Automatic Transaxle Unit: Reassembly: Reassembly
- BEARING POSITION
- Check each bearing position and installation direction.
Standard Bearing Position
Mark Front Race Diameter (mm (in.))
Inside/OutsideThrust Bearing Diameter (mm (in.))
Inside/OutsideRear Race Diameter (mm (in.))
Inside/OutsideA - 57.2 (2.25)/84.96 (3.34) 56.4 (2.220)/83.0 (3.268) B - 37.73 (1.49)/58.0 (2.28) 29.9 (1.18)/55.5 (2.19) C - 33.85 (1.33)/52.2 (2.06) - D - 23.5 (0.925)/44.0 (1.73) - E - 36.3 (1.43)/52.2 (2.06) 34.5 (1.36)/48.5 (1.91) F - 34.6 (1.362)/52.2 (2.06) - G 40.3 (1.59)/58.0 (2.28) 38.6 (1.52)/60.0 (2.36) 38.6 (1.52)/58.0 (2.28) H - 53.6 (2.11)/69.6 (2.74) - I - 33.8 (1.33)/48.2 (1.90) 30.3 (1.19)/46.0 (1.81) J - 53.6 (2.11)/70.18 (2.76) or 69.6 (2.74) -
- Check each bearing position and installation direction.
- INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
- Install the apply tube and 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.
- Install the apply tube and clamp to the transaxle housing with the bolt.
- INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
- Install a new oil seal ring to the transaxle housing.
- INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
- Using SST and a press, press in the underdrive cylindrical roller bearing.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-60020
- 09951-00810
- SST: 09950-70010
- 09951-07100
NOTE:Do not apply excessive pressure.
- SST: 09950-60020
- Using SST and a press, press in the underdrive cylindrical roller bearing.
- INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
- Install 2 new oil seal rings to the transaxle.
- INSTALL UNDERDRIVE BRAKE PISTON
- Wrap vinyl tape around SST 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wrapped tape is about 5.0 mm (0.197 in.)
- SST: 09950-60010
- 09951-00320
NOTE:Clean SST to remove oil deposits before wrapping with vinyl tape.
- SST: 09950-60010
- Using SST and a press, press in the needle-roller bearing to the transaxle until the wrapped vinyl tape contacts the transaxle case.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-60010
- 09951-00320
- SST: 09950-70010
- 09951-07100
- SST: 09950-60010
- Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
- Install the underdrive brake piston to the transaxle.
- Using SST, a snap ring expander and press, press in the piston return spring and snap ring to the transaxle.
- SST: 09387-00020
NOTE:Do not apply excessive pressure.
- Wrap vinyl tape around SST 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wrapped tape is about 5.0 mm (0.197 in.)
- INSTALL NO. 2 BREATHER PLUG
- INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
- Using a screwdriver, press in the snap ring to the transaxle.
- INSTALL COUNTER DRIVE GEAR
- Using SST and a press, press in the 2 bearing outer races to the transaxle.
- SST: 09950-60020
- 09951-00890
- SST: 09950-70010
- 09951-07150
- SST: 09950-60020
- Using SST and a press, press in the tapered roller bearing to the counter drive gear until the bearing race contacts the snap ring.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09649-17010
NOTE:Do not apply excessive pressure.
- Using SST and a press, install the counter drive gear and bearing to the transaxle.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-70010
- 09951-07150
- SST: 09950-60020
- 09951-00750
NOTE:Do not apply excessive pressure.
- SST: 09950-70010
- Using SST and a press, press in the 2 bearing outer races to the transaxle.
- INSTALL 1ST AND REVERSE BRAKE PISTON
- Coat 2 new O-rings with ATF.
- Install the 2 O-rings to the 1st and reverse brake piston.
- Coat the 1st and reverse brake piston with ATF, and install it to the transaxle.
- INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
- Using SST, a press and snap ring expander, press the 1st and reverse brake return spring sub-assembly and snap ring to the transaxle.
- SST: 09387-00070
NOTE:- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.
- Using SST, a press and snap ring expander, press the 1st and reverse brake return spring sub-assembly and snap ring to the transaxle.
- INSTALL FRONT PLANETARY RING GEAR
- Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
- INSTALL FRONT PLANETARY GEAR ASSEMBLY
- Install the front planetary gear assembly to the brake hub.
- Using SST and a press, press-fit the front planetary gear.
- SST: 09950-60010
- 09951-00500
- SST: 09950-70010
- 09951-07100
NOTE:Do not apply excessive pressure.
- SST: 09950-60010
- Install a new washer as shown in the illustration.
- Using SST, install the nut.
- SST: 09387-00030
- SST: 09387-00080
Torque: 280 N*m (2855 kgf*cm, 206 ft.*lbf)
- Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 RPM. If the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
- SST: 09387-00080
Turning torque at 60 RPM
Torque: 0.5 to 1.0 N*m (5 to 10 kgf*cm, 4 to 9 in.*lbf)
for a new bearing
Torque: 0.3 to 0.5 N*m (3 to 5 kgf*cm, 3 to 4 in.*lbf)
for a used bearing
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
- Using a chisel and hammer, stake the washer.
- INSTALL INPUT SUN GEAR
- Install the 2 thrust bearings, bearing race and input sun gear to the front planetary gear.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Standard Bearing and Race Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Bearing 34.6 (1.362) 52.2 (2.055) Race 40.3 (1.587) 58.0 (2.283) Bearing 38.6 (1.52) 60.0 (2.362)
- Install the 2 thrust bearings, bearing race and input sun gear to the front planetary gear.
- INSTALL REAR PLANETARY GEAR ASSEMBLY
- INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
- Install the 5 plates and 5 discs.
Install in order
P - D - P - D - P - D - P - D - P - D
HINT:
P = Plate
D = Disc
- Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).
- Select an appropriate flange so that the pack clearance will meet the specified value.
0.75 to 1.21 mm (0.0295 to 0.0476 in.)
HINT:
Pack clearance = Dimension A - Flange thickness
Flange Thickness
Mark Thickness (mm (in.)) Mark Thickness (mm (in.)) 1 1.8 (0.0709) 5 2.2 (0.0866) 2 1.9 (0.0748) 6 2.3 (0.0906) 3 2.0 (0.0787) 7 2.4 (0.0945) 4 2.1 (0.0827) 8 2.5 (0.0984) - Install the flange.
- Install the 5 plates and 5 discs.
- INSTALL 2ND BRAKE PISTON O-RING
- Coat 2 new O-rings with ATF, and install them into the 2nd brake piston.
- INSTALL 2ND BRAKE PISTON
- Press the 2nd brake piston into the 2nd brake cylinder by hand.
- INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
- Install the piston return spring.
- Place SST on the piston return spring, and compress the piston return spring with a press.
- SST: 09387-00060
- Using a screwdriver, install the snap ring.NOTE:
Be sure that the end gap of the snap ring is not aligned with the piston return spring claw.
- INSTALL 2ND BRAKE PISTON ASSEMBLY
- Install the 2nd brake piston to the transaxle.
- Install the snap ring and measure the inside diameter.
Standard inside diameter
More than 167 mm (6.57 in.)
NOTE:- Check the direction of the tapered snap ring when installing it.
- If the diameter does not satisfy the specified value, replace the snap ring with a new one.
- INSTALL ONE-WAY CLUTCH OUTER SLEEVE
- Install the one-way clutch outer sleeve to the 2nd brake cylinder.
NOTE:
Check the direction of the outer sleeve.
- Install the one-way clutch outer sleeve to the 2nd brake cylinder.
- INSTALL ONE-WAY CLUTCH ASSEMBLY
- Install the inner race to the one-way clutch.
NOTE:
Check the direction of the inner race.
- Check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.
- Install the one-way clutch and thrust bearing to the one-way clutch outer sleeve.
Standard Thrust Bearing Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Thrust Bearing 53.6 (2.110) 69.6 (2.740) NOTE:Install the thrust bearing properly so that un-colored race will be visible.
- Install the inner race to the one-way clutch.
- INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
- Coat the No. 2 washer with petroleum jelly, and install it onto the rear planetary sun gear.
- Coat the thrust bearing with petroleum jelly, and install it onto the rear planetary sun gear.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Standard Thrust Bearing Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Thrust Bearing 33.8 (1.331) 48.2 (1.898) - Install the rear planetary sun gear to the rear planetary gear.
- INSTALL 2ND BRAKE CLUTCH DISC
- Install the 3 discs and 3 plates to the transaxle.
Install in order
P - D - P - D - P - D
HINT:
P = Plate
D = Disc
- Temporarily install the snap ring.
- Using a vernier caliper, measure the distance between the disc surface and snap ring surface.
- Select an appropriate flange so that the pack clearance will meet the specified value.
Standard pack clearance
0.50 to 0.91 mm (0.0197 to 0.0358 in.)
HINT:
Pack clearance = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)
Flange Thickness
Mark Thickness (mm (in.)) Mark Thickness (mm (in.)) 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 - - Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
NOTE:
Position the snap ring so that its gap is visible through the groove of the transaxle case.
- Install the 3 discs and 3 plates to the transaxle.
- INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
- Coat the direct clutch piston with ATF, and install it to the direct clutch drum.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Be careful not to damage the lip seal of the direct clutch piston.
- Install the direct clutch return spring sub-assembly to the direct clutch drum.
- Install the clutch balancer to the direct clutch drum.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Be careful not to damage the lip seal of the direct clutch balancer.
- Place SST on the clutch balancer and compress the piston return spring with a press.
- SST: 09387-00020
- Using a snap ring expander, install the snap ring to the direct clutch drum.NOTE:
- Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.
- Coat the direct clutch piston with ATF, and install it to the direct clutch drum.
- INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
- Install the 3 plates, 3 discs and flange to the direct clutch drum.
Install in order
P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange
- Using a screwdriver, install the snap ring.
- Check that the end gap of the snap ring is not aligned with one of the cutouts.
- Install the 3 plates, 3 discs and flange to the direct clutch drum.
- INSPECT PACK CLEARANCE OF DIRECT CLUTCH See step 15
- INSPECT DIRECT MULTIPLE DISC CLUTCH DISC See step 16
- INSTALL DIRECT CLUTCH
- Install the bearing race to the direct clutch.
Standard Bearing Race Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Bearing Race 30.3 (1.193) 46.0 (1.811) - Install the direct clutch and thrust bearing to the rear planetary sun gear.
NOTE:
The discs in the direct clutch should be completely mated with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
- Clean the connector part of the transaxle case and rear cover.
- 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 a vernier caliper (Dimension B).
- Measure the 2 places of the rear cover as shown in the illustration. Calculate dimension C using the following formula:
HINT:
Dimension C = Dimension (1) - Dimension (2)
- Calculate the end play value using the following formula:NOTE:
Make sure that the colored race side is facing the direct clutch assembly.
HINT:
End play = Dimension C - Dimension B
End play
0.20 to 0.93 mm (0.00787 to 0.0366 in.)
Select a thrust bearing which satisfies the end play value and install it.
Standard Bearing Thickness and Diameter
Thickness Inside (mm (in.)) Outside (mm (in.)) 3.58 mm (0.1409 in.) 53.6 (2.110) 69.6 (2.740) 3.88 mm (0.1528 in.) 53.6 (2.110) 70.18 (2.763)
- Install the bearing race to the direct clutch.
- INSTALL NO. 1 GOVERNOR APPLY GASKET
- Install 2 new governor apply gaskets.
- INSTALL FRONT CLUTCH APPLY TUBE
- Install the clamp to the front clutch 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.
- Install the clamp to the front clutch apply tube.
- INSTALL BRAKE APPLY TUBE
- 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.
- Install the 2 apply tubes and to the transaxle with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTE:Each pipe should be securely inserted until it reaches the stopper.
- Install the clamp to the brake apply tube.
- INSTALL NO. 1 TRANSAXLE CASE PLUG
- Install 2 new O-rings to the 2 plugs.
- Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
- INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY
- Using SST and a press, press in the needle roller bearing.
- SST: 09950-60010
- 09951-00230
- 09952-06010
Standard depth
12.05 to 12.75 mm (0.474 to 0.501 in.)
NOTE:- Face the inscribed side of the bearing race up.
- Keep pressing until the specified value is obtained.
- SST: 09950-60010
- Apply adhesive to the 2 screws.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
- Using a T30 "TORX" socket wrench, install the transaxle rear cover plate with the 2 screws.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
- Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
- Remove any packing material and be careful not to get oil on the contact surfaces of the transaxle rear cover or the transaxle.
- Apply FIPG to the cover.
FIPG
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
- Coat the needle roller bearing with ATF.
- Apply adhesive to the threads of the bolts labeled A.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
- Install the 11 bolts.
Bolt A.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
Other bolts
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
- Using SST and a press, press in the needle roller bearing.
- INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
- Install the 3 discs and 3 plates to the transaxle.
Install in order
P - D - P - D - P - D
HINT:
P = Plate
D = Disc
- Using a screwdriver, install the snap ring.
- Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2
, 57 psi).
Standard pack clearance
1.59 to 2.20 mm (0.0626 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will meet the specified value.
Standard Flange Thickness
Mark Thickness (mm (in.)) Mark Thickness (mm (in.)) 1 3.0 (0.118) 3 3.4 (0.134) 2 3.2 (0.126) - - - Temporarily remove the snap ring and attach the flange. Reinstall the snap ring.
- Install the 3 discs and 3 plates to the transaxle.
- INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY See step 22
- INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY
- Install the outer race retainer to the one-way clutch.
- Install the one-way clutch to the transaxle.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Make sure that the mark on the one-way clutch outer race is visible.
- Using a screwdriver, install the snap ring to the transaxle.
- INSTALL UNDERDRIVE CLUTCH PISTON SET
- Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
NOTE:
Be careful not to damage the O-ring.
- Install the underdrive piston return spring sub-assembly to the underdrive clutch drum.
- Install the clutch balancer to the underdrive clutch drum.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Be careful not to damage the lip seal of the clutch balancer.
- Place SST on the clutch balancer and compress the piston return spring with a press.
- SST: 09350-32014
- 09351-32070
- SST: 09350-32014
- Using a snap ring expander, install the snap ring to the underdrive clutch drum.NOTE:
- Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.
- Set the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.
NOTE:
Do not align the end gap of the snap ring with any of the stoppers.
- Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
- INSTALL UNDERDRIVE CLUTCH DRUM O-RING
- Coat a new O-ring with ATF, and install it to the underdrive clutch drum.
- INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
- Install the 3 plates, 3 discs and flange to the underdrive clutch drum.
Install in order
P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange
- Using a screwdriver, install the underdrive clutch flange hole snap ring.
- Check that the end gap of the snap ring is not aligned with one of the cutouts.
- Install the 3 plates, 3 discs and flange to the underdrive clutch drum.
- INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH See step 9
- INSTALL UNDERDRIVE CLUTCH ASSEMBLY
- INSTALL UNDERDRIVE PLANETARY RING GEAR
- Install a new snap ring to the outer race of the angular ball bearing.
HINT:
If replacing the bearing, also replace the counter driven gear with a new one.
- Using a piston ring compressor, squeeze the snap ring.
- Using SST and a press, press in the outer race of the angular ball bearing.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09950-60020
- 09951-00890
- SST: 09950-70010
- 09951-07100
NOTE:Do not damage the snap ring during installation of the outer race.
- SST: 09950-60020
- Install the underdrive planetary ring gear to the counter driven gear.
- Using snap ring pliers, install the snap ring.
- Install a new snap ring to the outer race of the angular ball bearing.
- INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
- Using SST and a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear.
- SST: 09726-40010
- SST: 09950-60010
- 09951-00260
- SST: 09950-70010
- 09951-07100
- Install the counter driven gear with planetary ring gear to the underdrive planetary gear.
- Using SST and a press, press in the angular ball bearing inner race (front side).
- SST: 09726-40010
- SST: 09950-60010
- 09951-00260
- SST: 09950-70010
- 09951-07100
NOTE:Rotate the counter driven gear while pressing.
- Using SST and a press, press in the parking lock gear.
- SST: 09316-20011
- SST: 09950-60010
- 09951-00260
- SST: 09950-70010
- 09951-07100
NOTE:Rotate the counter driven gear while pressing.
- Using SST and a press, press in the differential drive pinion.
- SST: 09726-40010
- SST: 09950-60010
- 09951-00260
- SST: 09950-70010
- 09951-07100
NOTE:Rotate the counter driven gear while pressing.
- Using SST and a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear.
- INSTALL CYLINDRICAL ROLLER BEARING INNER RACE
- Using SST and a press, press in the cylindrical roller bearing inner race.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- SST: 09515-21010
- SST: 09950-60010
- 09951-00260
- SST: 09950-70010
- 09951-07100
NOTE:Rotate the counter driven gear while pressing.
- Using SST and a press, press in the cylindrical roller bearing inner race.
- INSTALL UNDERDRIVE INPUT SHAFT NUT
- Clamp the underdrive planetary gear in a soft jaw vise.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Be careful not to damage the differential drive pinion.
- Using a socket wrench, install a new lock nut.
Torque: 280 N*m (2855 kgf*cm, 207 ft.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)
- Clamp the underdrive planetary gear in a soft jaw vise.
- INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD See step 8
- INSTALL UNDERDRIVE INPUT SHAFT NUT
- Using a pin punch and a hammer, stake the lock nut.
NOTE:
Make sure that there are no cracks on the nut.
- Using a pin punch and a hammer, stake the lock nut.
- INSTALL UNDERDRIVE PLANETARY GEAR
- Install the pawl pin and spring to the parking lock pawl.
- Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.
- Install the underdrive planetary gear to the transaxle.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly.
- Install the parking lock pawl shaft.
- Install the pawl shaft clamp with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
- Using a straightedge and a vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).Fig 100: Measuring Gap Between Top Of Differential Drive Pinion In Underdrive Planetary Gear And Contact Surface Of Transaxle And Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Make a note of dimension D as it is necessary for the following process.
- As shown in the illustration, measure the 2 places of the transaxle housing. Calculate dimension E using the following formula:
NOTE:
Make a note of dimension E as it is necessary for the following process.
HINT:
Dimension E = Dimension (1) - Dimension (2)
- INSTALL MULTIPLE DISC CLUTCH HUB
- Install the bearing race to the transaxle while checking its direction.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Standard Bearing Race Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Bearing Race 34.5 (1.358) 48.5 (1.909) - Coat the thrust bearing with petroleum jelly, and install them onto the multiple disc clutch hub.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Standard Thrust Bearing Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Thrust Bearing 36.3 (1.429) 52.2 (2.055) - Install the bearing to the multiple disc clutch hub.
Standard Bearing Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Bearing 23.5 (0.925) 44.0 (1.732) - Install the multiple disc clutch hub to the transaxle.
- Install the bearing race to the transaxle while checking its direction.
- INSTALL INPUT SHAFT OIL SEAL RING
- Compress the oil seal ring from both sides to reduce dimension A.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Standard dimension A
5 mm (0.197 in.)
- Coat the oil seal ring with ATF and install it to the input shaft.
- Compress the oil seal ring from both sides to reduce dimension A.
- INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
- Coat 2 new O-rings with ATF, and install them to the forward clutch piston.
- Install the forward clutch piston to the forward clutch drum.
- INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
- Place the return spring onto the piston.
- Place SST on the return spring, and compress the return spring with a press.
- SST: 09350-32014
- Install the snap ring using a snap ring expander. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.NOTE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.
- Set the end gap of the snap ring in the piston shown in the illustration.
NOTE:
Do not align the end gap of the snap ring with any of the stoppers.
- INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
- Install the 5 plates, 5 discs and flange.
Install in order
P - D - P - D - P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange
- Using a screwdriver, install the snap ring.
- Check that the end gap of the snap ring is not aligned with one of the cutouts.
- Install the 5 plates, 5 discs and flange.
- INSPECT PACK CLEARANCE OF FORWARD CLUTCH See step 3
- INSPECT FORWARD MULTIPLE DISC CLUTCH DISC See step 4
- INSTALL FORWARD CLUTCH ASSEMBLY
- Install the thrust bearing to the forward clutch.
Standard Thrust Bearing Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Thrust Bearing 33.85 (1.333) 52.2 (2.055) NOTE:Install the thrust bearing properly so that the race "B" will be visible.
- Install the forward clutch to the multiple clutch hub.
NOTE:
Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely.
- Install the thrust bearing to the forward clutch.
- INSTALL OVERDRIVE BRAKE GASKET
- Install 2 new overdrive brake gaskets.
- INSTALL DIFFERENTIAL GEAR ASSEMBLY
- Install the differential gear to the transaxle.
- INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
- Install the thrust bearing underdrive race to the underdrive planetary gear.
- INSTALL THRUST NEEDLE ROLLER BEARING
- Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select and install the appropriate bearing race to satisfy the specified end play value.
HINT:
End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 in.) - bearing race thickness.
End play
0.50 to 0.99 mm (0.0196 to 0.0389 in.)
Standard Race Thickness
E - D (mm (in.)) Thickness (mm (in.)) Less than 7.64 (0.3008) 3.5 (0.138) 7.64 (0.3008) 3.8 (0.150) Standard Bearing and Bearing Race Diameter
Item Inside (mm (in.)) Outside (mm (in.)) Bearing 57.2 (2.252) 84.96 (3.3449) Bearing Race 56.4 (2.220) 83.0 (3.268)
- Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select and install the appropriate bearing race to satisfy the specified end play value.
- INSTALL OIL PUMP ASSEMBLY
- Install the oil pump to the transaxle with the 7 bolts.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
- Coat the O-ring of the oil pump with ATF.
- Install the oil pump to the transaxle with the 7 bolts.
- INSTALL TRANSAXLE HOUSING
- Remove any packing material and be careful not to get oil on the contact surface of the transaxle housing.
- Apply FIPG to the transaxle.
FIPG
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
- Install the transaxle housing to the transaxle with the 18 bolts.
Bolt A and D
Torque: 22 N*m (225 kgf*cm, 16 ft.*lbf)
Bolt B and C
Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
Bolt E
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
HINT:
Each bolt length is indicated below.
Bolt length
Bolt A 50 mm (1.969 in.)
Bolt B 50 mm (1.969 in.)
Bolt C 42 mm (1.654 in.)
Bolt D 72 mm (2.834 in.)
Bolt E 50 mm (1.969 in.)
NOTE:Because the bolts labeled A are seal bolts, apply FIPG to new bolts and tighten them within 10 minutes after application.
FIPG
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
- INSTALL NO. 1 TRANSAXLE CASE PLUG
- Install 2 new O-rings to the 2 plugs.
- Install the 2 plugs to the transaxle housing.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
- INSPECT INPUT SHAFT END PLAY See step 2
- SECURE AUTOMATIC TRANSAXLE ASSEMBLY
- Secure the automatic transaxle assembly on wooden blocks.
- INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
- Coat a new oil seal with ATF.
- Install the oil seal to the transaxle.
- INSTALL PARKING LOCK ROD SUB-ASSEMBLY
- Install the parking lock rod to the manual valve lever.
- INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
- Install a new spacer and manual valve lever shaft to the transaxle.
- Using a pin punch and hammer, tap in a new pin.
- Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft.
- Using a pin punch, stake the spacer through the small hole.
- Check that the spacer does not turn.
- INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
- Using needle-nose pliers, install the retainer spring.
- INSTALL PARKING LOCK PAWL BRACKET
- Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
Bolt length
25 mm (0.984 in.)
- Install the parking lock pawl bracket with the 2 bolts.
- INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
- Install the manual detent spring and cover with the 2 bolts.
NOTE:
Make sure to install the manual detent spring and cover in this order.
Bolt A
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
Bolt B
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
HINT:
Each bolt length is indicated below.
- Bolt A 27 mm (1.063 in.)
- Bolt B 16 mm (0.630 in.)
- Install the manual detent spring and cover with the 2 bolts.
- INSTALL B-3 ACCUMULATOR PISTON
- Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.
- Install the 2 springs to the transaxle.
- Coat the piston with ATF, and install it to the transaxle.
Standard Accumulator Spring Length and Diameter
Spring Free Length
Outer Diameter (mm (in.))Color B-3 Inner 60.24 (2.3716)
15.9 (0.626)Yellowish green B-3 Outer 74.61 (2.9374)
21.7 (0.854)Blue
- INSTALL C-1 ACCUMULATOR PISTON
- Coat 2 new O-rings with ATF, and install them to the C-1 accumulator piston.
- Install the spring to the transaxle.
- Coat the piston with ATF, and install it to the transaxle.
Standard Accumulator Spring Length and Diameter
Spring Free Length
Outer Diameter (mm (in.))Color C-1 81.53 (3.2098)
18.5 (0.728)Pink
- INSTALL C-3 ACCUMULATOR PISTON
- Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.
- Coat the piston with ATF, install it to the transaxle case.
Standard Accumulator Spring Length and Diameter
Spring Free Length
Outer Diameter (mm (in.))Color C-3 90.49 (3.5626)
19.2 (0.756)White - Install the spring to the C-3 accumulator piston.
- INSTALL CHECK BALL BODY
- Install the check ball body and spring.
- INSTALL BRAKE DRUM GASKET
- Coat a new brake drum gasket with ATF, and install it to the transaxle case.
- INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
- Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
- INSTALL NO. 1 GOVERNOR APPLY GASKET
- Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case.
- INSTALL TRANSMISSION WIRE
- Coat a new O-ring with ATF, and install it to the transmission wire.
- Install the transmission wire retaining bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- INSTALL TRANSMISSION VALVE BODY ASSEMBLY
- Align the groove of the manual valve with the pin of lever.
- Install the 17 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
NOTE:- Push the valve body against the accumulator piston spring and the check ball body to install it.
- Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.
HINT:
Each bolt length is indicated below.
Bolt length
Bolt A 25 mm (0.984 in.)
Bolt B 41 mm (1.614 in.)
Bolt C 45 mm (1.771 in.)
- Connect the 5 solenoid connectors.
- Coat the O-ring of the temperature sensor with ATF.
- Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
- INSTALL VALVE BODY OIL STRAINER ASSEMBLY
- Coat a new O-ring with ATF.
- Install the O-ring to the oil strainer.
- Install the oil strainer with the 3 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
- INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
- Install the 3 magnets to the oil pan.
- Apply adhesive or equivalent to the 18 bolts.
Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTE:Since the bolts are seal bolts, apply adhesive to the bolts and tighten them within 10 minutes of application.
- Using a new gasket, install the oil pan to the transaxle case with the 18 bolts.
Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
- INSTALL NO. 1 TRANSAXLE CASE PLUG
- Coat 4 new O-rings with ATF, and install them to the 4 plugs.
- Install the 4 plugs to the transaxle case.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
- INSTALL SPEED SENSOR
- Coat 2 new O-rings with ATF, and install them to the 2 speed sensors.
- Install the 2 speed sensors with the 2 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
- INSTALL OIL COOLER INLET TUBE UNION
- Coat a new O-ring with ATF, and install it to the union.
- Install the union to the transaxle.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
- INSTALL OIL COOLER OUTLET TUBE UNION
- Coat a new O-ring with ATF, and install it to the union.
- Install the union to the transaxle.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
- INSTALL BREATHER PLUG HOSE
- INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
- Install the park/neutral position switch to the manual valve shaft.
- Temporarily install the 2 bolts.
- Install a new lock plate and tighten the manual valve shaft nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- Temporarily install the control shaft lever.
- Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
- Remove the control shaft lever.
- Align the groove with the neutral basic line.
- Hold the switch in this position and tighten the 2 bolts.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
- Using a screwdriver, stake the nut with the lock plate.
- Install the control shaft lever with the washer and nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)