Get AUTOMATIC TRANSAXLE (A246E) Guide for Toyota Avensis 4 Door First Generation (1997-2003)

AUTOMATIC TRANSAXLE (A246E)

AUTOMATIC TRANSAXLE SYSTEM . . . . . . .

NEUTRAL START SWITCH . . . . . . . . . . . . . . .

VALVE BODY ASSEMBLY . . . . . . . . . . . . . . . .

DIFFERENTIAL OIL SEAL . . . . . . . . . . . . . . . .

SHIFT LOCK SYSTEM . . . . . . . . . . . . . . . . . . .

FLOOR SHIFT ASSEMBLY (LHD) . . . . . . . . . .

AX–1

AX–3

AX–4

AX–7

AX–8

AX–11

FLOOR SHIFT ASSEMBLY (RHD) . . . . . . . . . AX–20

AUTOMATIC TRANSAXLE UNIT . . . . . . . . . . . AX–28

TORQUE CONVERTER AND

DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . AX–33

AX–1

AUTOMATIC TRANSAXLE (A246E)

–

AUTOMATIC TRANSAXLESYSTEM

AUTOMATIC TRANSAXLE SYSTEM

AX02L–04

PRECAUTION

If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section.

AVENSIS/CORONA SUP (RM781E)

AX–2

AUTOMATIC TRANSAXLE (A246E)

–

AUTOMATIC TRANSAXLESYSTEM

AX02M–06

OPERATION

Forward Clutch (C )

1

No.2 One–Way Clutch (F )

2

2nd Coast Brake (B )

1

2nd Brake (B )

2

1st and Reverse Brake (B )

3

Direct Clutch (C )

2

Front Planetary Gear Unit

No.1 One–Way Clutch (F )

1

Rear Planetary Gear Unit

U/D Planetary Gear Unit

U/D Brake (B )

4

U/D Clutch (C )

3

U/D One–Way Clutch (F )

3

No. 2

Solenoid

Valve

No. 1

Solenoid

Valve

Shift Lever

Gear

C

1

C

2

C

3

B

F

3

1

2

3

4

1

2

Range

P

R

N

Park

ON

OFF

F

Reverse

Neutral

OFF

ON

F

1st

F

2nd

F

ON

F

D

2

3rd

O/D

1st

OFF

ON

F

OFF

ON

F

2nd

3rd*

1st

ON

F

OFF

ON

F

OFF

ON

F

L

2nd*

ON

F

F : Operating

*: Down–shift only in the 3rd gear for the 2 range and 2nd gear for the L range – no up–shift

F00484

AVENSIS/CORONA SUP (RM781E)

AX–3

AUTOMATIC TRANSAXLE (A246E)

–

NEUTRAL START SWITCH

AX0PK–02

ON–VEHICLE REPAIR

1.

REMOVE LH ENGINE UNDER COVER

2.

3.

DISCONNECT SHIFT CABLE FROM CONTROL SHIFT

LEVER

DISCONNECT NEUTRAL START SWITCH CONNEC-

TOR

Q08545

4.

REMOVE NEUTRAL START SWITCH

(a) Remove the nut, washer and control shaft lever.

(b) Pry out the lock washer and remove the manual valve

shaft nut.

(c) Remove the 2 bolts and pull out the neutral start switch.

D08573

5.

INSTALL AND ADJUST NEUTRAL START SWITCH

(a) Install the neutral start switch with 2 bolts.

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

(b) Install a new lock plate and tighten the nut.

Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)

(c) Stake the nut with lock plate.

(d) Install the control shift lever, washer and nut.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

6.

7.

CONNECT NEUTRAL START SWITCH CONNECTOR

CONNECT SHIFT CABLE TO CONTROL SHIFT LEVER

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

8.

CHECK NEUTRAL START SWITCH OPERATION

Check that the engine can be started with the shift lever only in

the N or P range, but not in other ranges.

If not as started above, carry out the adjustment procedure

(See page DI–3).

9.

INSTALL LH ENGINE UNDER COVER

10. TEST DRIVE VEHICLE

AVENSIS/CORONA SUP (RM781E)

AX–4

AUTOMATIC TRANSAXLE (A246E)

–

VALVE BODY ASSEMBLY

AX0PL–02

ON–VEHICLE REPAIR

1.

REMOVE LH ENGINE UNDER COVER

2.

3.

REMOVE DRAIN PLUG AND DRAIN ATF

REMOVE OIL PAN AND GASKET

Remove the 18 bolts.

NOTICE:

S

Some fluid will remain in the oil pan.

Remove all pan bolts, and carefully remove the oil

pan assembly.

S

4.

5.

Discard the gasket.

REMOVE 2 MAGNETS FROM OIL PAN

EXAMINE PARTICLES IN PAN

F00483

Remove the magnets and use them to collect any steel chips.

Look carefully at the chips and particles in the pan and the mag-

net to anticipate what type of wear you will find in the transaxle.

Steel (magnetic): bearing, gear and plate wear

Brass (non–magnetic): bushing wear

6.

REMOVE OIL STRAINER

Remove the 3 bolts and oil strainer.

NOTICE:

Be careful as some fluid will come out with the oil strainer.

D08576

7.

DISCONNECT SOLENOID CONNECTOR

(a) Remove the 2 bolts and wire retainers.

(b) Disconnect the 4 solenoid connecters.

D08577

AVENSIS/CORONA SUP (RM781E)

AX–5

AUTOMATIC TRANSAXLE (A246E)

–

VALVE BODY ASSEMBLY

8.

REMOVE MANUAL DETENT SPRING

Remove the bolt and manual detent spring.

F00673

9.

REMOVE VALVE BODY

(a) Remove the 17 bolts.

D08579

(b) While disconnecting the manual valve connecting rod

from the manual valve lever, remove the valve body with

the manual valve together.

10. INSTALL VALVE BODY

(a) While connecting the manual valve connecting rod to the

manual valve lever, install the valve body with the manual

valve together.

AT5616

(b) Install the 17 bolts.

Bolt length:

B

A: 20 mm (0.79 in.)

B: 28 mm (1.10 in.)

C: 50 mm (1.97 in.)

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

A

B

A

C

A

D08579

11. INSTALL MANUAL DETENT SPRING

Install the manual detent spring and bolt.

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

12. CONNECT 4 SOLENOID CONNECTORS

(a) Connect the 4 solenoid connectors.

(b) Install the wire retainer and bolt.

Torque: 6.4 N·m (65 kgf·cm, 56 in.·lbf)

F00673

AVENSIS/CORONA SUP (RM781E)

AX–6

AUTOMATIC TRANSAXLE (A246E)

–

VALVE BODY ASSEMBLY

13. INSTALL OIL STRAINER

Install the oil strainer with the 3 bolts.

Bolt length:

A

A bolt: 12 mm (0.47 in.)

B bolt: 20 mm (0.79 in.)

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

B

D08576

14. INSTALL MAGNETS IN OIL PAN

15. INSTALL OIL PAN AND GASKET

(a) Install a new gasket to the oil pan and install them to the

transaxle.

(b) Install the 18 bolts.

Torque: 5.3 N·m (55 kgf·cm, 48 in.·lbf)

16. INSTALL DRAIN PLUG

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

17. INSTALL LH ENGINE UNDER COVER

18. FILL ATF AND CHECK FLUID LEVEL (See page

DI–3)

D08582

AVENSIS/CORONA SUP (RM781E)

AX–7

AUTOMATIC TRANSAXLE (A246E)

–

DIFFERENTIALOIL SEAL

DIFFERENTIAL OIL SEAL

AX02R–06

ON–VEHICLE REPAIR

1.

2.

3.

DRAIN ATF

REMOVE LH AND RH ENGINE UNDER COVERS

REMOVE LH AND RH DRIVE SHAFTS (See page

SA–3)

F00483

Z02840

Z02841

Z04055

4.

REMOVE LH AND RH OIL SEAL

SST

Using SST, drive out the oil seal.

SST 09308–00010

5.

INSTALL LH SIDE OIL SEAL

LH side

(a) Using SST, drive in a new oil seal.

SST 09350–32014 (09351–32111, 09351–32130)

Oil seal drive in depth:

5.3 ± 0.5 mm (0.209 ± 0.020 in.)

(b) Coat the lip of oil seal with MP grease.

SST

6.

INSTALL RH SIDE OIL SEAL

RH side

(a) Using SST, drive in a new oil seal until SST makes contact

with the case surface.

SST

SST 09350–32014 (09351–32130, 09351–32150)

Oil seal drive in depth:

3.1 ± 0.5 mm (0.122 ± 0.020 in.)

(b) Coat the lip of the oil seal with MP grease.

7.

INSTALL LH AND RH DRIVE SHAFTS (See page

SA–12)

8.

9.

FILL AND CHECK FLUID LEVEL (See page DI–3)

INSTALL LH AND RH ENGINE UNDER COVERS

AVENSIS/CORONA SUP (RM781E)

AX–8

AUTOMATIC TRANSAXLE (A246E)

–

SHIFTLOCK SYSTEM

SHIFT LOCK SYSTEM

AX10R–01

LOCATION

KeyInterlockSolenoid

Stop Light Switch

Shift Lock Control Computer

D10026

AVENSIS/CORONA SUP (RM781E)

AX–9

AUTOMATIC TRANSAXLE (A246E)

–

SHIFTLOCK SYSTEM

AX10S–01

INSPECTION

5 (IG)

1 (ACC)

1.

LHD:

4 (KLS+)

INSPECT SHIFT LOCK CONTROL COMPUTER

Using a voltmeter, measure the voltage at each terminal.

HINT:

3 (E)

Do not disconnect the shift lock control computer connector.

2 (STP)

Wire harness side

D00758

Terminal

MeasuringCondition

Voltage (V)

10 – 14

1 – 3 (ACC – E)

5 – 3 (IG – E)

Ignition switch ACC

Ignition switch ON

10 – 14

2 – 3 (STP – E)

Depressing brake pedal

10 – 14

(1) Ignition switch ACC and P range

0

+

4 – 3 (KLS – E)

(2) Ignition switch ACC and except P range

7.5 – 11

6 – 9.5

(3) Ignition switch ACC and except P range (After approx. 1 second)

2.

RHD:

INSPECT SHIFT LOCK CONTROL COMPUTER

Using a voltmeter, measure the voltage at each terminal.

HINT:

Do not disconnect the shift control computer connector.

D05910

Terminal

MeasuringCondition

Voltage (V)

10 – 14

2 – 3 (ACC – E)

4 – 3 (IG – E)

5 – 3 (STP – E)

Ignition switch ACC

Ignition switch ON

10 – 14

Depressing brake pedal

10 – 14

(1) Ignition switch ACC and P range

0

+

1 – 3 (KLS – E)

(2) Ignition switch ACC and except P range

7.5 – 11

6 – 9.5

(3) Ignition switch ACC and except P range (After approx. 1 second)

AVENSIS/CORONA SUP (RM781E)

AX–10

AUTOMATIC TRANSAXLE (A246E)

–

SHIFTLOCK SYSTEM

3.

INSPECT KEY INTERLOCK SOLENOID

(a) Disconnect the solenoid connector.

(b) Using an ohmmeter, measure the resistance between the

terminals.

–

+

KLS

Standard resistance: 12.5 – 16.5 Ω

If the resistance value is not as specified, replace the solenoid.

D08869

(c) Provide the battery voltage between the terminals.

Check that the solenoid can be heard its operating.

If the operation is not as specified, replace the solenoid.

–

+

KLS

D08870

AVENSIS/CORONA SUP (RM781E)

AX–11

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX02U–07

COMPONENTS

Parking Brake Cover

12 (120, 9)

Clip

Shift Control Cable

Shift Lever Assembly

Cap

Rear Console Box

: Specified torque

N·m (kgf·cm, ft·lbf)

D10190

AVENSIS/CORONA SUP (RM781E)

AX–12

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

Pattern Select Switch

Position Indicator

Upper Housing

Shift Lever Knob Sub–assembly

Spring

Shift Lever Knob

Sleeve

Shift Lever Button

Detent Rod

Position Indicator

Slide Cover

O/D Main Switch

L

Position

Indicator Plate

Spring

Position Indicator

Lower Housing

Shift Lever Knob Cover

Cap

Bulb

Grooved Pin

Spring Plate

Indicator Light

Wire

Shift Lever Sub–assembly

Shift Lever Plate

Shift Lock Release Button

Spring

Shift Lock

Control Computer

Control Shaft

Collar

MP grease

L Precoated part

D09906

AVENSIS/CORONA SUP (RM781E)

AX–13

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX10T–01

REMOVAL

1.

2.

REMOVE REAR CONSOLE (See page BO–8)

REMOVE SHIFT LEVER ASSEMBLY

(a) Disconnect the 3 connectors and wire harness.

(b) Remove the clip and disconnect the shift control cable.

(c) Remove the 4 bolts and floor shift assembly.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D02081

AVENSIS/CORONA SUP (RM781E)

AX–14

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX0C5–03

DISASSEMBLY

1.

REMOVE O/D MAIN SWITCH TERMINAL

(a) Remove the O/D main switch connector from the shift le-

ver plate.

3

(b) Disengage the secondary locking device.

(c) Release the locking lug of the terminals 2 and 4, and pull

the terminals out from the rear.

2

1

Secondary Locking Device

A00451

2.

REMOVE SHIFT LEVER KNOB SUB–ASSEMBLY

(a) Remove the 2 screws and shift lever knob sub–assembly.

NOTICE:

Pay attention not to put unnatural load onto O/D main

switch wire harness.

(b) Remove the shift lever knob cover.

(c) Remove the shift lever button and spring.

(d) Remove the O/D main switch.

3.

4.

REMOVE INDICATOR LIGHT WIRE

REMOVE CAP AND BULB FROM INDICATOR LIGHT

WIRE

5.

REMOVE INDICATOR HOUSING

Remove the screws and an indicator housing.

6.

DISASSEMBLE INDICATOR HOUSING

(a) Remove the pattern select switch.

(b) Remove the position indicator lower housing.

(c) Remove the shift lock release button and spring.

(d) Remove the position indicator slide cover.

(e) Remove the position indicator plate.

D08694

7.

Remove the 2 screws and shift lock control computer.

8. REMOVE SPRING PLATE

REMOVE SHIFT LOCK CONTROL COMPUTER

AVENSIS/CORONA SUP (RM781E)

AX–15

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

9.

REMOVE SHIFT LEVER SUB–ASSEMBLY

(a) Using a screwdriver and a hammer, remove the control

shaft.

(b) Remove the shift lever sub–assembly.

F00683

D04313

F00687

F00685

10. DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY

(a) Measure the distance ”A” between the lower edge of the

shift lever knob sleeve and the upper edge of the shift le-

ver sub–assembly.

A

(b) Using a hammer, remove the grooved pin.

NOTICE:

When pressing down the grooved pin, if doing it at the

place other than the notch, there may be fear of damaging

the shift lever sub–assembly.

(c) Remove the detent rod and spring.

(d) Remove the shift lever knob sleeve from the detent rod.

11. REMOVE COLLARS

Using a screwdriver and a hammer, remove the 4 collars.

AVENSIS/CORONA SUP (RM781E)

AX–16

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX0C6–03

REASSEMBLY

1.

2.

INSTALL COLLARS

INSTALL SHIFT LEVER KNOB SLEEVE TO DETENT

ROD

3.

ASSEMBLE SHIFT LEVER SUB–ASSEMBLY

: Apply MP Grease

(a) Apply MP grease on the compression spring, the detent

rod and the shift lever sub–assembly.

(b) Install the spring and the detent rod to shift lever sub–as-

sembly.

F00686

F00684

F00688

F00689

(c) Place the shift lever sub–assembly as shown in the il-

lustration.

(d) Insert the grooved pin in the detent rod pin hole.

NOTICE:

Correct

Wrong

S

Assemble the grooved pin to ensure that it fits into the

guide hole of the shift lever sub–assembly in parallel.

Take care not to insert the pin in the wrong direction

of the detent rod.

S

(e) Meet the grooved pin with the notch of the guide hole.

AVENSIS/CORONA SUP (RM781E)

AX–17

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

(f)

Press the pin with a hammer.

A: 10.0 – 10.4 mm (0.39 – 0.41 in.)

Shift Lever

Sub–assembly

A

NOTICE:

When pressing in the grooved pin, if doing it at the place

other than the notch, the shift lever sub–assembly might be

damaged.

Detent Rod

4.

CHECK DETENT ROD OPERATION

Grooved Pin

F01188

D04313

F00690

F00691

F00692

A00452

5.

INSTALL SHIFT LEVER KNOB SLEEVE DETENT ROD

Drive the shift lever knob sleeve to the distance A measured be-

fore removal.

A

6.

INSTALL SHIFT LEVER SUB–ASSEMBLY

(a) Apply MP grease.

: Apply MP Grease

(b) Using a brass bar and a hammer, install the control shaft

and the shift lever sub–assembly to the shift lever plate.

NOTICE:

Take care not to install them in the wrong direction of the

shift lever sub–assembly.

7.

INSTALL SPRING PLATE

8.

INSTALL SHIFT LOCK CONTROL COMPUTER

Install the shift control control computer and 2 screws.

NOTICE:

Install the grooved pin into the groove of the shift lock unit

as shown in the illustration.

AVENSIS/CORONA SUP (RM781E)

AX–18

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

9.

ASSEMBLE INDICATOR HOUSING

(a) Install the position indicator plate.

(b) Install the position indicator slide cover.

(c) Install the spring and shift lock release button.

(d) Install the position indicator lower housing.

(e) Install the pattern select switch.

NOTICE:

Do not make indicator housing dirty with MP grease.

10. INSTALL INDICATOR HOUSING

Install the screws and an indicator housing.

11. INSTALL CAP AND BULB TO INDICATOR LIGHT WIRE

12. INSTALL INDICATOR LIGHT WIRE

13. INSTALL SHIFT LEVER KNOB SUB–ASSEMBLY

(a) Install the O/D main switch.

(b) Install the spring and shift lever button.

(c) Install the shift lever knob cover.

HINT:

Apply MP grease to shift lever knob button.

(d) Install the shift lever sub–assembly and 2 screws.

HINT:

Coat the threads of the screws with sealant.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

NOTICE:

Make sure not to catch O/D main switch wire harness.

(e) Install the O/D main switch wire harness securely to hung

on the hook of the shift lever sub–assembly.

14. INSTALL O/D MAIN SWITCH TERMINAL

AVENSIS/CORONA SUP (RM781E)

AX–19

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX02Y–07

INSTALLATION

INSTALL FLOOR SHIFT ASSEMBLY

Installation is in the reverse order of removal (See page

AX–13).

HINT:

After installation, adjust shift lever ranges (See page DI–3) and

inspect shift lever operation.

S

When shifting it to each range, make sure that the shifting

lever moves smoothly, can be moderately operated and

the range indicator displays correctly.

Ranges which can be operated without pressing the

shift lever nob button

R → N → D→ 2

With the brake pedal depressed,

shift while holding the lock

release button in. (The ignition

switch must be in ON position.)

Ranges which can be operated only with pressing the

shift lever nob button

P → R, 2 → L, N → R → P

When starting the engine, make sure that the vehicle

moves forward when shifting from N to D range, and

moves rearward when shifting to R range.

Shift while holding the lock

release button in.

S

Shift normally

D02013

AVENSIS/CORONA SUP (RM781E)

AX–20

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX01B–03

COMPONENTS

12 (120, 9)

Clip

Rear Console Box

Shift Control Cable

Shift Lever

Assembly

Cap

Parking Brake Cover

N·m (kgf·cm, ft·lbf) : Specified torque

D02091

AVENSIS/CORONA SUP (RM781E)

AX–21

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

Shift Lever Button

Spring

Pattern Select Switch

Shift Lever Knob

Position Indicator Plate

Position Indicator

Upper Housing

L

O/D Main

Switch

Position Indicator

Slide Cover

Detent Rod

Bulb

Shift Lever Knob

Cover

Indicator Light Wire

Spring

Stopper Pin

Control Shaft

Detent Roller

Holder

Spring

Shift Lever Sub–Assembly

Shift Lock Plate

Shift Lock Control Computer

Shift Lock Release Button

Spring

Shift Lever

Plate

x4

Collar

MP grease

L Precoated part

D09907

AVENSIS/CORONA SUP (RM781E)

AX–22

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX10U–01

REMOVAL

1.

2.

REMOVE REAR CONSOLE (See page BO–8)

REMOVE FLOOR SHIFT ASSEMBLY

(a) Disconnect the connectors.

(b) Remove the clip and disconnect the shift control cable.

(c) Remove the 4 bolts and shift lever assembly.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D02093

AVENSIS/CORONA SUP (RM781E)

AX–23

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX10V–01

DISASSEMBLY

1.

REMOVE O/D MAIN SWITCH TERMINAL

(a) Remove O/D main switch connector from the shift lever

plate.

3

(b) Disengage the secondary locking device.

(c) Disengage the locking lug of the terminals 2 and 4, and

pull the terminals out from the rear.

2

1

2.

REMOVE SHIFT LEVER KNOB SUB–ASSEMBLY

Secondary Locking Device

A00451

(a) Remove the 2 screws and shift lever knob sub–assembly.

NOTICE:

Pay attention not to apply unnatural load onto O/D main

switch wire harness.

(b) Remove the Shift lever knob cover.

(c) Remove the Shift lever button and spring.

(d) Remove the O/D main switch.

3.

4.

5.

REMOVE INDICATOR LIGHT WIRE

REMOVE BULB FROM INDICATOR LIGHT WIRE

REMOVE INDICATOR HOUSING SUB–ASSEMBLY

6.

DISASSEMBLE INDICATOR HOUSING SUB–AS-

SEMBLY

(a) Remove the position indicator side cover.

(b) Remove the position indicator plate.

(c) Remove the pattern select switch.

D02094

7.

REMOVE SHIFT LOCK CONTROL COMPUTER

Remove the 3 screws and shift lock control computer.

D09908

8.

REMOVE STOPPER PIN, DETENT ROD AND SPRING

AVENSIS/CORONA SUP (RM781E)

AX–24

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

9.

REMOVE SHIFT LEVER SUB–ASSEMBLY

(a) Using an extension bar and hammer, remove the control

shaft.

(b) Remove the shift lever sub–assembly.

D02095

D02096

D02040

10. DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY

(a) Remove the Detent roller holder.

(b) Remove the Compression spring.

11. REMOVE COLLARS

Using an extension bar and hammer, remove the 4 collars.

AVENSIS/CORONA SUP (RM781E)

AX–25

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX10W–01

REASSEMBLY

1.

INSTALL COLLARS

2.

ASSEMBLE SHIFT LEVER SUB–ASSEMBLY

: Apply MP Grease

(a) Apply the MP grease to the detent roller holder, compres-

sion spring and shift lever sub–assembly.

(b) Install the compression spring to the detent roller holder.

(c) Install the detent roller holder with the compression spring

to the shift lever sub–assembly.

D02096

3.

INSTALL SHIFT LEVER SUB–ASSEMBLY

: Apply MP Grease

(a) Apply the MP grease to the control shaft and shift lever

sub–assembly.

(b) Using an extension bar and hammer, install the control

shaft and shift lever sub–assembly to the shift lever plate.

D02041

4.

INSTALL SPRING, DETENT ROD AND STOPPER PIN

(a) Apply the MP grease to the detent rod and stopper pin.

(b) Install the compression spring and detent rod to the shift

lever sub–assembly.

(c) Insert the stopper pin in the stopper pin hole.

NOTICE:

Take care not to insert the pin in the wrong direction

against the detent rod.

5.

INSTALL SHIFT LOCK CONTROL COMPUTER

Install the shift lock control computer with 3 screws.

6.

7.

CHECK SHIFT LEVER OPERATION

ASSEMBLE INDICATOR HOUSING SUB–ASSEMBLY

(a) Install the pattern select switch.

(b) Install the position indicator plate.

(c) Install the position indicator slide plate.

8.

9.

INSTALL INDICATOR HOUSING SUB–ASSEMBLY

INSTALL BULB TO INDICATOR LIGHT WIRE

10. INSTALL INDICATOR LIGHT WIRE

AVENSIS/CORONA SUP (RM781E)

AX–26

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

11. INSTALL SHIFT LEVER KNOB SUB–ASSEMBLY

HINT:

Apply MP grease to the shift lever knob button.

(a) Install the O/D main switch.

(b) Install the shift lever button and spring.

(c) Install the shift lever knob cover.

(d) Install the shift lever knob sub–assembly and 2 screws.

HINT:

Coat the threads of the screws with sealant.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

NOTICE:

Make sure not to catch O/D main switch wire harness.

(e) Install the O/D main switch wire harness securely and

hang it on the hook of the shift lever sub–assembly.

12. INSTALL O/D MAIN SWITCH TERMINAL

AVENSIS/CORONA SUP (RM781E)

AX–27

AUTOMATIC TRANSAXLE (A246E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX01F–03

INSTALLATION

INSTALL FLOOR SHIFT ASSEMBLY

Installation is in the reverse order of removal (See page

AX–22).

HINT:

After installation, adjust shift lever ranges (See page DI–3) and

inspect shift lever operation.

S

When shifting it to each range, make sure that the shifting

lever moves smoothly, can be moderately operated and

the range indicator displays correctly.

Ranges which can be operated without pressing the

shift lever nob button

R → N → D→ 2

With the brake pedal depressed,

shift while holding the lock

release button in. (The ignition

switch must be in ON position.)

Ranges which can be operated only with pressing the

shift lever nob button

P → R, 2 → L, N → R → P

When starting the engine, make sure that the vehicle

moves forward when shifting from N to D range, and

moves rearward when shifting to R range.

Shift while holding the lock

release button in.

S

Shift normally

D02013

AVENSIS/CORONA SUP (RM781E)

AX–28

AUTOMATIC TRANSAXLE (A246E)

–

AUTOMATIC TRANSAXLE UNIT

AX02Z–04

COMPONENTS

Battery

RH Drive Shaft

Air Cleaner Assembly

87 (890, 64)

13 (130, 9)

39 (400, 29)

Torque Converter Clutch

25 (250, 18)

64 (650, 47)

52 (530, 38)

28 (290, 21)

46 (470, 34)

x 6

18 (185, 13)

Ground Cable

Hole Plug

87 (890, 64)

39 (400, 29)

z Snap Ring

23 (230, 17)

LH Drive Shaft

225(2,305, 167)

Starter

Control Cable

z Cotter Pin

Plug for

Hydraulic Test

Clip

64 (650, 47)

Lock Nut Cap

Exhaust Front Pipe

12 (120, 9)

62 (630, 46)

z

z Gasket

127(1,300, 94)

43 (440, 32)

Engine Under Cover RH

Suction Hose (RHD)

Front Center Member

z

62 (630, 46)

73 (740, 54)

Engine Under Cover LH

Grommet

x 5

72 (740, 53)

Grommet

73 (740, 54)

Front Center Member

Protector

x 5

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part

39 (400, 29)

D10025

AVENSIS/CORONA SUP (RM781E)

AX–29

AUTOMATIC TRANSAXLE (A246E)

–

AUTOMATIC TRANSAXLE UNIT

AX10X–01

REMOVAL

1.

2.

3.

REMOVE BATTERY

REMOVE AIR CLEANER

REMOVE GROUND CABLE

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

4.

REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING

BOLTS FROM TRANSAXLE SIDE

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

REMOVE UPPER SIDE STARTER MOUNTING BOLT

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

DISCONNECT VEHICLE SPEED SENSOR CONNEC-

TOR

5.

6.

7.

REMOVE LH AND RH ENGINE UNDER COVERS

F00497

F00483

F00705

8.

9.

REMOVE DRAIN PLUG AND DRAIN ATF

Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

REMOVE LH AND RH DRIVE SHAFTS (See page

SA–3)

10. DISCONNECT SOLENOID CONNECTOR AND NEU-

TRAL START SWITCH CONNECTOR

(a) Disconnect the solenoid connector and the neutral start

switch connector.

(b) Remove the wire harness clamps.

11. REMOVE SHIFT CONTROL CABLE

(a) Remove the nut from the control shift lever.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

(b) Remove the clip and disconnect the control cable.

12. REMOVE FRONT CENTER MEMBER

(a) RHD:

Remove the nut and disconnect the suction hose from the

front center member.

AVENSIS/CORONA SUP (RM781E)

AX–30

AUTOMATIC TRANSAXLE (A246E)

–

AUTOMATIC TRANSAXLE UNIT

(b) Remove the 9 bolts, 3 grommets, front center member

protector and front center member.

Torque:

A

C

A: 73 N·m (740 kgf·cm, 54 ft·lbf)

B: 39 N·m (400 kgf·cm, 29 ft·lbf)

C: 72 N·m (740 kgf·cm, 53 ft·lbf)

A

B

D02064

F00482

F00496

D00655

F00493

13. REMOVE STARTER

(a) Remove the nut and cable, and disconnect the connector.

(b) Remove the bolt and the starter.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

14. INSTALL ENGINE SUPPORT FIXTURE

15. REMOVE UPPER SIDE ENGINE LEFT MOUNTING

BOLT

Torque: 87 N·m (890 kgf·cm, 64 ft·lbf)

16. REMOVE OIL COOLER HOSE

Loosen the 2 clips and disconnect the 2 oil cooler hoses.

17. REMOVE HEAT INSULATOR

Remove the 2 bolts and a nut.

Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

AX–31

AUTOMATIC TRANSAXLE (A246E)

–

AUTOMATIC TRANSAXLE UNIT

18. JACK UP TRANSAXLE

F00479

F00478

F00477

19. REMOVE TRANSAXLE

(a) Remove the hole plug.

(b) Turn the crankshaft to gain access and remove the 6 bolts

holding the crankshaft pulley set bolt with a wrench.

Torque: 28 N·m (290 kgf·cm, 21 ft·lbf)

HINT:

At the time of installation, please refer to the following item.

First install green colored bolt and then 5 other bolts.

(c) Remove the 4 bolts.

Torque:

Bolt A: 46 N·m (470 kgf·cm, 34 ft·lbf)

Bolt B: 23 N·m (230 kgf·cm, 17 ft·lbf)

(d) Lower the engine to move it to the left side and remove

the transaxle from the engine.

A

B

AVENSIS/CORONA SUP (RM781E)

AX–32

AUTOMATIC TRANSAXLE (A246E)

–

AUTOMATIC TRANSAXLE UNIT

AX031–05

INSTALLATION

1.

CHECK TORQUE CONVERTER INSTALLATION

Using calipers and a straight edge, measure the distance be-

tween the installed surface and the front surface of the trans-

axle housing.

Correct distance: More than 15.5 mm (0.610 in.)

2.

TRANSAXLE INSTALLATION

Installation is in the reverse order of removal (See page

AX–29).

F00502

HINT:

S

After installation, adjust the shift control cable and neutral

start switch (See page DI–3).

S

Fill ATF and check fluid level (See page DI–3).

Perform the test drive of the vehicle (See page DI–3).

AVENSIS/CORONA SUP (RM781E)

AX–33

AUTOMATIC TRANSAXLE (A246E)

–

TORQUE CONVERTER AND DRIVE PLATE

SST

TORQUE CONVERTER AND DRIVE

PLATE

AX032–04

INSPECTION

1.

INSPECT ONE–WAY CLUTCH

(a) Install SST into the inner race of the one–way clutch.

SST 09350–32014 (09351–32010)

(b) Install SST so that it fits in the notch of the converter hub

and outer race of the one–way clutch.

AT0953

SST 09350–32014 (09351–32020)

(c) With the torque converter setting up on its side, check that

the one–way clutch locks when it is turned counterclock-

wise, and rotates smoothly clockwise.

Hold

If necessary, clean the converter and retest the one–way

clutch.

Lock

Replace the converter if the one–way clutch still fails the test.

Free

Turn

AT3306

F00487

F00488

2.

MEASURE DRIVE PLATE RUNOUT AND INSPECT

RING GEAR

(a) Set up a dial indicator and measure the drive plate runout.

(b) Check the damage of the ring gear.

Maximum runout: 0.20 mm (0.0079 in.)

If the runout is not within the specification or ring gear is dam-

aged, replace the drive plate.

Torque: 64 N·m (650 kgf·cm 47 ft·lbf)

3.

MEASURE TORQUE CONVERTER SLEEVE RUNOUT

Temporarily mount the torque converter to the drive plate. Set

up a dial indicator and measure the torque converter sleeve

runout.

Maximum runout: 0.30 mm (0.0118 in.)

If the runout is not within the specification, try to correct by reori-

enting the installation of the converter.

HINT:

Mark the position of the converter to ensure the correct installa-

tion.

AVENSIS/CORONA SUP (RM781E)

AUTOMATIC TRANSAXLE (A246E) for Your Toyota Avensis 4 Door First Generation (1997-2003)

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