2005 TOYOTA AVENSIS oil

D09176
D09177
AT0103
D09637
40±16
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
9. FIX AUTOMATIC TRANSAXLE ASSY
10. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the 18 bolts.
(b) Remove the oil pan and 2 magnets.
11. REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET
(a) Remove the gasket from the oil pan.
12. INSPECT AUTOMATIC TRANSAXLE OIL PAN
SUB±ASSY
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non±magnetic).... bushing wear
13. REMOVE TRANSMISSION WIRE
(a) Remove the 5 connectors from the shift solenoid valves.
(b) Remove the bolt, clamp and ATF temperature sensor.

D03547
D03636
D09179
D09180
D03553
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±17
U241E A/T REPAIR MANUAL (RM840U)
(c) Remove the bolt and transaxle solenoid wire from the
transaxle case.
(d) Remove the O±ring from the transaxle solenoid wire.
14. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O±ring from the oil strainer.
15. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and
the valve body assy.

D03556
D03902
D03557
D03903
D03558
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±19
U241E A/T REPAIR MANUAL (RM840U)
(b) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the
oil hole and remove the C
3 accumulator piston.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing.
(c) Remove the O±ring from the C
3 accumulator piston.
21. REMOVE C±1 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the C
1 accumulator piston and com-
pression spring.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing.
(b) Remove the 2 O±rings from the C
1 accumulator piston.
22. REMOVE B±3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the B
3 accumulator piston and 2 com-
pression springs.
NOTICE:

Blowing off the air may cause the piston's jump±out.
When removing the piston, hold it with your hand us-
ing a waste cloth.

Take care not to splash ATF when air±blowing.

D03564
D03565
D03905
D03566
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±21
U241E A/T REPAIR MANUAL (RM840U)
(b) Using a pin punch and hammer, drive out the manual
valve lever shaft spring pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.
(c) Remove the manual valve lever shaft and manual valve
lever.
27. REMOVE PARKING LOCK ROD SUB±ASSY
(a) Remove the parking lock rod from the manual valve lever.
28. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the trans-
axle case.
29. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle case with the oil pump side facing up.

D08046
C83145
D09182
D03606
SST
D03915
40±22
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
30. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
END Play: 0.26 ± 1.25 mm (0.0103 ± 0.0492 in.)
31. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 2 transaxle case No 1 plugs.
(b) Remove the 2 O±rings from the transaxle case plug.
32. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing with a
plastic hammer to remove the transaxle housing from the
transaxle case.
NOTICE:
Differential may be accidentally removed when the trans-
axle housing is removed.
33. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the cylindrical roller bearing from the
transaxle case.
SST 09514±35011
34. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.

D03569
D25505
D25506
D03577
D03573
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±23
U241E A/T REPAIR MANUAL (RM840U)
35. REMOVE OIL PUMP ASSY
(a) Remove the 7 bolts and oil pump assy from the transaxle
case.
36. REMOVE THRUST NEEDLE ROLLER BEARING
(a) Remove thrust needle roller bearing from the U/D plane-
tary gear assy.
37. REMOVE THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Remove thrust bearing race No. 2 from the U/D planetary
gear assy.
38. REMOVE FRONNT DIFFERENTIAL ASSY
(a) Remove the front differential assy from the transaxle
case.
39. REMOVE OVERDRIVE BRAKE GASKET
(a) Remove the 2 O/D brake gaskets from the transaxle case.

D03610
SST
D08051
D03806
D03914
C83141
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
40±27
U241E A/T REPAIR MANUAL (RM840U)
47. REMOVE UNDERDRIVE BRAKE RETURN SPRING
SUB±ASSY
(a) Using SST, a snap ring expander and a press, remove the
snap ring from the transaxle case.
SST 09387±00020
(b) Remove the U/D brake return spring sub±assy from the
U/D brake piston.
48. INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB±ASSY
(a) Using vernier calipers, measure the free length of the U/D
brake return spring sub±assy together with the spring
seat.
Standard free length: 14.04 mm (0.5213 in.)
49. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 U/D clutch drum oilseal rings from the
transaxle case.
50. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove 2 transaxle case No. 1 plugs from the transaxle
rear cover.
(b) Remove 2 O±rings from the 2 transaxle case No. 1 plugs.

D09183
D09184
C83140
D03801
SST
D03799
40±28
± AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U241E)
U241E A/T REPAIR MANUAL (RM840U)
51. REMOVE TRANSAXLE REAR COVER SUB±ASSY
(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic
hammer to remove the transaxle rear cover from the
transaxle case.
(c) Remove the 2 outer rear clutch oil seal rings from the
transaxle rear cover.
(d) Using a torx socket wrench T30, remove the 2 screws and
transaxle rear cover plate.
(e) Using SST, remove the needle±roller bearing from the
transaxle rear cover.
SST 09387±00040 (09387±01010, 09387±01030,
09387±01040)
52. REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove the U/D brake piston.