Get AUTOMATIC TRANSAXLE (U240E) -> Valve Body Assembly Guide for Toyota Avensis 4 Door First Generation (1997-2003)

AX–8

AUTOMATIC TRANSAXLE (U240E)

–

VALVE BODY ASSEMBLY

AX0LM–03

ON–VEHICLE REPAIR

1.

REMOVE LH ENGINE UNDER COVER

2.

3.

REMOVE DRAIN PLUG AND DRAIN ATF

REMOVE OIL PAN AND GASKET

NOTICE:

Some fluid will remain in the oil pan.

Remove the 18 bolts, and carefully remove the oil pan assem-

bly. Discard the gasket.

D07261

AT0103

D05879

D02934

4.

EXAMINE PARTICLES IN OIL PAN

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

Look carefully at the chips and particles in the pan and on the

magnet to anticipate what type of wear you will find in the trans-

axle.

Steel (magnetic)...bearing, gear and plate wear

Brass (non–magnetic)... bushing wear

5.

REMOVE OIL STRAINER

(a) Remove the 3 bolts and oil strainer.

(b) Remove the O–ring.

6.

7.

DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC-

TORS

REMOVE ATF TEMPERATURE SENSOR

Remove the bolt and lock plate, and remove the ATF tempera-

ture sensor.

8.

SEPARATE WIRE HARNESS FROM 2 CLAMPS

AVENSIS/CORONA SUP (RM781E)

AX–9

AUTOMATIC TRANSAXLE (U240E)

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VALVE BODY ASSEMBLY

9.

REMOVE VALVE BODY

Remove the 17 bolts and valve body.

NOTICE:

Be careful not to drop the check valve body, spring and ac-

cumulator piston.

D02935

D02936

D02937

D02938

D02937

10. REMOVE CHECK BALL BODY AND SPRING

11. REMOVE 2 APPLY GASKETS

12. REMOVE SHIFT SOLENOID VALVE

Remove the 5 bolts and 5 shift solenoid valves.

13. INSTALL SHIFT SOLENOID VALVE

Install the 5 shift solenoid valves with the 5 bolts.

Torque:

B

A

B

A

Bolt A: 6.6 N·m (67 kgf·cm, 58 in.·lbf)

Bolt B: 10.8 N·m (110 kgf·cm, 8 ft·lbf)

Bolt length:

Bolt A: 12 mm (0.47 in.)

Bolt B: 45 mm (1.77 in.)

14. INSTALL 2 APPLY GASKETS

(a) Coat 2 new apply gaskets with ATF.

(b) Install the 2 gaskets to the transaxle case.

AVENSIS/CORONA SUP (RM781E)

AX–10

AUTOMATIC TRANSAXLE (U240E)

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VALVE BODY ASSEMBLY

15. INSTALL CHECK VALVE AND SPRING

D02936

16. INSTALL VALVE BODY

A

(a) Align the groove of the manual valve with the pin of the

manual valve lever.

(b) Temporarily install the valve body with the 17 bolts.

Bolt length:

C

A

C

Bolt A: 25 mm (0.98 in.)

Bolt B: 41 mm (1.61 in.)

Bolt C: 45 mm (1.77 in.)

B

C

(c) Check that the manual valve lever contacts the center of

the roller at the tip of the detent spring.

(d) Tighten the 17 bolts.

D02935

B

Torque: 10.8 N·m (110 kgf·cm, 8 ft·lbf)

17. CLAMP WIRE HARNESS TO 2 CLAMPS

18. INSTALL ATF TEMPERATURE SENSOR

Install the ATF temperature sensor with the lock plate and bolt.

Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf)

19. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORS

D02934

20. INSTALL OIL STRAINER

(a) Coat a new O–ring with ATF.

(b) Install the O–ring to the oil strainer.

D05880

AVENSIS/CORONA SUP (RM781E)

AX–11

AUTOMATIC TRANSAXLE (U240E)

–

VALVE BODY ASSEMBLY

(c) Install the oil strainer with the 3 bolts.

Torque: 10.8 N·m (110 kgf·cm, 8 ft·lbf)

D05879

D02940

D07261

21. INSTALL MAGNET IN OIL PAN

Install the 3 magnets in the oil pan, as shown in the illustration.

22. INSTALL OIL PAN

Install the oil pan and a new gasket with the 18 bolts.

Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

23. INSTALL DRAIN PLUG

Install a new gasket and drain plug.

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

24. FILL ATF AND CHECK ATF LEVEL (See page DI–62)

25. INSTALL LH ENGINE UNDER COVER

AVENSIS/CORONA SUP (RM781E)

AUTOMATIC TRANSAXLE (U240E) -> Valve Body Assembly for Your Toyota Avensis 4 Door First Generation (1997-2003)

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