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Automatic Transaxle Unit: Reassembly

  1. BEARING POSITION 
    Fig 1: Identifying Bearing Position
    G04976223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THRUST BEARING DIAMETER AND REAR/FRONT RACE DIAMETER SPECIFICATION

    Mark Front Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Race Diameter Inside / Outside mm (in.)
    A - 57.2 (2.252) / 84.96 (3.3449) 56.4 (2.220) / 83.0 (3.268)
    B - 37.73 (1.4854) / 58.0 (2.283) -
    C - 33.85 (1.3327)/52.2 (2.055) -
    D 24.94 (0.9820) 23.5 (0.925)/44.0(1.732) -
    E - 36.3 (1.429) / 51.93 (2.0445) 34.5 (1.358) / 48.35 (1.9035)
    F 34.35 (1.3526) / 56.57 (2.2271) 32.45 (1.2776) / 56.48 (2.2236) -
    G 40.15 (1.5807) / 59.25 (2.3327) 38.65 (1.5217) / 59.79 (2.3539) 38.65 (1.5217) / 59.25 (2.3327)
    H - 53.6 (2.110)/69.6 (2.740) -
    I 33.02 (1.3000) / 45.8 (1.803) 31.85 (1.2539)/57.3 (2.256) -
    J - 24.79 (0.976)/39.5 (1.555) 23.6 (0.929) / 37.95 (1.4941)
    K - 56.3 (2.217) / 75.96 (2.9905) -
  2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      NOTE: Make sure to insert the pipe to the stopper.
      Fig 2: Identifying Differential Gear Lube Apply Tube And Transaxle Apply Tube Clamp
      G05000838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Install 2 new O-rings to the 2 No. 1 transaxle case plugs.
    2. Install the 2 No. 1 transaxle case plugs to the transaxle rear cover.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 3: Identifying O-Rings And Transaxle Case Plugs
      G04976198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Coat a new oil seal ring with ATF and install it to the transaxle housing.
      Fig 4: Identifying Underdrive Output Shaft Oil Seal Ring
      G05000840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Coat the underdrive cylindrical roller bearing with ATF.
    2. Using SST and a press, install the underdrive cylindrical roller bearing.

      SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) 

      NOTE: Do not apply excessive pressure to the bearing.
      Fig 5: Installing Underdrive Cylindrical Roller Bearing
      G04976227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Coat 2 new oil seal rings with ATF and install them to the transaxle rear cover.
      NOTE:
      • Do not expand the end gap of the oil seal ring too much.
      • Secure the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.
        Fig 6: Identifying Underdrive Clutch Drum Oil Seal Ring
        G05269001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NEEDLE ROLLER BEARING 
    1. Wrap vinyl tape around the SST 4.0 mm (0.157 in.) from the bottom of the SST until the thickness of the tape is approximately 5.0 mm (0.197 in.).

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: Clean the SST to remove deposited oil before wrapping vinyl tape.
      Fig 7: Wraping Vinyl Tape Around SST
      G05000843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the needle roller bearing with ATF.
    3. Using SST and a press, install the needle-roller bearing to the transaxle case.

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.
      Fig 8: Installing Needle-Roller Bearing To Transaxle Case
      G04976230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL UNDERDRIVE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF and install them to the underdrive brake piston.
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
      • Apply sufficient ATF to the O-ring before installing.
    2. Coat the underdrive brake piston with ATF.
      Fig 9: Locating Underdrive Brake Piston O-Ring
      G05268977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the underdrive brake piston to the transaxle case.
      NOTE: Be careful not to damage the O-ring.
      Fig 10: Identifying Underdrive Brake Piston
      G05269005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, install the snap ring to the transaxle case.
      Fig 11: Installing Snap Ring
      G05269006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      • Install the spring sub-assembly and check that all of the springs are fully engaged in the piston correctly.
      • The snap ring should be fully engaged in the groove of the transaxle case.
  10. INSTALL NO. 2 BREATHER PLUG 
  11. INSTALL COUNTER DRIVE GEAR BEARING 
    1. Coat the counter drive gear bearing with ATF.
    2. Using SST and a press, install the bearing outer race.

      SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010 

      NOTE:
      • Do not apply excessive pressure to the bearing.
      • Press-fit the bearing outer race until it contacts the transaxle case.
        Fig 12: Installing Bearing Outer Race
        G05000848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, install the snap ring.
      NOTE: The surface with a white mark of the snap ring should face upward.
      Fig 13: Installing Snap Ring
      G05000814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COUNTER DRIVE GEAR 
    1. Coat the counter drive gear with ATF.
    2. Using SST and a press, install the tapered roller bearing to the counter drive gear.

      SST 09950-70010 (09951-07150), 09649-17010 

      NOTE: Do not apply excessive pressure to the bearing.
      Fig 14: Installing Tapered Roller Bearing To Counter Drive Gear
      G05269009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the counter drive gear and bearing to the transaxle case.

      SST 09950-70010 (09951-07150), 09223-15030, 09527-17011, 09950-60020 (09951-00750) 

      NOTE: Do not apply excessive pressure to the counter drive gear.
      Fig 15: Installing Counter Drive Gear And Bearing To Transaxle Case
      G05000851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF.
    2. Install the 2 O-rings to the 1st and reverse brake piston.
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
      • Apply sufficient ATF to the O-rings before assembling them.
        Fig 16: Locating 1st And Reverse Brake Piston O-Ring
        G05268969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 1st and reverse brake piston with ATF and install it to the transaxle case.
      NOTE: Be careful not to damage the O-ring.
      Fig 17: Identifying 1st And Reverse Brake Piston
      G05000853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.

      SST 09387-00070 

    2. Using a snap ring expander, install the snap ring to the transaxle case.
      Fig 18: Installing Snap Ring
      G04976241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      • Install the spring sub-assembly and check that all of the springs are fit in the piston correctly.
      • The snap ring should be fully engaged in the groove of the cylinder.
      • Fix the snap ring to the inside of the claw of the spring seat firmly.
  15. INSTALL FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
      NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.
      Fig 19: Identifying Snap Ring And Front Planetary Ring Gear
      G05000807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the front planetary gear assembly to the brake hub.
      Fig 20: Installing Front Planetary Gear Assembly To Brake Hub
      G05000806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press-fit the front planetary gear assembly.

      SST 09950-60010 (09951-00500), 09950-70010 (09951-07100) 

      NOTE:
      • Do not apply excessive pressure to the planetary gear assembly.
      • Press the inner race of the LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no preload should be applied to one pair of the tapered roller bearings (left and right).
        Fig 21: Installing Front Planetary Gear Assembly
        G05269016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new washer as shown in the illustration.
      Fig 22: Identifying Washer
      G05000858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, install the nut.

      SST 09387-00030,09387-00080 

      Torque: 280 N*m (2,854 kgf*cm, 207 ft.*lbf) 

      NOTE: Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.
      Fig 23: Installing Front Planetary Gear Nut
      G04976178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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 as specified, gradually tighten the nut until it reaches the specified value.

      SST 09387-00080 

      Standard: Turning torque at 60 RPM 

      Bearing: 

      New Bearing: 

      Fig 24: Measuring Turning Torque Of Bearing
      G04976247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) 

      Used Bearing: 0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

    6. Tighten the nut gradually until the specified turning torque of the tapered roller bearing is measured.

      Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf) 

    7. Using a chisel and hammer, stake the front lock washer.
      Fig 25: Staking Front Lock Washer
      G05000861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL INPUT SUN GEAR 
    1. Coat the 2 thrust bearings with ATF.
    2. Install the 2 thrust bearings, the bearing race, and the input sun gear to the front planetary gear assembly.
      NOTE:
      • Install the bearing race on the side of the front planetary carrier. Make sure that the race is installed in the correct direction.
      • When installing the thrust bearing and front sun gears, make sure that they are installed in the correct direction.
      • Install the bearing race on the side of the front sun gear. Make sure that the race is installed in the correct direction.
      • Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.
        Fig 26: Identifying Thrust Bearings, Bearing Race And Input Sun Gear
        G05000862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Thrust bearing and bearing race diameter: mm (in.) 

      THRUST BEARING AND BEARING RACE DIAMETER SPECIFICATION

        Inside Outside
      Thrust Bearing, A 32.5(1.28) 56.5 (2.224)
      Bearing Race, B 40.2(1.583) 59.3 (2.335)
      Thrust Bearing, C 38.6(1.520) 59.7 (2.35)
      Bearing Race, D 38.6(1.520) 59.3 (2.335)
  18. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Install the rear planetary gear assembly to the rear planetary ring gear.
      Fig 27: Identifying Rear Planetary Gear Assembly
      G05000800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
      NOTE: Confirm that the snap ring is engaged in the groove of the 1st and reverse brake hub correctly.
      Fig 28: Installing Snap Ring
      G04976173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Coat the 6 discs with ATF.
    2. Install the 6 plates and 6 discs.
      NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
      Fig 29: Identifying Plates And Discs
      G05269024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE 
    1. Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
    2. Select an appropriate flange so that the pack clearance will be within the specified range.

      Pack clearance: 1.16 to 1.35 mm (0.0457 to 0.0531 in.) 

      Fig 30: Measuring Distance Between Disc Surface And Contact Surface Of 2nd Brake Cylinder
      G05000832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Piston stroke = Dimension A - Flange thickness

      Flange thickness: mm (in.) 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      1 1.8(0.071) 5 2.2 (0.087)
      2 1.9(0.075) 6 2.3(0.091)
      3 2.0 (0.079) 7 2.4 (0.094)
      4 2.1 (0.083) 8 2.5 (0.098)
    3. Install the flange.
      Fig 31: Identifying Flange
      G05000867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL 2ND BRAKE PISTON ASSEMBLY 
    1. Install the 2nd brake piston assembly to the transaxle case.
      Fig 32: Identifying 2nd Brake Piston Assembly
      G05269027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the snap ring and measure the inside diameter.

      Inside diameter: Greater than 167 mm (6.57 in.) 

      NOTE:
      • Make sure that the tapered snap ring is installed in the correct direction.
      • When the diameter is not as specified, replace the snap ring with a new one.
      • After installing, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.
        Fig 33: Installing Snap Ring
        G05269028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL ONE-WAY CLUTCH SLEEVE OUTER 
    1. Install the one-way clutch sleeve outer to the 2nd brake cylinder assembly.
      NOTE: Make sure that the outer sleeve is installed in the correct direction.
      Fig 34: Identifying One-Way Clutch Sleeve Outer
      G05269029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL ONE-WAY CLUTCH ASSEMBLY 
    1. Install the one-way clutch inner race to the one-way clutch.
      NOTE:
      • Make sure that the inner race is installed in the correct direction.
      • Confirm that the discrimination mark can be seen.
        Fig 35: Identifying One-Way Clutch Inner Race
        G05268952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the rotating direction of one-way clutch for the lock or free operation as shown in the illustration.
      Fig 36: Checking Rotating Direction Of One-Way Clutch
      G05000872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the one-way clutch and thrust needle roller bearing to the one-way clutch sleeve outer.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER SPECIFICATION

        Inside Outside
      Bearing 53.6(2.110) 69.4 (2.732)
      NOTE: Install the thrust bearing properly so that no-colored race can be seen.
      Fig 37: Identifying One-Way Clutch And Thrust Needle Roller Bearing
      G05269032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER 
    1. Coat the No. 1 planetary carrier thrust washer with yellow petrolatum, and install the washer onto the planetary sun gear assembly.
      NOTE: After installing, confirm that the projection should be firmly engaged in the hole of the planetary sun gear assembly.
      Fig 38: Identifying Planetary Carrier Thrust Washer
      G05268954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Coat the No. 2 planetary carrier thrust washer with yellow petrolatum, and install the washer onto the rear planetary sun gear.
      Fig 39: Identifying Rear Planetary Sun Gear Assembly And Planetary Carrier Thrust Washer
      G05268950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER SPECIFICATION

        Inside Outside
      Race, A 33.0(1.299) 45.4(1.787)
      Bearing, B 31.85(1.254) 45.2(1.78)
      Fig 40: Identifying Bearing And Bearing Race
      G05269035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rear planetary sun gear assembly to the rear planetary gear.
      NOTE: After installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.
      Fig 41: Identifying Rear Planetary Sun Gear Assembly
      G05268948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL 2ND BRAKE CLUTCH DISC 
    1. Coat the 4 discs with ATF.
    2. Install the 4 discs and 4 plates to the transaxle case.
    3. Temporarily install the snap ring.
      Fig 42: Identifying Discs And Plates
      G05269037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSPECT PACK CLEARANCE OF 2ND BRAKE 
    1. Using vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
    2. Select an appropriate flange so that the pack clearance will be within the specified range.

      Clearance: 0.62 to 0.91 mm (0.0244 to 0.0358 in.) 

      HINT:

      Piston stroke = Dimension B - Flange thickness Snap ring thickness 1.6 mm (0.063 in.)

      Fig 43: Measuring Distance Between Disc Surface And Snap Ring Surface
      G05000833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Flange thickness: mm (in.) 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      1 3.0(0.118) 5 3.4 (0.134)
      2 3.1 (0.122) 6 3.5(0.138)
      3 3.2(0.126) 7 3.6(0.142)
      4 3.3 (0.130) 8 -
    3. Temporarily remove the snap ring, attach the selected flange, and reinstall the snap ring.
      NOTE: Secure the snap ring so that the ends can be seen through the groove of the transaxle case.
      Fig 44: Identifying Snap Ring
      G05269039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY 
    1. Install the direct clutch hub to the planetary gear assembly.
      NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation.
    2. Coat the thrust bearing with ATF.
    3. Install the bearing race and the thrust bearing to the direct clutch hub.
      Fig 45: Identifying Overdrive Direct Clutch Hub
      G04976267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to drop the bearing when it is installed.

      Bearing and race diameter: mm (in.) 

      BEARING AND RACE DIAMETER SPECIFICATION

        Inside Outside
      Bearing, A 24.7 (0.972) 39.5 (1.555)
      Race, B 23.6 (0.929) 38.0(1.496)
  29. INSTALL DIRECT CLUTCH ASSEMBLY 
    1. Coat the thrust bearing with ATF.
    2. Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.
      NOTE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
      Fig 46: Installing Direct Clutch And Thrust Bearing
      G05269041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the connecting part of the transaxle case and the rear cover.
    4. As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using vernier calipers (Dimension C).
      Fig 47: Measuring Distance Between Transaxle Case And Straightedge
      G05000883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using vernier calipers and a straightedge, measure the dimension shown in the illustration.
    6. Calculate the end play using the following formula. Select a thrust bearing which satisfies the end play and install the selected bearing.

      End play: 0.244 to 0.901 mm (0.0096 to 0.0355 in.) 

      Fig 48: [Measuring Dimension]
      G05000884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that the no-colored race side is facing the direct clutch assembly.

      HINT:

      End play = Dimension D - Dimension C

      Bearing thickness and diameter: mm (in.) 

      BEARING THICKNESS AND DIAMETER SPECIFICATION

      Thickness Inside Outside
      3.6(0.1417) 56.3(2.217) 75.7 (2.980)
      3.8 (0.1496) 56.3(2.217) 75.7 (2.980)
  30. INSTALL NO. 1 GOVERNOR APPLY GASKET 
    1. Install 3 new No. 1 governor apply gaskets to the transaxle case.
      Fig 49: Locating Governor Apply Gaskets
      G04976282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL BRAKE APPLY TUBE 
    1. Install the clamp to the brake apply tube.
      NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.
    2. Install the clutch apply tube.
      Fig 50: Identifying Brake Apply Tube
      G04976283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the brake apply tube and a bolt to the transaxle case.

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

      NOTE: The tube should be securely inserted until it reaches the stopper.
      Fig 51: Identifying Brake Apply Tube And Clutch Apply Tube
      G05000786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL NEEDLE ROLLER BEARING 
    1. Using SST and a press, press the needle roller bearing into the transaxle rear cover.

      SST 09950-60010 (09951-00230, 09952-06010) 

      Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 in.) 

      NOTE:
      • The engraved mark side of the bearing should face upward.
      • Repeat press fitting until the specified value is obtained.
        Fig 52: Installing Needle Roller Bearing Into Transaxle Rear Cover
        G05269047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat a needle roller bearing with ATF.
  33. INSTALL REAR CLUTCH OIL SEAL RING OUTER 
    1. Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.
      NOTE: The snap ring should be fully engaged in the groove of the drum.
      Fig 53: Identifying Rear Clutch Oil Seal Ring Outer
      G05000783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Coat 4 new O-rings with ATF.
    2. Install the 4 O-rings to the 4 No. 1 transaxle case plugs.
    3. Install the 4 No. 1 transaxle case plugs to the transaxle rear cover.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 54: Identifying O-Ring And Transaxle Case Plugs
      G05000782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
    2. Apply FIPG to the cover.

      FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 55: Identifying FIPG Applying Area Of Transaxle Rear Cover
      G04976288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that the FIPG is applied in a bead (section diameter: (j>1.2) so that the entire sealing surface will be evenly sealed. The FIPG should also protrude slightly from the flange after the assembly of the parts has been completed.
    3. Apply liquid sealer to the "A" bolt threads.

      Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

    4. Install the 11 bolts.

      Torque: Bolt A 19 N*m (190 kgf*cm, 14 ft.*lbf) 

      Other bolts: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

      Fig 56: Locating Transaxle Rear Cover Bolts
      G05000892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Coat the 4 discs with ATF.
    2. Install the 4 discs, 4 plates, and flange to the transaxle case.
      NOTE: Make sure that discs, plate, and flange assembly are installed in the correct order.
      Fig 57: Identifying Discs, Plates And Flange
      G05000893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
      NOTE: The snap ring should be fully engaged in the groove of the drum.
      Fig 58: Installing Snap Ring
      G04976140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE 
    1. Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi). Pack clearance: 1.81 to 2.20 mm (0.0713 to 0.0866 in.)

      HINT:

      Select an appropriate flange from the table below so that it will be within the specified range.

      Fig 59: Measuring Underdrive Brake Pack Clearance
      G04976211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Flange thickness: mm (in.) 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness Mark Thickness
      1 3.0(0.118) 4 3.1 (0.122)
      2 3.2 (0.126) 5 3.3(0.130)
      3 3.4(0.134) - -
    2. Temporarily remove the snap ring and attach it to the flange.
    3. Reinstall the snap ring.
  38. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Install the underdrive clutch assembly to the one-way clutch.
    2. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.
      Fig 60: Inspecting Underdrive One-Way Clutch Assembly
      G04976212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Install the outer race retainer to the one-way clutch.
      NOTE: Secure the outer race retainer to the external tooth of the one-way clutch firmly.
      Fig 61: Identifying Outer Race Retainer
      G05269056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the one-way clutch to the transaxle case.
      NOTE: Make sure that the mark on the one-way clutch outer race can be seen.
      Fig 62: Identifying Mark On 1-Way Clutch Outer Race
      G05000898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transaxle case.
      NOTE: The snap ring should be fully engaged in the groove of the transaxle case.
      Fig 63: Installing Snap Ring
      G04976294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY 
    1. Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.

      Bearing and bearing race diameter: mm (in.) 

      BEARING AND BEARING RACE DIAMETER SPECIFICATION

        Inside Outside
      Bearing 37.73(1.4854) 58.0 (2.2835)
      Race 29.9(1.1772) 55.5 (2.185)
      Fig 64: Identifying Underdrive Clutch Assembly
      G04976295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the underdrive clutch assembly to the transaxle case.
      NOTE: Do not damage the oil seal when installing the underdrive clutch drum sub-assembly.
  41. INSTALL PARKING LOCK PAWL 
    1. Install the pawl pin and spring to the parking lock pawl.
      Fig 65: Identifying Pawl Pin, Spring And Parking Lock Pawl
      G04976296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the parking lock pawl, shaft, and spring to the transaxle case as shown in the illustration.
      Fig 66: Identifying Spring, Pawl Pin And Parking Lock Pawl
      G05000774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Install the underdrive planetary gear assembly to the transaxle case.
      NOTE:
      • Fully engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assembly and install them securely.
      • Check the number and position of the gear teeth.
        Fig 67: Installing Underdrive Planetary Gear Assembly To Transaxle Case
        G05000773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the parking lock pawl shaft.
      Fig 68: Installing Parking Lock Pawl Shaft
      G04976299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the pawl shaft clamp with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 69: Identifying Pawl Shaft Clamp Bolt
      G05269064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E).
      NOTE: Record dimension E for the following process.
      Fig 70: Measuring Gap Between Top Of Differential Drive Pinion And Transaxle Case Contact Surface
      G05000906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below.
      NOTE: Record dimension F for the following process.

      HINT:

      Dimension F = Dimension (1) - Dimension (2)

      Fig 71: Identifying Dimensions
      G05000907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL MULTIPLE DISC CLUTCH HUB 
    1. Install the No. 1 thrust bearing race to the transaxle case while checking its direction.

      Bearing race diameter: mm (in.) 

      BEARING RACE DIAMETER SPECIFICATION

        Inside Outside
      Bearing race 39.5(1.555) 45.8(1.803)
      Fig 72: Identifying Thrust Bearing Race
      G05269067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the thrust needle roller bearing and race with yellow petrolatum, and install them onto the multiple disc clutch hub.

      Thrust bearing and race diameter: mm (in.) 

      THRUST BEARING AND BEARING RACE DIAMETER SPECIFICATION

        Inside Outside
      Thrust Bearing 36.4 (1.433) 52.2 (2.055)
      Fig 73: Identifying Thrust Needle Roller Bearing And Multiple Disc Clutch Hub
      G05269068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the needle roller bearing with ATF.
    4. Install the needle roller bearing to the multiple clutch hub.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER SPECIFICATION

        Inside Outside
      Bearing 23.6 (0.929) 44(1.732)
    5. Install the multiple clutch hub to the transaxle case.
      Fig 74: Identifying Thrust Needle Roller Bearing And Multiple Disc Clutch Hub
      G05000910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL FORWARD CLUTCH ASSEMBLY 
    1. Coat the thrust needle roller bearing with ATF.
    2. Install the thrust needle roller bearing to the forward clutch.

      Thrust bearing diameter: mm (in.) 

      THRUST BEARING DIAMETER SPECIFICATION

        Inside Outside
      Thrust Bearing 33.58(1.3220) 51.9(2.043)
      NOTE: Install the thrust bearing properly so that the no-colored race or blue ink jet race can be seen.
      Fig 75: Identifying Thrust Needle Roller Bearing
      G05269070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the forward clutch to the forward clutch assembly.
      NOTE:
      • Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.
      • Be careful not to damage the bushing inside of the forward clutch hub during installation.
        Fig 76: Identifying Forward Clutch Assembly
        G04976128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL OVERDRIVE BRAKE GASKET 
    1. Install 2 new overdrive brake gaskets.
      Fig 77: Installing Overdrive Brake Gaskets
      G04976127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL DIFFERENTIAL GEAR ASSEMBLY 
    1. Install the differential gear assembly to the transaxle case.
      Fig 78: Installing Differential Gear Assembly To Transaxle Case
      G05000765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE 
    1. Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly.
      Fig 79: Identifying Thrust Bearing Underdrive Race And Underdrive Planetary Gear Assembly
      G05268923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. Coat the thrust needle roller bearing with ATF.
    2. Calculate the end play using the following formula and values of dimension E and F that are measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate No. 2 underdrive planetary gear thrust bearing race which satisfies the specified end play, and install the selected bearing race.

      End play: 0.498 to 0.993 mm (0.01961 to 0.03909 in.) 

      HINT:

      End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 in.) - No. 2 underdrive thrust bearing race thickness.

      Fig 80: Identifying Thrust Needle Roller Bearing, Forward Clutch Assembly And Differential Gear Assembly
      G05269075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Race thickness: mm (in.) 

      RACE THICKNESS SPECIFICATION

      F-E Thickness
      Less than 7.72 (0.3039) 3.5(0.138)
      7.72 (0.3039) 3.8 (0.150)

      Bearing and bearing race diameter: mm (in.) 

      BEARING AND BEARING RACE DIAMETER SPECIFICATION

        Inside Outside
      Bearing 57.2 (2.252) 84.96 (3.345)
      Bearing race 56.4 (2.22) 83 (3.268)
  49. INSTALL OIL PUMP ASSEMBLY 
    1. Install the oil pump to the transaxle case with the 7 bolts.

      Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf) 

      Fig 81: Locating Oil Pump Assembly Bolts
      G05269076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the O-ring of the oil pump with ATF.
      NOTE: Confirm that the input shaft rotates smoothly with the manual operation after installing the oil pump.
      Fig 82: Identifying Oil Pump O-Ring
      G05269077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL TRANSAXLE HOUSING 
    1. Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
    2. Apply FIPG to the transaxle case.

      FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 83: Identifying FIPG Applying Area Of Transaxle Case
      G05000919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing and 16 bolts to the transaxle case.

      Torque: 

      Bolt A 

      25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Bolt B, E 

      33 N*m (337 kgf*cm, 24 ft.*lbf) 

      Bolt C 

      29 N*m (295 kgf*cm, 21 ft.*lbf) 

      Bolt D 

      28 N*m (286 kgf*cm, 21 ft.*lbf) 

      Fig 84: Identifying Transaxle Housing Bolts
      G05269079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply seal packing to bolts A and D.

      Seal packing: Toyota Genuine Seal Packing 2403, Three Bond 2403 or equivalent 

      Bolt length 

      Bolt A, D, E: 

      50 mm (1.969 in.) 

      Bolt B, C: 

      42 mm (1.654 in.) 

      NOTE: Tighten the bolts within 10 minutes of sealant application.
  51. INSPECT INPUT SHAFT END PLAY 
    1. Using a dial indicator, measure the input shaft end play.

      End play: 0.262 to 1.249 mm (0.0103 to 0.0492 in.) 

      Fig 85: Measuring Input Shaft End Play
      G05269080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. FIX AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Fix the transaxle assembly on wooden blocks.
      Fig 86: Fixing Automatic Transaxle Assembly On Wooden Blocks
      G04976316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Coat a new oil seal with MP grease.
    2. Install the oil seal to the transaxle case.

      SST 09950-60010 (09951-00230), 09950-70010 (09951-07100) 

      Oil seal installation depth: 0.5 to -0.5 mm (0.02 to -0.02 in.) 

      Fig 87: Installing Manual Valve Lever Shaft Oil Seal
      G04976317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Install the parking lock rod to the manual valve lever.
      Fig 88: Identifying Parking Lock Rod Sub-Assembly
      G05000759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Install a new spacer and manual valve lever shaft to the transaxle case.
      NOTE: Do not damage the oil seal when installing the shaft to the transaxle case.
      Fig 89: Installing Spacer
      G05130148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, drive in a new pin.
      Fig 90: Installing Pin Using Pin Punch And Hammer
      G05000757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
    4. Using a pin punch, stake the spacer through the small hole.
    5. Check that the spacer does not turn.
      Fig 91: [Identifying Staking Position In Spacer]
      G05000927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, install the retainer spring.
      NOTE: Hang the spring on the shaft firmly.
      Fig 92: Installing Manual Valve Lever Shaft Retainer Spring
      G04976114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL PARKING LOCK PAWL BRACKET 
    1. Install the parking lock pawl bracket with the 2 bolts.

      Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) 

      Bolt length: 25 mm (0.984 in.) 

      NOTE: Make sure that the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.
      Fig 93: Locating Parking Lock Pawl Bracket Bolts
      G05269088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Install the manual detent spring sub-assembly with the 2 bolts.
      NOTE: Make sure to install the manual detent spring and cover in this order.

      HINT:

      Tighten bolt A first, and then bolt B.

      Torque: Bolt A 

      20 N*m (205 kgf*cm, 15 ft.*lbf) 

      Fig 94: Locating Manual Detent Spring Sub-Assembly Bolts
      G05000930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt B 

      12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Bolt length: 

      Bolt A: 27 mm (1.063 in.) 

      Bolt B: 16 mm (0.630 in.) 

  59. INSTALL B-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF and install it to the B-3 accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 95: Locating B-3 Accumulator Piston O-Ring
      G05268911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF and install it to the transaxle case.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
      Fig 96: Locating ATF Applying Area Of B-3 Accumulator Piston
      G04976326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Accumulator spring: 

      B-3 ACCUMULATOR PISTON SPRING SPECIFICATION

      Free length Outer diameter mm (in.) Color
      Inner 62.00 (2.4409) / 15.50(0.610) Purple
      Outer 74.23 (2.9224) / 21.70(0.854) Purple
  60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON 
    1. Coat 2 new O-rings with ATF and install them to the reverse accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
    2. Coat the piston with ATF and install it to the transaxle case.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
      Fig 97: Locating Reverse Clutch Accumulator Piston O-Ring
      G04976327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Accumulator spring: 

      REVERSE CLUTCH ACCUMULATOR PISTON SPRING SPECIFICATION

      Free length Outer diameter mm (in.) Color
      60.96 (2.3999) / 14.10(0.555) Yellow
      Fig 98: Locating ATF Applying Area Of Reverse Clutch Accumulator Piston
      G05269093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL C-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF and install it to the C-3 accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 99: Locating C-3 Accumulator Piston O-Ring
      G05130158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF and install it to the transaxle case.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.

      Accumulator spring: 

      C-3 ACCUMULATOR PISTON SPRING SPECIFICATION

      Free length Outer diameter mm (in.) Color
      72.20 (2.8425) / 19.0(0.748) Colorless
      Fig 100: Installing C-3 Accumulator Piston
      G04976330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the spring to the C-3 accumulator piston.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
      Fig 101: Identifying C-3 Accumulator Piston Spring
      G05269096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CHECK BALL BODY 
    1. Coat the check ball body with ATF.
    2. Install the check ball body and spring.
      NOTE: Be sure to place the spring in the hole in the check ball body. Make sure that they are installed in the correct direction.
      Fig 102: Identifying Check Ball Body And Spring
      G04976106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL BRAKE DRUM GASKET 
    1. Coat a new brake drum gasket with ATF and install it to the transaxle case.
      NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Make sure that they are installed in the correct direction.
      Fig 103: Locating Brake Drum Gasket
      G04976105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET 
    1. Coat a new transaxle case 2nd brake gasket with ATF and install it to the transaxle case.
      NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Make sure that they are installed in the correct direction.
      Fig 104: Locating Transaxle Case 2nd Brake Gasket
      G04976104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL NO. 1 GOVERNOR APPLY GASKET 
    1. Coat a new No. 1 governor apply gasket with ATF and install it to the transaxle case.
      NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Make sure that they are installed in the correct direction.
      Fig 105: Locating Governor Apply Gasket
      G04976103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL TRANSMISSION WIRE 
    1. Coat a new O-ring with ATF and install it to the transmission wire.
      NOTE: Make sure that the O-ring is not twisted, protruded, or pinched when installing the wire transmission to the transaxle case. Apply sufficient ATF to the O-ring before installation.
      Fig 106: Locating Transmission Wire O-Ring
      G05000942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt that retains the transmission wire.

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

      Fig 107: Locating Transmission Wire Bolt
      G04976340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. CONNECT TRANSMISSION WIRE 
    1. Coat an O-ring of the ATF temperature sensor with ATF.
    2. Install the ATF temperature sensor with the lock plate and bolt.

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

    3. Connect the 7 solenoid connectors.
      NOTE:
      • Connect the connectors A, B, C, D, E, F, G, in the order from the shortest to longest.
      • Apply ATF to the bolt.
        Fig 108: Locating Solenoid Connectors
        G05000944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts.

      Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

      Bolt length: 

      Bolt A: 25 mm (0.984 in.) 

      Bolt B: 57 mm (2.244 in.) 

      Bolt C: 41 mm (1.614 in.) 

      Fig 109: Locating Transmission Valve Body Assembly Bolts
      G04975962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Push the valve body against the accumulator piston spring and the check ball body to install the valve body.
      • When installing the valve body to the transaxle case, do not hold the solenoids.
      • Temporarily tighten the bolts marked (1) in the illustration first because they are positioning bolts.
  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the oil strainer.
      NOTE: Make sure that the O-ring is not twisted or pinched. Apply sufficient ATF to the O-ring before installation.
      Fig 110: Locating Oil Strainer O-Ring
      G05268899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil strainer and 3 bolts to the valve body.

      Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

      NOTE: Apply ATF to the bolts.
      Fig 111: Locating Oil Strainer Bolts
      G05000598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Install the 2 magnets to the oil pan.
    2. Apply seal packing to 18 new bolts.

      Seal packing: THREE BOND 2430 or equivalent 

      Fig 112: Identifying Magnets
      G05000948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil pan and new oil pan gasket to the transaxle case with the 18 bolts.

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

      NOTE:
      • Tighten the bolts within 10 minutes of sealant application.
      • Completely remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket before installing the oil pan to the case.
        Fig 113: Locating Oil Pan Bolts
        G04975941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Coat 4 new O-rings with ATF, and install them to the 4 No. 1 transaxle case plugs.
    2. Install the 4 No. 1 transaxle case plugs to the transaxle case.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 114: Identifying O-Rings And Transaxle Case Plugs
      G04976344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. INSTALL SPEED SENSOR 
    1. Coat 2 new O-rings with ATF and install them to the 2 sensors.
    2. Install the 2 sensors to the transaxle case with the 2 bolts.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

      Fig 115: Identifying Speed Sensors
      G05269110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF and install it to the elbow.
    2. Install the elbow to the transaxle case.

      Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf) 

      Fig 116: Identifying Outlet Oil Cooler Tube Union And O-Ring
      G05268889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF and install it to the union.
    2. Install the union to the transaxle case.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Fig 117: Identifying Inlet Oil Cooler Tube Union And O-Ring
      G05268888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL BREATHER PLUG HOSE 
    1. Install the breather plug hose to the transaxle case firmly.
  76. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the 2 adjusting bolts.
    2. Install a new nut stopper and nut.

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

      Fig 118: Locating Park/Neutral Position Switch Bolts
      G05000954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the control shaft lever.
      Fig 119: Identifying Control Shaft Lever
      G05269114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
    5. Remove the control shaft lever.
      Fig 120: Turning Lever Counterclockwise
      G05000956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Align the groove with the neutral basic line.
    7. Tighten the 2 bolts.

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

      Fig 121: Aligning Groove With Neutral Basic Line
      G05000957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a screwdriver, stake the nut with the nut stopper.
      Fig 122: Staking Nut With Nut Stopper
      G05269117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the control shaft lever, washer, and nut.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  77. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
    2. Install the bolt and speedometer driven hole cover sub-assembly to the transaxle assembly.

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

      Fig 123: Locating Control Shaft Lever Nut
      G05000959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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