AUTOMATIC TRANSAXLE UNIT REASSEMBLY


  1. BEARING POSITION

    A017DTLE01
    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. A017C1CE08

      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.

  3. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A017B9I

      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 }

  4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING


    1. A017BJ6E11

      Coat a new oil seal ring with ATF and install it to the transaxle housing.

  5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING


    1. A017G0UE01

      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.

  6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING


    1. A017CW6E10

      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.

  7. INSTALL NEEDLE ROLLER BEARING


    1. A017FPGE01

      Wrap vinyl tape around SST 4.0 mm (0.157 in.) from the bottom of 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 SST to remove deposited oil before wrapping vinyl tape.

    2. Coat the needle roller bearing with ATF.

    3. A017FO7E01

      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.

  8. INSTALL UNDERDRIVE BRAKE PISTON


    1. A017G2KE04

      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.

    3. A017FPPE03

      Install the underdrive brake piston to the transaxle case.

      Note

      Be careful not to damage the O-ring.

  9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A017CNIE01

      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.

      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. A017BS4E01

      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.

    3. A017C6ZE01

      Using a snap ring expander, install the snap ring.

      Note

      The surface with a white mark of the snap ring should face upward.

  12. INSTALL COUNTER DRIVE GEAR


    1. A017DNLE01

      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.

    3. A017DV3E02

      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.

  13. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. A017DE9E03

      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.

    3. A017FI7E01

      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.

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


    1. A017CF4E01

      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.

      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. A017CZ6E06

      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.

  16. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A017BMOE01

      Install the front planetary gear assembly to the brake hub.

    2. A017B2ZE05

      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 pre-load should be applied to one pair of the tapered roller bearings (left and right).

    3. A017BJZ

      Install a new washer as shown in the illustration.

    4. A017FF2E01

      Using SST, install the nut.

      SST
      09387-00030
      09387-00080
      Torque:
      280 N*m  { 2854 kgf*cm, 207 ft.*lbf }

      Note

      Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.

    5. A017C5XE01

      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
      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)

      Tech Tips

      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  { 3569 kgf*cm, 258 ft.*lbf }
    7. A017CB3E01

      Using a chisel and hammer, stake the front lock washer.

  17. INSTALL INPUT SUN GEAR


    1. A017F5CE02

      Coat the 2 thrust bearings with ATF.

    2. Install the 2 thrust bearings, the 3 bearing races, and the input sun gear to the transaxle case.

      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.

      Thrust bearing and bearing race diameter: mm (in.)
      Inside Outside
      Bearing Race, A 34.5 (1.358) 56.82 (2.2370)
      Thrust Bearing, B 32.4 (1.276) 56.62 (2.2291)
      Bearing Race, C 40.3 (1.587) 58.0 (2.284)
      Thrust Bearing, D 40.3 (1.587) 58.1 (2.287)
      Bearing Race, E 38.6 (1.520) 58.0 (2.284)

  18. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. A017DVQE06

      Install the rear planetary gear assembly to the rear planetary ring gear.

    2. A017DIOE01

      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.

  19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A017FZHE02

      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.

  20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE


    1. A017FQUE01

      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.)

      Tech Tips

      Piston stroke = Dimension A - Flange thickness

      Flange thickness: mm (in.)
      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. A017ETP

      Install the flange.

  21. INSTALL 2ND BRAKE PISTON ASSEMBLY


    1. A017FYZE07

      Install the 2nd brake piston assembly to the transaxle case.

    2. A017F8OE01

      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.

  22. INSTALL ONE-WAY CLUTCH SLEEVE OUTER


    1. A017C8QE03

      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.

  23. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A017DDTE06

      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.

    2. A017FB7E01

      Check the rotating direction of one-way clutch for the lock or free operation as shown in the illustration.

    3. A017D76E05

      Install the one-way clutch and thrust needle roller bearing to the one-way clutch sleeve outer.

      Bearing diameter: mm (in.)
      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.

  24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER


    1. A017G19E05

      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.

  25. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. A017BV7E04

      Coat the No. 2 planetary carrier thrust washer with yellow petrolatum, and install the washer onto the rear planetary sun gear.

    2. A017EQ0E09

      Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

      Bearing diameter: mm (in.)
      Inside Outside
      Race, A 33.0 (1.299) 45.4 (1.787)
      Bearing, B 31.85 (1.254) 45.2 (1.78)
    3. A017GBIE07

      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.

  26. INSTALL 2ND BRAKE CLUTCH DISC


    1. A017DDKE02

      Coat the 4 discs with ATF.

    2. Install the 4 discs and 4 plates to the transaxle case.

    3. Temporarily install the snap ring.

  27. INSPECT PACK CLEARANCE OF 2ND BRAKE


    1. A017BQTE01

      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.)

      Tech Tips

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

      Flange thickness: mm (in.)
      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. A017E8ZE01

      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.

  28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY


    1. A017E62E08

      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.

      Note

      Be careful not to drop the bearing when it is installed.

      Bearing and race diameter: mm (in.)
      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. A017B8OE05

      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.

    3. A017DI8E01

      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).

    5. A017EHKE01

      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.)

      Note

      Make sure that the no-colored race side is facing the direct clutch assembly.

      Tech Tips

      End play = Dimension D - Dimension C

      Bearing thickness and diameter : mm (in.)
      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. A017CFJ

      Install 3 new No. 1 governor apply gaskets to the transaxle case.

  31. INSTALL BRAKE APPLY TUBE


    1. A017CO0E02

      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.

    3. A017EORE03

      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.

  32. INSTALL NEEDLE ROLLER BEARING


    1. A017FVHE01

      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.

    2. Coat a needle roller bearing with ATF.

  33. INSTALL REAR CLUTCH OIL SEAL RING OUTER


    1. A017B9HE01

      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.

  34. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A017BO1

      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 }

  35. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY


    1. A017C0XE02

      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 seal packing to the cover.

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

      Note

      Make sure that the seal packing is applied in a bead (section diameter: φ1.2) so that the entire sealing surface will be evenly sealed. The seal packing should also protrude slightly from the flange after the assembly of the parts has been completed.

    3. A017DT5E03

      Apply liquid sealer to the "A" bolt threads.

      Adhesive
      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 }

  36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC


    1. A017FPNE01

      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.

    3. A017D0WE01

      Using a screwdriver, install the snap ring.

      Note

      The snap ring should be fully engaged in the groove of the drum.

  37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE


    1. A017B5B

      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.)

      Tech Tips

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

      Flange thickness: mm (in.)
      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. A017BQ0E01

      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.

  39. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY


    1. A017GAFE03

      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.

    2. A017BTHE02

      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.

    3. A017E04E01

      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.

  40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY


    1. A017D3U

      Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.

      Bearing and bearing race diameter: mm (in.)
      Inside Outside
      Bearing 37.73 (1.4854) 58.0 (2.2835)
      Race 29.9 (1.1772) 55.5 (2.185)

    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. A017EJGE01

      Install the pawl pin and spring to the parking lock pawl.

    2. A017F62

      Temporarily install the parking lock pawl, shaft, and spring to the transaxle case as shown in the illustration.

  42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A017BLNE06

      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.

    2. A017CX3

      Install the parking lock pawl shaft.

    3. A017BGTE05

      Install the pawl shaft clamp with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    4. A017D9GE01

      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.

    5. A017D7FE01

      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.

      Tech Tips

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

  43. INSTALL MULTIPLE DISC CLUTCH HUB


    1. A017D84E08

      Install the No. 1 thrust bearing race to the transaxle case while checking its direction.

      Bearing race diameter: mm (in.)
      Inside Outside
      Bearing race 39.5 (1.555) 45.8 (1.803)
    2. A017G9SE06

      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.)
      Inside Outside
      Thrust Bearing 36.4 (1.433) 52.2 (2.055)

    3. Coat the needle roller bearing with ATF.

    4. A017F2CE05

      Install the needle roller bearing to the multiple clutch hub.

      Bearing diameter: mm (in.)
      Inside Outside
      Bearing 23.6 (0.929) 44 (1.732)

    5. Install the multiple clutch hub to the transaxle case.

  44. INSTALL FORWARD CLUTCH ASSEMBLY


    1. A017CC9E03

      Coat the thrust needle roller bearing with ATF.

    2. Install the thrust needle roller bearing to the forward clutch.

      Thrust bearing diameter: mm (in.)
      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.

    3. A017D11E04

      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.

  45. INSTALL OVERDRIVE BRAKE GASKET


    1. A017FIN

      Install 2 new overdrive brake gaskets.

  46. INSTALL DIFFERENTIAL GEAR ASSEMBLY


    1. A017FVCE11

      Install the differential gear assembly to the transaxle case.

  47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE


    1. A017FQ9E01

      Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly.

  48. INSTALL THRUST NEEDLE ROLLER BEARING


    1. A017FRZE01

      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.)

      Tech Tips

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

      Race thickness: mm (in.)
      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.)
      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. A017G38E03

      Install the oil pump to the transaxle case with the 7 bolts.

      Torque:
      22 N*m  { 226 kgf*cm, 16 ft.*lbf }
    2. A017CRWE05

      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.

  50. INSTALL TRANSAXLE HOUSING


    1. A017G8DE14

      Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.

    2. Apply seal packing to the transaxle case.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal Bead Width
      1.2 mm (0.047 in.)
    3. A017BQUE04

      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
      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 }

      Tech Tips

      Apply adhesive to bolts A and D.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Bolt length
      Bolt A, B
      50 mm (1.969 in.)
      Bolt C
      42 mm (1.654 in.)
      Bolt D
      72 mm (2.835 in.)

      Note

      Apply adhesive to the bolts and tighten them within 10 minutes of application.

      Tech Tips

      Bolt A is a non-reusable bolt. However, bolt A can be used after cleaning it.

  51. INSPECT INPUT SHAFT END PLAY


    1. A017CCNE01

      Using a dial indicator, measure the input shaft end play.

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

  52. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY


    1. A017B93

      Support the transaxle assembly on wooden blocks.

  53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A017BGUE01

      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.)

  54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A017DN7E01

      Install the parking lock rod to the manual valve lever.

  55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A017BSUE01

      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.

    2. A017B1I

      Using a pin punch and hammer, drive in a new pin.

    3. A017C2F

      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.

  56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING


    1. A017FFB

      Using needle-nose pliers, install the retainer spring.

      Note

      Hang the spring on the shaft firmly.

  57. INSTALL PARKING LOCK PAWL BRACKET


    1. A017GBQE01

      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.

  58. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A017E06E01

      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.

      Tech Tips

      Tighten bolt A first, and then bolt B.

      Torque:
      Bolt A
      20 N*m  { 205 kgf*cm, 15 ft.*lbf }
      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. A017BYIE10

      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.

    2. A017CJIE01

      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:

      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. A017DNZE08

      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. A017FZKE02

      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:

      Free length

      Outer diameter mm (in.)

      		 Color

      60.96 (2.3999) /

      14.10 (0.555)

      		 Yellow

  61. INSTALL C-3 ACCUMULATOR PISTON


    1. A017G0YE04

      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.

    2. A017D5H

      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:

      Free length

      Outer diameter mm (in.)

      		 Color

      72.20 (2.8425) /

      19.0 (0.748)

      		 Colorless
    3. A017G2B

      Install the spring to the C-3 accumulator piston.

      Note

      Install the springs to each accumulator piston, checking the identification color or each spring.

  62. INSTALL CHECK BALL BODY


    1. A017EHEE01

      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.

  63. INSTALL BRAKE DRUM GASKET


    1. A017BYS

      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.

  64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET


    1. A017FNA

      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.

  65. INSTALL NO. 1 GOVERNOR APPLY GASKET


    1. A017F8Q

      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.

  66. INSTALL TRANSMISSION WIRE


    1. A017BPUE01

      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.

    2. A017E7EE10

      Install the bolt that retains the transmission wire.

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

  67. CONNECT TRANSMISSION WIRE


    1. A017CAKE05

      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.

  68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A017D1GE02

      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.)

      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. A017FA6E03

      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.

    2. A017EEM

      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.

  70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A017EJDE03

      Install the 2 magnets to the oil pan.

    2. Apply adhesive to 18 new bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A017DMJ

      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


      • Apply adhesive to the bolts and tighten them within 10 minutes of 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.

  71. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A017EEW

      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 }

  72. INSTALL SPEED SENSOR


    1. A017FHVE01

      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 }

  73. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)


    1. A017D40E05

      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 }

  74. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION)


    1. A017EQVE04

      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 }

  75. INSTALL BREATHER PLUG HOSE


    1. Install the breather plug hose to the transaxle case firmly.

  76. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A017DOZ

      Install the park/neutral position switch to the manual valve shaft.

    2. Temporarily install the 2 bolts.

    3. A017CJC

      Place a new lock plate and tighten the nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

    4. Temporarily install the control shaft lever.

    5. A017FSH

      Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.

    6. Remove the control shaft lever.

    7. A017DHUE04

      Align the groove with the neutral basic line.

    8. Hold the switch position and tighten the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    9. A017BBJ

      Using a screwdriver, bend the tabs of the lock plate.

    10. A017FG9

      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 }