AUTOMATIC TRANSAXLE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Check each bearing position and installation direction.

B001O99E01
B001OILE01
Mark

Front Race Diameter

Inside / Outside (mm (in.))

Thrust Bearing Diameter

Inside / Outside (mm (in.))

Rear Race Diameter

Inside / Outside (mm (in.))
A - 57.7 (2.27) / 75.2 (2.96) -
B - 29.1 (1.15) / 48.6 (1.91) 30.7 (1.21) / 48.3 (1.90)
C - 62.6 (2.46) / 82.4 (3.24) 65.9 (2.59) / 82.3 (3.24)
D 59.4 (2.34) / 76 (2.99) 53.46 (2.10) / 79 (3.11) -
E - 56.1 (2.21) / 81.1 (3.19) -
F - 61.2 (2.41) / 79 (3.11) -
G - 28 (1.10) / 47.1 (1.85) 26.1 (1.03) / 44 (1.73)
H 52.2 (2.06) / 70.4 (2.77) 48.9 (1.93) / 72.0 (2.83) -

PROCEDURE


  1. INSTALL COUNTER DRIVE GEAR BEARING

    Note

    Perform this procedure only when replacement of the counter drive gear bearing or transaxle case sub-assembly is necessary.


    1. B001ON2E04

      Using SST and a press, install a new counter drive gear bearing (outer race) and snap ring to the transaxle case sub-assembly.

      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07100 )

  2. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)


    1. B001O8ZE08

      Using SST and a hammer, install a new front differential case rear tapered roller bearing (outer race) to the transaxle case sub-assembly.

      SST
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07150 )

      Note

      Make sure to install the front differential case rear tapered roller bearing (outer race) so that there is no clearance between the front differential case rear tapered roller bearing (outer race) and transaxle case sub-assembly.

  3. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)


    1. Install the shim to the transaxle housing.

    2. B001OKDE07

      Using SST and a hammer, install a new front differential case front tapered roller bearing (outer race) to the transaxle housing.

      SST
      09950-60020   ( 09951-00790 )
      09950-70010   ( 09951-07150 )

      Note

      Make sure to install the front differential case front tapered roller bearing (outer race) so that there is no clearance between the front differential case front tapered roller bearing (outer race), shim and transaxle housing.

  4. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (INNER RACE)


    1. B001NZGE02

      Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the front differential case.

      SST
      09726-36010
      09950-70010   ( 09951-07100 )

      Note


      • Do not damage the front differential case rear tapered roller bearing (inner race) cage when installing the front differential case rear tapered roller bearing (inner race).

      • Make sure to install the front differential case rear tapered roller bearing (inner race) so that there is no clearance between the front differential case rear tapered roller bearing (inner race) and front differential case.

  5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (INNER RACE)


    1. B001NYME02

      Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the front differential case.

      SST
      09523-36010
      09950-60010   ( 09951-00540 )
      09950-70010   ( 09951-07100 )

      Note


      • Do not damage the front differential case front tapered roller bearing (inner race) cage when installing the front differential case front tapered roller bearing (inner race).

      • Make sure to install the front differential case front tapered roller bearing (inner race) so that there is no clearance between the front differential case front tapered roller bearing (inner race) and front differential case.

  6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case sub-assembly.

    2. A01W44J

      Install the front differential case to the transaxle case sub-assembly.

    3. B001NYEE01

      Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.

      Torque:
      Bolt (A)
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    4. B001OMLE04

      Using SST, turn the front differential case right and left 2 or 3 times to settle the bearings.

      SST
      09564-33010

    5. Using SST and a torque wrench, measure the turning torque of the differential side bearings while rotating SST at 10 rpm.

      SST
      09564-33010
      Turning Torque
      1.3 to 1.7 N*m (13 to 17 kgf*cm, 12 to 15 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim for the front differential case front tapered roller bearing (outer race) so that the turning torque is within the specified range.

      Shim Thickness
      Part No.

      Thickness

      (mm (in.))
      90564-69001 2.000 (0.0787)
      90564-69002 2.025 (0.0797)
      90564-69003 2.050 (0.0807)
      90564-69004 2.075 (0.0817)
      90564-69005 2.100 (0.0827)
      90564-69006 2.125 (0.0837)
      90564-69007 2.150 (0.0846)
      90564-69008 2.175 (0.0856)
      90564-69009 2.200 (0.0866)
      90564-69010 2.225 (0.0876)
      90564-69011 2.250 (0.0886)
      90564-69012 2.275 (0.0896)
      90564-69013 2.300 (0.0906)
      90564-69014 2.325 (0.0915)
      90564-69015 2.350 (0.0925)
      90564-69016 2.375 (0.0935)
      90564-69017 2.400 (0.0945)
      90564-69020 2.425 (0.0955)
      90564-69021 2.450 (0.0965)
      90564-69022 2.475 (0.0974)
      90564-69023 2.500 (0.0984)
      90564-69024 2.525 (0.0994)
      90564-69025 2.550 (0.100)
      90564-69026 2.575 (0.101)
      90564-69027 2.600 (0.102)
      90564-69028 2.625 (0.103)
      90564-69029 2.650 (0.104)
      90564-69030 2.675 (0.105)
      90564-69031 2.700 (0.106)
      90564-69032 2.725 (0.107)
      90564-69033 2.750 (0.108)
      90564-69034 2.775 (0.109)
      90564-69035 2.800 (0.110)
      90564-69036 2.825 (0.111)
      90564-69037 2.850 (0.112)
      90564-69038 2.875 (0.113)

    6. Remove the 20 bolts and transaxle housing from the transaxle case sub-assembly.

    7. Remove the front differential case from the transaxle case sub-assembly.

  7. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)


    1. B001OGLE01

      Using SST and a hammer, install a new differential drive pinion tapered roller bearing LH (outer race) to the transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00630 )
      09950-70010   ( 09951-07100 )

      Note

      Make sure to install the differential drive pinion tapered roller bearing LH (outer race) so that there is no clearance between the differential drive pinion tapered roller bearing LH (outer race) and transaxle case sub-assembly. If there is any clearance, the turning torque of the counter driven gear cannot be measured correctly.

  8. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (OUTER RACE)


    1. B001NY3E07

      Install the shim to the transaxle housing.

    2. Using SST, install a new differential drive pinion tapered roller bearing RH (outer race) to the transaxle housing.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

      Note

      Make sure to install the differential drive pinion tapered roller bearing RH (outer race) so that there is no clearance between the differential drive pinion tapered roller bearing RH (outer race), shim and transaxle housing. If there is any clearance, the turning torque of the counter driven gear cannot be measured correctly.

  9. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (INNER RACE)


    1. B001OR1E01

      Using SST and a press, install a new differential drive pinion tapered roller bearing LH (inner race) to the counter driven gear.

      SST
      09950-60010   ( 09951-00400 )

      Note

      Make sure to install the differential drive pinion tapered roller bearing LH (inner race) so that there is no clearance between the differential drive pinion tapered roller bearing LH (inner race) and counter driven gear. If there is any clearance, the turning torque of the counter driven gear cannot be measured correctly.

  10. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (INNER RACE)


    1. B001OQZE01

      Using SST and a press, install a new differential drive pinion tapered roller bearing RH (inner race) to the counter driven gear.

      SST
      09950-60010   ( 09951-00490 )

      Note

      Make sure to install the differential drive pinion tapered roller bearing RH (inner race) so that there is no clearance between the differential drive pinion tapered roller bearing RH (inner race) and counter driven gear. If there is any clearance, the turning torque of the counter driven gear cannot be measured correctly.

  11. ADJUST COUNTER DRIVEN GEAR PRELOAD


    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case sub-assembly.

    2. B001OED

      Install the counter driven gear to the transaxle case sub-assembly.

    3. B001NMQ

      Install the front differential case to the transaxle case sub-assembly.

    4. B001NYEE01

      Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.

      Torque:
      Bolt (A)
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    5. B001NZNE01

      Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm.

      SST
      09564-33010
      Turning Torque
      Differential side bearing preload + 2.9 to 6.1 N*m (30 to 62 kgf*cm, 26 to 54 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim for the differential drive pinion tapered roller bearing RH (outer race) so that the turning torque is within the specified range.

      Shim Thickness
      Part No.

      Thickness

      (mm (in.))
      90564-61022 2.000 (0.0787)
      90564-61023 2.025 (0.0797)
      90564-61024 2.050 (0.0807)
      90564-61025 2.075 (0.0817)
      90564-61026 2.100 (0.0827)
      90564-61027 2.125 (0.0837)
      90564-61028 2.150 (0.0846)
      90564-61029 2.175 (0.0856)
      90564-61030 2.200 (0.0866)
      90564-61031 2.225 (0.0876)
      90564-61032 2.250 (0.0886)
      90564-61033 2.275 (0.0896)
      90564-61034 2.300 (0.0906)
      90564-61035 2.325 (0.0915)
      90564-61036 2.350 (0.0925)
      90564-61037 2.375 (0.0935)
      90564-61038 2.400 (0.0945)
      90564-61039 2.425 (0.0955)
      90564-61040 2.450 (0.0965)
      90564-61041 2.475 (0.0974)
      90564-61042 2.500 (0.0984)
      90564-61043 2.525 (0.0994)
      90564-61044 2.550 (0.100)
      90564-61045 2.575 (0.101)
      90564-61046 2.600 (0.102)
      90564-61047 2.625 (0.103)
      90564-61048 2.650 (0.104)
      90564-69049 2.675 (0.105)
      90564-61050 2.700 (0.106)
      90564-61051 2.725 (0.107)
      90564-61052 2.750 (0.108)
      90564-61053 2.775 (0.109)
      90564-61054 2.800 (0.110)
      90564-61055 2.825 (0.111)
      90564-61056 2.850 (0.112)
      90564-61057 2.875 (0.113)
      90564-61058 2.900 (0.114)
      90564-61059 2.925 (0.115)
      90564-61060 2.950 (0.116)
      90564-61061 2.975 (0.117)
      90564-61062 3.000 (0.118)

    6. Remove the 20 bolts and transaxle housing from the transaxle case sub-assembly.

    7. Remove the front differential case from the transaxle case sub-assembly.

    8. Remove the counter driven gear from the transaxle case sub-assembly.

  12. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B001NV6E10
      Text in Illustration
      *a Depth

      Coat the lip of a new manual valve lever shaft oil seal with a small amount of MP grease.

    2. Using SST and a hammer, install the manual valve lever shaft oil seal to the transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00230 )
      09950-70010   ( 09951-07100 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note

      Make sure the manual valve lever shaft oil seal is installed in the correct direction.

  13. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B001ODM

      Install the manual valve lever shaft sub-assembly to the transaxle case sub-assembly.

      Note

      Do not damage the manual valve lever shaft oil seal when installing the manual valve lever shaft sub-assembly to the transaxle case sub-assembly.

    2. A01W5HC

      Using needle-nose pliers, install the manual valve lever shaft retainer spring to the manual valve lever shaft sub-assembly.

  14. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01W4CX

      Align the protrusions on the parking lock rod sub-assembly with the notches on the manual valve lever shaft sub-assembly and install the parking lock rod sub-assembly.

  15. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01W3II

      Install the manual detent spring sub-assembly and manual detent spring cover to the transaxle case sub-assembly with the bolt.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

      Note

      Make sure to install the manual detent spring sub-assembly first and then the manual detent spring cover.

  16. INSTALL NO. 3 BRAKE PISTON


    1. B001OFWE02
      Text in Illustration
      *1 O-ring

      Coat 2 new O-rings with ATF and install them to the No. 3 brake piston.

      Note

      Ensure that the 2 O-rings are not twisted.

    2. B001OBME01
      Text in Illustration
      *1 No. 3 Brake Piston

      Temporarily install the No. 3 brake piston to the transaxle case sub-assembly.

    3. B001OHJE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

      Temporarily install the pawl stopper plate to the transaxle case sub-assembly with the 2 bolts.

      Note

      After installing, make sure that the protrusions on the No. 3 brake piston and grooves on the pawl stopper plate are aligned.

    4. Press the No. 3 brake piston into the transaxle case sub-assembly.

      Note

      Make sure that the O-rings of the No. 3 brake piston are not twisted or caught on the transaxle case sub-assembly.

      Tech Tips

      Use the installation surface of the No. 3 brake piston return spring sub-assembly to press the No. 3 brake piston into the transaxle case sub-assembly.

    5. Remove the 2 bolts and pawl stopper plate from the transaxle case sub-assembly.

    6. B001OF8E02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 No. 3 Brake Piston Return Spring Sub-assembly

      Install the No. 3 brake piston return spring sub-assembly to the transaxle case sub-assembly.

      Note

      Install the No. 3 brake piston return spring sub-assembly as shown in the illustration.

    7. Place SST on the No. 3 brake piston return spring sub-assembly and compress the No. 3 brake piston return spring sub-assembly with a press.

      B001OEIE02
      Text in Illustration
      *1 Snap Ring - -
      *a Protective Tape - -
      SST
      09387-00070

      Note

      Stop the press when the No. 3 brake piston return spring sub-assembly is flush with the snap ring groove. This prevents the No. 3 brake piston return spring sub-assembly from being deformed.

    8. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the transaxle case sub-assembly as shown in the illustration.

      Note


      • Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.

      • Be sure to orient the snap ring so that the edges do not protrude into a cutout on the No. 3 brake piston return spring sub-assembly as shown in the illustration.

  17. INSTALL COUNTER DRIVE GEAR


    1. B001OJNE02

      Using SST and a press, install a new counter drive gear bearing inner race (front side) to the counter drive gear.

      SST
      09387-00020

      Note

      Make sure to install the counter drive gear bearing inner race (front side) so that there is no clearance between the counter drive gear bearing inner race (front side) and counter drive gear.

    2. Install 2 new counter drive gear bearings (balls and cage) to the counter drive gear bearing (outer race).

    3. B001OJSE02

      Using SST, install the counter drive gear with counter drive gear bearing inner race (front side) and a new counter drive gear bearing inner race (rear side) to the transaxle case sub-assembly.

      SST
      09223-15030
      09527-17011
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07100 )

  18. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B001NNAE02

      Using SST and a press, install a new front planetary gear assembly to the transaxle case sub-assembly.

      SST
      09223-15030
      09527-17011
      09951-01100

  19. INSTALL NO. 2 BRAKE PISTON


    1. B001NRBE01
      Text in Illustration
      *1 O-ring

      Coat 2 new O-rings with ATF and install them to the No. 2 brake piston.

      Note

      Ensure that the 2 O-rings are not twisted.

    2. B001OCA

      Install the No. 2 brake piston to the transaxle case sub-assembly.

      Note

      Be careful not to damage the 2 O-rings.

  20. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. B001O7M

      Install the 1st and reverse brake return spring sub-assembly to the transaxle case sub-assembly.

    2. Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring sub-assembly with a press.

      B001OOPE02
      Text in Illustration
      *a Protective Tape *b Snap Ring End Position
      SST
      09387-00060

      Note

      Stop the press when the 1st and reverse brake return spring sub-assembly is flush with the snap ring groove. This prevents the 1st and reverse brake return spring sub-assembly from being deformed.

    3. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the transaxle case sub-assembly as shown in the illustration.

      Note


      • Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.

      • Be sure to orient the snap ring so that the edges do not protrude into one of the cutouts on the transaxle case sub-assembly as shown in the illustration.

      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

  21. INSTALL NO. 2 BRAKE DISC


    1. B001OBHE01
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

      Install the 4 No. 2 brake discs, 4 No. 2 brake plates and No. 2 brake flange to the transaxle case sub-assembly.

      Note

      Make sure that the No. 2 brake discs, No. 2 brake plates and No. 2 brake flange are installed in the correct order.

    2. B001OA8E02
      Text in Illustration
      *a Protective Tape
      *b Snap Ring End Position

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the transaxle case sub-assembly.

      Note


      • Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.

      • Be sure to orient the snap ring so that the edges do not protrude into one of the cutouts on the transaxle case sub-assembly as shown in the illustration.

      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

  22. INSPECT CLEARANCE OF NO. 2 BRAKE PISTON

    Click here

  23. INSTALL PLANETARY RING GEAR FLANGE


    1. B001OM5E06
      Text in Illustration
      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 Planetary Ring Gear

      Install the planetary ring gear flange to the planetary ring gear.

    2. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the planetary ring gear.

      Note

      Confirm that the snap ring is correctly located in the groove of the planetary ring gear.

  24. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. B001OPOE05
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

      Install the outer race retainer to the one-way clutch assembly.

    2. Install the one-way clutch assembly to the planetary ring gear.

      Note

      Make sure that the one-way clutch assembly is installed in the correct direction as shown in the illustration.

    3. B001OA7E06
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 One-way Clutch Assembly
      *3 Outer Race Retainer
      *4 Transaxle Case Sub-assembly

      Coat the thrust needle roller bearing with ATF and install it to the front planetary gear assembly.

      Thrust Needle Roller Bearing Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 56.1 (2.21) 81.1 (3.19)

      Note

      Be sure to install the thrust needle roller bearing so that the temper colored side of the race is visible.

    4. Install the one-way clutch assembly with planetary ring gear to the transaxle case sub-assembly.

      Note


      • Make sure that there is no clearance between the outer race retainer and claw on the one-way clutch assembly. If there is any clearance, the spring of the outer race retainer will be deformed.

      • Ensure that there is no clearance between the one-way clutch assembly and transaxle case sub-assembly.

    5. B001O4AE02
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the transaxle case sub-assembly.

      Note


      • Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.

      • Be sure to orient the snap ring so that the edges do not protrude into one of the cutouts on the transaxle case sub-assembly as shown in the illustration.

  25. INSTALL PARKING LOCK PAWL


    1. B001NMUE02
      Text in Illustration
      *1 Parking Lock Pawl Pin
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 Parking Lock Pawl

      Install the parking lock pawl to the transaxle case sub-assembly with the parking lock pawl shaft.

    2. Install the parking lock pawl pin to the transaxle case sub-assembly.

    3. B001O8C

      Install the spring to the parking lock pawl pin.

      Note

      Make sure that one end of the spring is secured in the hole of the transaxle case sub-assembly and the other end is positioned on the parking lock pawl as shown in the illustration.

  26. INSTALL PARKING LOCK SLEEVE


    1. A01VZXW

      Install the parking lock sleeve to the transaxle case sub-assembly.

  27. INSTALL PAWL STOPPER PLATE


    1. A01W3ES

      Install the pawl stopper plate to the transaxle case sub-assembly with the 2 bolts.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

  28. INSTALL NO. 1 TRANSMISSION CASE PLATE


    1. Clean and degrease the bolt and installation hole in the transaxle case sub-assembly.

    2. B001NSBE38
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the end of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

    3. B001NWZE05

      Install the No. 1 transmission case plate to the transaxle case sub-assembly with the bolt.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Tighten the bolt with the part (A) of the No. 1 transmission case plate contacting the transaxle case sub-assembly as shown in the illustration.

  29. INSTALL PAWL SHAFT CLAMP


    1. A01W552

      Install the pawl shaft clamp to the transaxle case sub-assembly with the bolt.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

  30. INSTALL COUNTER DRIVEN GEAR


    1. A01W27A

      Install the counter driven gear to the transaxle case sub-assembly.

  31. INSTALL COUNTER DRIVE GEAR NUT


    1. B001OG8E04

      Turn the manual valve lever shaft sub-assembly counterclockwise to set it to the P position as shown in the illustration.

    2. B001OIZE01

      Using SST, install a new counter drive gear nut to the front planetary gear assembly.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. B001OFVE01

      Turn the manual valve lever shaft sub-assembly 2 notches clockwise to set it to the N position as shown in the illustration.

    4. Remove the counter driven gear from the transaxle case sub-assembly.

    5. B001OJ3E02

      Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm.

      SST
      09387-00130
      Turning Torque
      0.1 to 0.8 N*m (1 to 8 kgf*cm, 1 to 7 in.*lbf)

      • If the measured value is less than the specified range, gradually tighten the counter drive gear nut until the turning torque falls within the specified range.

      • If the measured value is greater than the specified range, loosen the counter drive gear nut and then tighten it gradually until the turning torque falls within the specified range.

      Maximum Torque
      180 N*m (1835 kgf*cm, 133 ft.*lbf)
    6. B001OJCE04

      Using SST and a hammer, stake the front planetary gear assembly.

      SST
      09930-00010

    7. Install the counter driven gear to the transaxle case sub-assembly.

  32. INSTALL FRONT DIFFERENTIAL CASE


    1. A01VZXX

      Install the front differential case to the transaxle case sub-assembly.

  33. INSTALL NO. 1 BRAKE PISTON


    1. B001O8ME01
      Text in Illustration
      *1 O-ring

      Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A01VZNS

      Install the No. 1 brake piston to the front oil pump assembly.

      Note

      Be careful not to damage the 2 O-rings.

  34. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A01W125

      Install the 3 2nd brake piston return spring sub-assemblies to the front oil pump assembly.

      Note

      Make sure that the 3 2nd brake piston return spring sub-assemblies are installed to the protrusions on the front oil pump assembly.

  35. INSTALL NO. 1 BRAKE DISC


    1. B001OCSE01
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

      Install the 3 No. 1 brake discs, 3 No. 1 brake plates and No. 1 brake flange to the front oil pump assembly.

      Note


      • Make sure that the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are installed in the correct order.

      • Be sure to install the No. 1 brake flange in the correct direction.

    2. Place SST on the No. 1 brake flange and compress the No. 1 brake flange with a press.

      SST
      09387-00070
      09495-65040

      Note

      Stop the press when the 2nd brake piston return spring sub-assemblies are flush with the snap ring groove. This prevents the 2nd brake piston return spring sub-assemblies from being deformed.

    3. B001OK6E02
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front oil pump assembly as shown in the illustration.

      Note


      • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.

      • Make sure to align the protruding part of the snap ring with the cutout (#1) of the front oil pump assembly shown in the illustration to install the snap ring.

    4. A01W0PV

      Install the brake snap ring stopper to the front oil pump assembly.

      Note

      Be sure to install the brake snap ring stopper in the correct direction.

    5. B001O1ME03

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front oil pump assembly as shown in the illustration.

      Note


      • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.

      • Make sure to align the protruding part of the snap ring with the cutout (#2) of the front oil pump assembly shown in the illustration to install the snap ring.

    6. B001OARE03
      Text in Illustration
      *1 Brake Snap Ring Stopper
      *2 Snap Ring
      *a Correctly installed

      Check that the brake snap ring stopper can be turned by hand.

      Note

      If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or a snap ring may not have been completely located in the groove on the front oil pump assembly. Remove and reinstall the snap ring and brake snap ring stopper.

  36. INSPECT CLEARANCE OF NO. 1 BRAKE PISTON

    Click here

  37. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. B001ONNE01
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

      Coat the thrust needle roller bearing with ATF and install it to the front oil pump assembly.

      Thrust Needle Roller Bearing Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 57.7 (2.27) 75.2 (2.96)

      Note

      Be sure to install the thrust needle roller bearing so that the temper colored side of the race is visible.

    2. Install the underdrive planetary sun gear to the front oil pump assembly.

  38. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. B001OLPE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Sub-assembly
      *4 Oil Seal Ring

      Coat 3 new oil seal rings with ATF and install them to the input shaft sub-assembly.

      Note

      Do not expand the gap of the oil seal ring excessively.

    2. Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the input shaft sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 29.1 (1.15) 48.6 (1.91)
      Thrust bearing race 30.7 (1.21) 48.3 (1.90)

      Note

      Be sure to install the thrust needle roller bearing in the correct direction.

    3. A01W4MG

      Install the input shaft sub-assembly to the front oil pump assembly.

  39. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B001OPXE06
      Text in Illustration
      *1 Planetary Sun Gear Sub-assembly
      *2 Underdrive Planetary Gear Assembly
      *3 Snap Ring

      Using a snap ring expander, install the snap ring to the underdrive planetary gear assembly.

    2. Using a snap ring expander, install the planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded.

  40. INSTALL UNDERDRIVE PLANETARY RING GEAR

    Tech Tips

    Perform this procedure only when replacement of the underdrive planetary ring gear or No. 3 brake hub is necessary.


    1. A01W529

      Install the snap ring to the underdrive planetary ring gear.

    2. B001NMZE02
      Text in Illustration
      *a Protective Tape

      While compressing the snap ring with a screwdriver with its tip wrapped with protective tape, install the underdrive planetary ring gear to the No. 3 brake hub.

      Note

      Confirm that the snap ring is correctly located in the groove of the No. 3 brake hub.

  41. INSTALL NO. 3 BRAKE HUB


    1. B001O0EE09
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the underdrive planetary gear assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 62.6 (2.46) 82.4 (3.24)
      Thrust bearing race 65.9 (2.59) 82.3 (3.24)

      Note

      Be sure to install the thrust needle roller bearing so that the temper colored side of the race is visible.

    2. B001OAJ

      Install the No. 3 brake hub to the underdrive planetary gear assembly.

  42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01W4WB

      Install the underdrive planetary gear assembly to the front oil pump assembly.

  43. INSTALL NO. 3 BRAKE DISC


    1. B001OQJE01
      Text in Illustration
      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc

      Install the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates to the front oil pump assembly.

      Note

      Make sure that the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are installed in the correct order.

    2. B001NZIE03

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front oil pump assembly.

      Note


      • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.

      • Make sure that the snap ring ends are positioned as shown in the illustration (A).

  44. INSPECT CLEARANCE OF NO. 3 BRAKE PISTON

    Click here

  45. INSTALL FRONT OIL PUMP ASSEMBLY


    1. B001OABE04
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 O-ring

      Coat a new O-ring with ATF and install it to the transaxle case sub-assembly.

    2. Coat the thrust needle roller bearing with ATF.

    3. Install the thrust needle roller bearing to the counter drive gear nut.

      Thrust Needle Roller Bearing Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 53.46 (2.10) 79 (3.11)

      Note

      Be sure to install the thrust needle roller bearing so that the temper colored side of the race is visible.

    4. Coat the thrust bearing race with MP grease.

    5. B001NRME01
      Text in Illustration
      *1 Thrust Bearing Race

      Install the thrust bearing race to the underdrive planetary gear assembly.

      Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust bearing race 59.4 (2.34) 76 (2.99)
    6. A01W4Q0

      Coat a new front oil pump body O-ring with ATF and install it to the front oil pump body sub-assembly.

      Note

      Make sure that the front oil pump body O-ring is installed correctly with the identification line facing outward and check that it is not twisted, protruding or damaged.

    7. B001O30E06
      Text in Illustration
      *1 Gasket

      Install the front oil pump assembly to the transaxle case sub-assembly with the 7 bolts.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

    8. Coat a new gasket with ATF and install it to the front oil pump assembly.

  46. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. Clean and degrease the 3 bolts and installation holes in the transaxle housing.

    2. B001NSBE38
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 3 bolts, apply adhesive to the 3 bolts and install them within 10 minutes of adhesive application.

    3. A01W3GH

      Install the transaxle housing oil separator to the transaxle housing with the 3 bolts.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

  47. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. Clean and degrease the bolt and installation hole in the transaxle housing.

    2. B001NSBE38
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the end of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

    3. A01W55E

      Install the differential gear lube apply tube to the transaxle housing.

      Note

      Insert the differential gear lube apply tube into the transaxle housing until it makes contact with the stopper.

    4. Install the clamp to the transaxle housing with the bolt.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

      Note

      There should be clearance between the differential gear lube apply tube and clamp.

  48. INSTALL TRANSAXLE HOUSING


    1. A01W0JO

      Clean and degrease the 3 bolts and installation holes in the transaxle case sub-assembly.

    2. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case sub-assembly.

      Note

      Make sure that there is no ATF on the contact surfaces.

    3. B001O9IE01
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case sub-assembly.

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

      Note


      • Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface of the transaxle case sub-assembly.

      • After applying FIPG, install the transaxle housing to the transaxle case sub-assembly within 3 minutes and tighten the bolts within 20 minutes.

    4. A01W0L5

      Install the transaxle housing to the transaxle case sub-assembly with the 17 bolts.

      Torque:
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
    5. B001NSBE38
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 3 bolts, apply adhesive to the 3 bolts and install them within 10 minutes of adhesive application.

    6. A01W2K0

      Install the 3 bolts.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

  49. INSPECT CLEARANCE OF NO. 1 CLUTCH

    Click here

  50. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. B001O8BE07
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

      Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the rear multiple disc clutch assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 28 (1.10) 47.1 (1.85)
      Thrust bearing race 26.1 (1.03) 44 (1.73)

      Note

      Be sure to install the thrust needle roller bearing so that the temper colored side of the race is visible.

    2. B001O0BE02
      Text in Illustration
      *1 Rear Planetary Sun Gear Assembly

      Install the rear planetary sun gear assembly to the rear multiple disc clutch assembly.

    3. B001O0ZE02
      Text in Illustration
      *1 Snap Ring

      Using a brass bar and a hammer, install the snap ring to the rear multiple disc clutch assembly.

      Tech Tips

      Use a piece of cloth to keep the snap ring from flying off.

  51. INSPECT CLEARANCE OF NO. 2 CLUTCH

    Click here

  52. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY


    1. B001OCGE05
      Text in Illustration
      *1 O-ring
      *2 Oil Seal Ring

      Coat a new O-ring with ATF and install it to the rear multiple disc clutch assembly.

      Note

      Ensure that the O-ring is not twisted.

    2. Coat a new oil seal ring with ATF and install it to the rear multiple disc clutch assembly.

    3. B001NRUE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Multiple Disc Clutch Assembly

      Coat the thrust needle roller bearing with ATF and install it to the transaxle case sub-assembly.

      Thrust Needle Roller Bearing Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 61.2 (2.41) 79 (3.11)

    4. Install the rear multiple disc clutch assembly to the transaxle case sub-assembly.

  53. INSPECT INTERMEDIATE SHAFT END PLAY

    Click here

  54. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. B001OL5E06
      Text in Illustration
      *a Depth

      Using SST and a hammer, install a new needle roller bearing to the rear transaxle cover sub-assembly.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Standard Depth
      21.5 to 21.9 mm (0.846 to 0.862 in.)

    2. Clean and degrease the 2 "TORX" screws and installation holes in the rear transaxle cover sub-assembly.

    3. B001OM9E02
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 2 "TORX" screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 2 "TORX" screws, apply adhesive to the 2 "TORX" screws and install them within 10 minutes of adhesive application.

    4. A01W1ZY

      Using a T30 "TORX" socket wrench, install the rear transaxle cover plate to the rear transaxle cover sub-assembly with the 2 "TORX" screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. B001OKHE01
      Text in Illustration
      *1 Oil Seal Ring

      Coat 2 new oil seal rings with ATF and install them to the rear transaxle cover sub-assembly.

      Note

      Confirm that the 2 oil seal rings are correctly located in the grooves of the rear transaxle cover sub-assembly.

    6. B001OIVE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

      Coat the thrust needle roller bearing and thrust bearing race with MP grease and install them to the rear transaxle cover sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 48.9 (1.93) 72.0 (2.83)
      Thrust bearing race 52.2 (2.06) 70.4 (2.77)
    7. A01W393

      Coat 3 new O-rings with ATF and install them to the transaxle case sub-assembly.

    8. A01W4IL

      Clean and degrease the 2 bolts and installation holes in the transaxle case sub-assembly.

    9. Remove any remaining seal packing from the contact surfaces of the rear transaxle cover sub-assembly and transaxle case sub-assembly.

      Note

      Make sure that there is no ATF on the contact surfaces.

    10. B001OQKE07
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case sub-assembly.

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

      Note


      • Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface of the transaxle case sub-assembly.

      • After applying FIPG, install the rear transaxle cover sub-assembly to the transaxle case sub-assembly within 3 minutes and tighten the bolts within 20 minutes.

    11. A01VZWD

      Install the rear transaxle cover sub-assembly to the transaxle case sub-assembly with the 12 bolts.

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    12. B001NSBE38
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 2 bolts, apply adhesive to the 2 bolts and install them within 10 minutes of adhesive application.

    13. A01W19J

      Install the 2 bolts.

      Torque:
      17 N*m  { 172 kgf*cm, 12 ft.*lbf }

  55. INSTALL REAR TRANSAXLE COVER PLUG


    1. A01W5OK

      Coat 3 new O-rings with ATF and install them to the 3 rear transaxle cover plugs.

      Note

      Ensure that the 3 O-rings are not twisted.

    2. Install the 3 rear transaxle cover plugs to the rear transaxle cover sub-assembly.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }

  56. INSTALL REFILL PLUG


    1. B001NQH

      Install a new gasket to the refill plug.

    2. Install the refill plug to the rear transaxle cover sub-assembly.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  57. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY

    Click here

  58. INSTALL NO. 1 CHECK VALVE SUB-ASSEMBLY


    1. A01W1NH

      Install the No. 1 check valve sub-assembly to the transaxle case sub-assembly.

      Note

      Be sure to install the No. 1 check valve sub-assembly in the correct direction.

  59. INSTALL TRANSAXLE CASE GASKET


    1. A01W3K0

      Coat 2 new transaxle case gaskets with ATF.

    2. Install the 2 transaxle case gaskets to the transaxle case sub-assembly.

  60. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. Coat the O-ring of the transmission wire with ATF.

    2. B001OCUE02
      Text in Illustration
      *1 Manual Valve Lever Shaft Sub-assembly Pin
      *2 Manual Valve
      *a Positioning Bolt

      Insert the manual valve lever shaft sub-assembly pin into the groove on the end of the manual valve as shown in the illustration and temporarily install the transmission valve body assembly to the transaxle case sub-assembly with the 11 bolts.

      Bolt Length
      Bolt

      Bolt Length

      (mm (in.))
      (A) 25 (0.984)
      (B) 30 (1.18)
      (C) and (D) 35 (1.38)

      Note


      • When installing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and transaxle case sub-assembly to interfere with each other.

      • Be sure to insert the pin of the manual valve lever shaft sub-assembly pin into the groove on the end of the manual valve.

    3. Fully tighten the 2 positioning bolts shown in the illustration.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    4. Fully tighten the 9 bolts to install the transmission valve body assembly.

      Torque:
      Bolt (A), (B), (C)
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }
      Bolt (D)
      9.6 N*m  { 98 kgf*cm, 85 in.*lbf }

  61. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. B001NRGE01
      Text in Illustration
      *1 O-ring

      Coat a new O-ring with ATF.

    2. Install the O-ring to the valve body oil strainer assembly.

      Note

      Ensure that the O-ring is not twisted.

    3. A01W1F5

      Install the valve body oil strainer assembly to the transmission valve body assembly with the 2 bolts.

      Torque:
      9.6 N*m  { 98 kgf*cm, 85 in.*lbf }

  62. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. B001NQSE01
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

      Install the 4 transmission oil cleaner magnets to the automatic transaxle oil pan sub-assembly as shown in the illustration.

  63. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET


    1. Install a new automatic transaxle oil pan gasket to the automatic transaxle oil pan sub-assembly.

  64. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01W596

      Clean and degrease the 2 bolts and installation holes in the transaxle case sub-assembly.

    2. A01W570

      Install the automatic transaxle oil pan sub-assembly with automatic transaxle oil pan gasket to the transaxle case sub-assembly with the 17 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note

      Completely remove any oil or grease from the contact surfaces of the transaxle case sub-assembly and automatic transaxle oil pan sub-assembly with automatic transaxle oil pan gasket before installation.

    3. B001NSBE38
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 2 bolts, apply adhesive to the 2 bolts and install them within 10 minutes of adhesive application.

    4. A01W0TV

      Install the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  65. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE


    1. A01W0UX

      Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle oil pan sub-assembly.

      Torque:
      0.8 N*m  { 8 kgf*cm, 7 in.*lbf }

  66. INSTALL OVERFLOW PLUG


    1. A01W0A7

      Using a 6 mm hexagon socket wrench, install the overflow plug and a new gasket to the automatic transaxle oil pan sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  67. INSTALL TRANSAXLE CASE OIL SEAL


    1. Coat the lip of a new transaxle case oil seal with MP grease.

    2. B001OJ1E06
      Text in Illustration
      *a Depth

      Using SST and a hammer, install the transaxle case oil seal to the transaxle case sub-assembly.

      SST
      09316-10010
      09950-70010   ( 09951-07100 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note


      • Make sure that the transaxle case oil seal is installed in the correct direction.

      • Do not damage the lip of the transaxle case oil seal.

  68. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. Coat the lip of a new front transaxle case oil seal with MP grease.

    2. B001NUSE03
      Text in Illustration
      *a Depth

      Using SST and a hammer, install the front transaxle case oil seal to the transaxle housing.

      SST
      09316-60011   ( 09316-00011 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note


      • Make sure that the front transaxle case oil seal is installed in the correct direction.

      • Do not damage the lip of the front transaxle case oil seal.

  69. INSTALL NO. 2 TRANSAXLE CASE PLUG


    1. Clean and degrease the 3 No. 2 transaxle case plugs and installation holes in the transaxle housing.

    2. Install 3 new gaskets to the 3 No. 2 transaxle case plugs.

    3. B001NU0E01
      Text in Illustration
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 3 No. 2 transaxle case plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 3 No. 2 transaxle case plugs, apply adhesive to the 3 No. 2 transaxle case plugs and install them within 10 minutes of adhesive application.

    4. A01W1AS

      Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs to the transaxle housing.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  70. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A01W2KB

      Coat 3 new O-rings with ATF and install them to the 3 No. 1 transaxle case plugs.

      Note

      Ensure that the 3 O-rings are not twisted.

    2. Install the 3 No. 1 transaxle case plugs to the transaxle case sub-assembly.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }

  71. INSTALL OIL COOLER INLET ELBOW


    1. Coat a new O-ring with ATF and install it to the oil cooler inlet elbow.

      Note

      Ensure that the O-ring is not twisted.

    2. B001OMJE02
      Text in Illustration
      *a Turn
      *b Hold
      *c 20 to 24°
      *d Torque Wrench Fulcrum Length

      Using SST, install the oil cooler inlet elbow to the transaxle case sub-assembly so that it is positioned as shown in the illustration.

      SST
      09922-10010
      Torque
      Specified tightening torque
      27 N*m (275 kgf*cm, 20 ft.*lbf)

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here

      • When using SST (fulcrum length of 137 mm (5.39 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 15 N*m (156 kgf*cm, 11 ft.*lbf)

  72. INSTALL OIL COOLER UNION SUB-ASSEMBLY


    1. B001ON9E02
      Text in Illustration
      *1 Union Bolt
      *2 Gasket

      Temporarily install the oil cooler union sub-assembly to the transaxle case sub-assembly with the bolt.

    2. Install the union bolt and 2 new gaskets to the transaxle case sub-assembly as shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

    3. Tighten the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  73. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B001NUW

      Temporarily install the park/neutral position switch assembly to the transaxle case sub-assembly with the 2 bolts.

      Note

      Before installing the park/neutral position switch assembly, remove any dirt or rust on the manual valve lever shaft sub-assembly. Be sure to install the park/neutral position switch assembly straight along the manual valve lever shaft sub-assembly while being careful not to deform the plate spring that supports the manual valve lever shaft sub-assembly. If the plate spring is deformed, the park/neutral position switch assembly cannot be reinstalled correctly.

    2. B001O9NE17
      Text in Illustration
      *a Protrusion

      Align the protrusions of the park/neutral position switch assembly as shown in the illustration.

    3. Tighten the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Note

      After installing the park/neutral position switch assembly, confirm that the 2 protrusions on the park/neutral position switch assembly are aligned.

  74. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. B001OEQ

      Install the transmission control shaft lever to the manual valve lever shaft sub-assembly with the washer and nut.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  75. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B001NXQE11
      Text in Illustration
      *1 No. 1 Breather Plug
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug
      *4 O-ring

      Coat a new O-ring with ATF and install it to the No. 2 breather plug.

      Note

      Ensure that the O-ring is not twisted.

    2. Install the No. 2 breather plug to the breather plug hose.

    3. Install the No. 1 breather plug to the breather plug hose.

    4. B001O2ME03
      Text in Illustration
      *1 No. 2 Breather Plug
      *a Boss

      Install the transmission breather hose sub-assembly to the transaxle case sub-assembly.

      Note

      Make sure that the stopper of the No. 2 breather plug is in contact with the side of the boss on the transaxle case sub-assembly.