAKE PISTON ASSY (U151E/U151F)
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB−ASSY
(a) Place SST on the return spring and compress.
SST 09387−00060
(b) Using a screwdriver, remove the snap ring.
(c) Remove the 2nd brake piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB−ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length:16.61mm (0.6539 in.)
3. REMOVE 2ND BRAKE PISTON
(a) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf/cm
2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.