AUTOMATIC TRANSAXLE UNIT REASSEMBLY


  1. BEARING POSITION


    1. Check each bearing position and installation direction.

      Tech Tips


      • Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

      • Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

        Serial Number Factory
        2########## for TMH Made
        3########## for TMMWV Made
      A01HO4UE01
      A01HMBKE03
      A01HPANE02
      for TMH Made:
      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 65.9 (2.59) / 80.3 (3.16) 62.6 (2.46) / 82.4 (3.24) -
      D 59.4 (2.34) / 77 (3.03) 53.1 (2.09) / 79 (3.11) -
      E - 56.1 (2.21) / 80.9 (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) -
      for TMMWV Made:
      Mark

      Front Race Diameter

      Inside / Outside mm (in.)

      Thrust Bearing Diameter

      Inside / Outside mm (in.)

      Rear Race Diameter

      Inside / Outside mm (in.)
      A - 57.9 (2.28) / 75.2 (2.96) -
      B - 29.3 (1.15) / 48.8 (1.92) 33.1 (1.30) / 48 (1.89)
      C 66.7 (2.63) / 82.1 (3.23) 62.8 (2.47) / 82.2 (3.24) -
      D 59.5 (2.34) / 76.3 (3.00) 52.9 (2.08) / 78.6 (3.09) -
      E - 62.5 (2.46) / 80.8 (3.18) -
      F - 61.4 (2.42) / 78.6 (3.09) -
      G - 28.8 (1.13) / 46.9 (1.85) 26.3 (1.04) / 44.3 (1.74)
      H 51.9 (2.04) / 71.8 (2.83) 49.1 (1.93) / 71.8 (2.83) -

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01HPWPE01

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

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

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

  3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01HOF5

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

      Note

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

    2. A01HQWY

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

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01HPA5

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

  5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01HPNTE01

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Note

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

  6. INSTALL NO. 3 BRAKE PISTON


    1. A01HN9D

      Coat the contact surface of the transaxle case with ATF.

    2. Coat the lip of the No. 3 brake piston with ATF.

    3. A01HOPU

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

    4. A01HPFWE02
      Text in Illustration
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

      Press the No. 3 brake piston into the transaxle case.

      Note


      • Make sure that the lip of the No. 3 brake piston is not twisted and does not get caught in the transaxle case.

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

      Tech Tips

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

    5. Install the brake piston return spring to the transaxle case.

    6. A01HQAGE01

      Remove the 2 bolts and pawl stopper plate from the transaxle case.

    7. A01HQFAE01

      Place SST on the brake piston return spring and compress the brake piston return spring using a press.

      SST
      09387-00070

      Note

      Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.

    8. Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration.

      Note


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

      • Be sure to orient the snap ring so that the edges do not protrude into one of the cutouts on the brake piston return spring as shown in the illustration.

  7. INSTALL COUNTER DRIVE GEAR

    Note

    Perform this procedure only when the counter drive gear bearing or transaxle case is replaced.


    1. A01HOUWE01

      Using SST and a press, install a new counter drive gear bearing and snap ring to the transaxle case.

      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07100 )
    2. A01HQ63E01

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

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

      Note

      There should not be any clearance between the bearing inner race (front side) and counter drive gear.

  8. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01HQWTE01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  9. INSTALL NO. 2 BRAKE PISTON


    1. A01HQ9IE03
      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. A01HO10

      Install the No. 2 brake piston to the transaxle case.

      Note

      Be careful not to damage the O-rings.

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


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

    2. A01HMEZE01

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

      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, install the snap ring to the transaxle case as shown in the illustration.

      Note


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

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

  11. INSTALL NO. 2 BRAKE DISC


    1. A01HNBEE02
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

      Install the 5 No. 2 brake discs, 5 No. 2 brake plates and No. 2 brake flange to the transaxle case.

      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. A01HR4S

      Using a screwdriver, install the snap ring to the transaxle case.

      Note


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

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

  12. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01HPPU

      Using a dial indicator, measure the clearance of the No. 2 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Standard clearance
      0.884 to 1.196 mm (0.0348 to 0.0471 in.)

      Tech Tips

      Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

      If the clearance is not as specified, select an appropriate No. 2 brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 5 flanges of different thicknesses.

      No. 2 Brake Flange Thickness: mm (in.)
      Mark Thickness
      40 4.0 (0.157)
      41 4.1 (0.161)
      42 4.2 (0.165)
      43 4.3 (0.169)
      44 4.4 (0.173)

  13. INSTALL PLANETARY RING GEAR FLANGE


    1. A01HNREE02
      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, 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.

  14. INSTALL PLANETARY RING GEAR


    1. A01HP64E02
      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 planetary ring gear to the one-way clutch assembly.

      Note

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

  15. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A01HMWDE01
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer

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

      Bearing Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Bearing 56.1 (2.21) 80.9 (3.19)
      Bearing Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Bearing 62.5 (2.46) 80.8 (3.18)

      Note

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

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

      Note

      Make sure that there is no clearance between the outer race retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the outer race retainer should be deformed and replace it with a new one.

    3. A01HOMO

      Using a screwdriver, install the snap ring to the transaxle case.

      Note


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

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

  16. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE


    1. A01HN2CE01

      Using SST and a hammer, install a new counter driven gear rear tapered roller bearing outer race to the transaxle case.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07100 )

      Note

      Be sure to install the counter driven gear rear tapered roller bearing outer race so that there is no clearance between the counter driven gear rear tapered roller bearing outer race and the transaxle case. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  17. INSTALL PARKING LOCK PAWL


    1. A01HNAWE02
      Text in Illustration
      *1 Parking Lock Pawl Shaft
      *2 Parking Lock Pawl
      *3 Spring
      *4 Parking Lock Pawl Pin

      Install the parking lock pawl to the transaxle case with the parking lock pawl shaft.

    2. Install the parking lock pawl pin to the transaxle case.

    3. A01HPO6

      Install the spring to the parking lock pawl.

      Note

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

  18. INSTALL PARKING LOCK SLEEVE


    1. A01HMQJ

      Install the parking lock sleeve to the transaxle case.

  19. INSTALL PAWL STOPPER PLATE


    1. A01HNAS

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  20. INSTALL PAWL SHAFT CLAMP


    1. A01HP5B

      Install the pawl shaft clamp to the transaxle case with the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  21. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. A01HQILE01

      Using SST and a press, install a new counter driven gear rear tapered roller bearing to the counter driven gear.

      SST
      09950-60010   ( 09951-00420 )

      Note

      Be sure to install the counter driven gear rear tapered roller bearing so that there is no clearance between the counter driven gear rear tapered roller bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  22. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. A01HPVGE01

      Using SST and a press, install a new counter driven gear front tapered roller bearing to the counter driven gear.

      SST
      09950-60010   ( 09951-00530 )

      Note

      Be sure to install the counter driven gear front tapered roller bearing so that there is no clearance between the counter driven gear front tapered roller bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  23. INSTALL COUNTER DRIVEN GEAR


    1. A01HQ54

      Install the counter driven gear to the transaxle case.

  24. INSTALL COUNTER DRIVE GEAR NUT


    1. A01HNXCE01

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

    2. A01HMRAE01

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. A01HNPNE01

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

    4. A01HOKSE01

      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 0.2 N*m (1 to 2 kgf*cm, 0.9 to 1.9 in.*lbf)

      If the measured value is not within the specified range, gradually tighten the nut until the turning torque falls within the specified range.

      Maximum Torque
      180 N*m (1835 kgf*cm, 133 ft.*lbf)
    5. A01HNHYE01

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

      SST
      09930-00010

  25. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01HMTH

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator at a right angle to one of the side gear teeth.

    3. Hold the pinion gear in the differential case and measure the backlash of the side gear.

      Standard backlash
      0.05 to 0.15 mm (0.00197 to 0.00591 in.)
      Thrust Washer Thickness
      Thickness Thickness
      1.50 mm (0.0591 in.) 1.75 mm (0.0689 in.)
      1.55 mm (0.0610 in.) 1.80 mm (0.0709 in.)
      1.60 mm (0.0630 in.) 1.85 mm (0.0728 in.)
      1.65 mm (0.0650 in.) 1.90 mm (0.0748 in.)
      1.70 mm (0.0669 in.) -

      If the backlash is not within the standard range, select another side gear thrust washer.

  26. INSTALL FRONT DIFFERENTIAL CASE


    1. A01HPRJ

      Install the front differential case to the transaxle case.

  27. INSTALL NO. 1 BRAKE PISTON


    1. A01HNY5E03
      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 O-rings are not twisted.

    2. A01HN1H

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01HONQ

      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.

  29. INSTALL NO. 1 BRAKE DISC


    1. A01HR4XE01
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

      Install the 4 No. 1 brake discs, 4 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 using a press.

      SST
      09387-00070
      09495-65040

      Note

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

    3. A01HNMOE01

      Using a screwdriver, install the snap ring to the front oil pump assembly as shown in the illustration (#1).

      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. A01HNN1

      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. A01HMCHE01

      Using a screwdriver, install the snap ring to the front oil pump assembly as shown in the illustration (#2).

      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. A01HNH7E04
      Text in Illustration
      *1 Snap Ring
      *2 Brake Snap Ring Stopper
      *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 rings and the brake snap ring stopper.

  30. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A01HNT2

      Using a dial indicator, measure the clearance of the No. 1 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Standard clearance
      0.807 to 0.974 mm (0.0318 to 0.0383 in.)

      Tech Tips

      Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

      If the clearance is not as specified, select an appropriate No. 1 brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      No. 1 Brake Flange Thickness: mm (in.)
      Mark Thickness
      30 3.0 (0.118)
      31 3.1 (0.122)
      32 3.2 (0.126)
      33 3.3 (0.130)
      34 3.4 (0.134)
      35 3.5 (0.138)

  31. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. A01HQUOE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Underdrive Planetary Sun Gear

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

      Bearing Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Bearing 57.7 (2.27) 75.2 (2.96)
      Bearing Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Bearing 57.9 (2.28) 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.

  32. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01HO5XE02
      Text in Illustration
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring
      *4 Input Shaft Sub-assembly

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

      Note

      Do not expand the gap of the input shaft oil seal rings excessively.

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

      Bearing and Race Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Bearing 29.1 (1.15) 48.6 (1.91)
      Race 30.7 (1.21) 48.3 (1.90)
      Bearing and Race Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Bearing 29.3 (1.15) 48.8 (1.92)
      Race 33.1 (1.30) 48 (1.89)

      Note

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

    3. A01HQFI

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

  33. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01HNIME03
      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.

  34. INSTALL NO. 3 BRAKE HUB


    1. A01HO3ZE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

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

      Bearing and Race Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Bearing 62.6 (2.46) 82.9 (3.26)
      Race 65.9 (2.59) 80.3 (3.16)
      Bearing and Race Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Bearing 62.8 (2.47) 82.2 (3.24)
      Race 66.7 (2.63) 82.1 (3.23)

      Note

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

    2. A01HPS7

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

  35. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01HO4D

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

  36. INSTALL NO. 3 BRAKE DISC


    1. A01HR4AE02
      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. A01HNA1E02

      Using a screwdriver, 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).

  37. INSPECT CLEARANCE OF NO. 3 BRAKE


    1. A01HQNWE04
      Text in Illustration
      *1 Front Oil Pump Assembly
      *2 No. 3 Brake Piston
      *a Dimension A
      *b Dimension B
      *c Contact surface of front oil pump assembly

      Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension A) while a load of 500 N (51 kgf, 112.4 lbf) is being applied to the flange.

      Tech Tips

      Measure dimension A at 3 points where the flange diameter is approximately 166 mm (6.54 in.) and calculate the average.

    2. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B).

      Tech Tips

      Measure dimension B at 3 points where the No. 3 brake diameter is approximately 166 mm (6.54 in.) and calculate the average.

    3. Calculate the clearance value using the following formula:

      Clearance = Dimension B - Dimension A

      Standard clearance
      0.599 to 0.761 mm (0.0236 to 0.0300 in.)

      If the clearance is not as specified, select an appropriate brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      No. 3 Brake Flange Thickness: mm (in.)
      Mark Thickness
      38 3.80 (0.150)
      39 3.90 (0.154)
      40 4.00 (0.157)
      41 4.10 (0.161)
      42 4.20 (0.165)
      43 4.30 (0.169)

  38. INSTALL FRONT OIL PUMP BODY O-RING


    1. A01HQYR

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

  39. INSTALL FRONT OIL PUMP ASSEMBLY


    1. A01HQQDE01
      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.

    2. Coat the thrust needle roller bearing and thrust needle roller race with ATF.

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

      Bearing and Race Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Bearing 53.1 (2.09) 79 (3.11)
      Bearing and Race Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Bearing 52.9 (2.08) 78.6 (3.09)

      Note

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

    4. A01HMGME01
      Text in Illustration
      *1 Thrust Needle Roller Race

      Install the thrust needle roller race to the underdrive planetary gear assembly.

      Bearing and Race Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Race 59.4 (2.34) 77 (3.03)
      Bearing and Race Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Race 59.5 (2.34) 76.3 (3.00)
    5. A01HOA0E02
      Text in Illustration
      *1 O-ring

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

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  40. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01HMZAE01

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

      Note

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

    2. Install the clamp to the differential gear lube apply tube with the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      Note

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

  41. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE


    1. A01HQ8AE01

      Install the shim to the transaxle housing.

    2. Using SST, install a new counter driven gear front tapered roller bearing outer race to the transaxle housing.

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

      Note

      Be sure to install the counter driven gear front tapered roller bearing outer race so that there is no clearance between the shim and the transaxle housing.

  42. ADJUST COUNTER DRIVEN GEAR PRELOAD


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

    2. A01HOQME02

      Install the transaxle housing to the transaxle case with the 20 bolts.

      Torque:
      Bolt (A)
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    3. A01HPAQE01

      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
      for TMH Made
      Differential side bearing preload + 2.2 to 4.1 N*m (22 to 42 kgf*cm, 19 to 36 in.*lbf)
      for TMMWV Made
      Differential side bearing preload + 3.2 to 5.7 N*m (33 to 58 kgf*cm, 28 to 50 in.*lbf)

      Tech Tips

      Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

      Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

      Serial Number Factory
      2########## for TMH Made
      3########## for TMMWV Made

      If the turning torque is not within the specified range, refer to the table below to select a shim for the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range.

      Shim Thickness: mm (in.)
      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.275 (0.0896) 2.525 (0.0994) 2.775 (0.109)
      2.025 (0.0797) 2.300 (0.0906) 2.550 (0.100) 2.800 (0.110)
      2.050 (0.0807) 2.325 (0.0915) 2.575 (0.101) 2.825 (0.111)
      2.075 (0.0817) 2.350 (0.0925) 2.600 (0.102) 2.850 (0.112)
      2.100 (0.0827) 2.375 (0.0935) 2.625 (0.103) 2.875 (0.113)
      2.125 (0.0837) 2.400 (0.0945) 2.650 (0.104) 2.900 (0.114)
      2.150 (0.0846) 2.425 (0.0955) 2.675 (0.105) 2.925 (0.115)
      2.175 (0.0856) 2.450 (0.0965) 2.700 (0.106) 2.950 (0.116)
      2.200 (0.0866) 2.475 (0.0974) 2.725 (0.107) 2.975 (0.117)
      2.225 (0.0876) 2.500 (0.0984) 2.750 (0.108) 3.000 (0.118)
      2.250 (0.0886) - - -
    4. A01HOQME04

      Remove the 20 bolts and transaxle housing.

  43. INSTALL TRANSAXLE HOUSING


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

      Note

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

    2. A01HO0RE04
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case.

      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.

    3. A01HNSKE05

      Temporarily install the transaxle housing to the transaxle case with the 17 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    4. A01HNSKE06

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

    5. 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. Install the 3 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  44. INSTALL NO. 1 CLUTCH DISC (for TMH Made)

    Note

    for TMMWV Made: The direct multiple disc clutch assembly cannot be disassembled.

    Tech Tips


    • Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

    • Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

      Serial Number Factory
      2########## for TMH Made
      3########## for TMMWV Made

    1. A01HPQZE03
      Text in Illustration
      *1 No. 1 Clutch Flange
      *2 No. 1 Clutch Plate
      *3 No. 1 Clutch Disc

      Install the No. 1 clutch flange, 4 No. 1 clutch discs and 4 No. 1 clutch plates to the direct multiple disc clutch assembly.

      Note

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

    2. A01HPBC

      Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly.

      Note

      Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.

  45. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    A01HP1IE02

    Note

    There are two different types of rear multiple disc clutch assembly. Refer to the illustration and visually inspect the rear multiple disc clutch assembly to determine if it is for TMH Made or for TMMWV Made.

    Tech Tips

    Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

    Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    Serial Number Factory
    2########## for TMH Made
    3########## for TMMWV Made
    Text in Illustration
    *A for TMMWV Made
    *B for TMH Made

    1. for TMH Made:


      1. A01HPKI

        Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.

      2. Using a dial indicator, measure the No. 1 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

        Tech Tips

        Measure the clearance at 3 points where the No. 1 clutch flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

        Pack Clearance
        0.806 to 0.974 mm (0.0317 to 0.0383 in.)

        If the pack clearance is not as specified, select an appropriate No. 1 clutch flange so that the pack clearance will be within the specified range.

        Tech Tips

        There are 6 No. 1 clutch flanges of different thicknesses.

        No. 1 Clutch Flange Thickness: mm (in.)
        Mark Thickness
        30 3.0 (0.118)
        31 3.1 (0.122)
        32 3.2 (0.126)
        33 3.3 (0.130)
        34 3.4 (0.134)
        35 3.5 (0.138)

    2. for TMMWV Made:


      1. A01HNX4

        Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.

      2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.

      3. A01HQCNE01
        Text in Illustration
        *a Feeler Gauge

        Using a feeler gauge, measure the No. 1 clutch pack clearance.

        Tech Tips

        Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

        Pack Clearance
        0.606 to 0.774 mm (0.0238 to 0.0305 in.)

        If the pack clearance is not as specified, replace the direct multiple disc clutch assembly.

  46. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. for TMH Made:


      1. A01HPSHE02
        Text in Illustration
        *1 Thrust Needle Roller Bearing
        *2 Thrust Needle Roller Race

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

        Bearing and Race Diameter: mm (in.)
        - Inside Outside
        Bearing 28 (1.10) 47.1 (1.85)
        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 thrust needle roller race is visible.

      2. A01HR1K

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

      3. A01HR2L

        Using a snap ring expander, install the snap ring to the direct multiple disc clutch assembly.

    2. for TMMWV Made:


      1. A01HPSOE02
        Text in Illustration
        *1 Thrust Needle Roller Bearing
        *2 Thrust Needle Roller Race

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

        Bearing and Race Diameter: mm (in.)
        - Inside Outside
        Bearing 28.8 (1.13) 46.9 (1.85)
        Race 26.3 (1.04) 44.3 (1.74)

        Note

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

    3. A01HO73

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

    4. A01HQTY

      Using a snap ring expander, install the snap ring to the direct multiple disc clutch assembly.

  47. INSTALL NO. 2 CLUTCH DISC (for TMH Made)

    Note

    for TMMWV Made: The direct multiple disc clutch assembly cannot be disassembled.

    Tech Tips


    • Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

    • Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

      Serial Number Factory
      2########## for TMH Made
      3########## for TMMWV Made

    1. A01HP5VE03
      Text in Illustration
      *1 No. 2 Clutch Plate
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Flange

      Install the No. 2 clutch flange, 3 No. 2 clutch discs and 3 No. 2 clutch plates to the direct multiple disc clutch assembly.

      Note

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

  48. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING (for TMH Made)

    Note

    for TMMWV Made: The direct multiple disc clutch assembly cannot be disassembled.

    Tech Tips


    • Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

    • Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

      Serial Number Factory
      2########## for TMH Made
      3########## for TMMWV Made

    1. A01HOWO

      Install the No. 2 direct clutch piston to the direct multiple disc clutch assembly.

      Note

      Be sure to engage the claws on the direct multiple disc clutch assembly in the grooves on the No. 2 direct clutch piston.

    2. A01HQJPE01

      Using a screwdriver, install the direct multiple disc clutch snap ring to the direct multiple disc clutch assembly.

      Note


      • Position the opening of the direct multiple disc clutch snap ring as shown in the illustration.

      • Confirm that the direct multiple disc clutch snap ring is correctly located in the groove of the direct multiple disc clutch assembly.

  49. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

    A01HP1IE02

    Note

    There are two different types of rear multiple disc clutch assembly. Refer to the illustration and visually inspect the rear multiple disc clutch assembly to determine if it is for TMH Made or for TMMWV Made.

    Tech Tips

    Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

    Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    Serial Number Factory
    2########## for TMH Made
    3########## for TMMWV Made
    Text in Illustration
    *A for TMMWV Made
    *B for TMH Made

    1. for TMH Made:


      1. A01HPKI

        Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.

      2. Using a dial indicator, measure the No. 1 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

        Tech Tips

        Measure the clearance at 3 points where the No. 1 clutch flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

        Pack Clearance
        0.806 to 0.974 mm (0.0317 to 0.0383 in.)

        If the pack clearance is not as specified, select an appropriate No. 1 clutch flange so that the pack clearance will be within the specified range.

        Tech Tips

        There are 6 No. 1 clutch flanges of different thicknesses.

        No. 1 Clutch Flange Thickness: mm (in.)
        Mark Thickness
        30 3.0 (0.118)
        31 3.1 (0.122)
        32 3.2 (0.126)
        33 3.3 (0.130)
        34 3.4 (0.134)
        35 3.5 (0.138)

    2. for TMMWV Made:


      1. A01HNX4

        Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.

      2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.

      3. A01HQCNE01
        Text in Illustration
        *a Feeler Gauge

        Using a feeler gauge, measure the No. 1 clutch pack clearance.

        Tech Tips

        Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

        Pack Clearance
        0.606 to 0.774 mm (0.0238 to 0.0305 in.)

        If the pack clearance is not as specified, replace the direct multiple disc clutch assembly.

  50. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01HQFJE01
      Text in Illustration
      *A for TMH Made
      *B for TMMWV Made
      *1 Intermediate Shaft Oil Seal
      *2 O-ring

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

    2. Coat a new intermediate shaft oil seal with ATF and install it to the direct multiple disc clutch assembly.

    3. Coat the thrust needle roller bearing with ATF and install it to the transaxle case.

      A01HQQQE01
      Text in Illustration
      *A for TMH Made *B for TMMWV Made
      *1 Direct Multiple Disc Clutch Assembly *2 Thrust Needle Roller Bearing
      Bearing Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Bearing 61.2 (2.41) 79 (3.11)
      Bearing Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Bearing 61.4 (2.42) 78.6 (3.09)

    4. Install the direct multiple disc clutch assembly to the transaxle case.

    5. Clean the contact surfaces of the transaxle case and rear transaxle cover sub-assembly.

    6. A01HOTKE03
      Text in Illustration
      *a Dimension A

      Place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension A).

    7. A01HNTVE04
      Text in Illustration
      *a Dimension B

      Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B).

    8. Calculate the end play value using the following formula:

      End play = Dimension B - Dimension A - Thrust needle roller bearing thickness

      End Play
      0.007 to 1.113 mm (0.000275 to 0.0438 in.)

  51. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01HR1GE01

      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. Apply adhesive to the 2 "TORX" screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A01HOV8E01

      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 }
    4. A01HQH5E02
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Needle Roller Race

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

      Bearing and Race Diameter (for TMH Made): mm (in.)
      - Inside Outside
      Bearing 48.9 (1.93) 72.0 (2.84)
      Race 52.2 (2.06) 70.4 (2.77)
      Bearing and Race Diameter (for TMMWV Made): mm (in.)
      - Inside Outside
      Bearing 49.1 (1.93) 71.8 (2.83)
      Race 51.9 (2.04) 71.8 (2.83)

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

    6. A01HMGAE01

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

      Note

      Ensure that the O-rings are not twisted.

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

    8. A01HOZJE06
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case.

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

      Note


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

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

    9. A01HPA8E03

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    10. A01HPA8E04

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

    11. 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.

    12. Install the 2 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    13. A01HNGN

      Install a new gasket to the refill plug.

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

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    15. A01HO3F

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

    16. Install the 3 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.

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

  52. INSPECT INPUT SHAFT END PLAY


    1. A01HQ8K

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

      End play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  53. INSTALL TRANSAXLE CASE GASKET


    1. A01HMDWE01

      Coat 2 new transaxle case gaskets with ATF and install them to the transaxle case.

  54. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


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

    2. A01HO2NE01

      Install the transmission valve body assembly to the transaxle case with the 11 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      -

      Bolt Length
      Bolt (A) 25 mm (0.984 in.)
      Bolt (B) 30 mm (1.18 in.)
      Bolt (C) 35 mm (1.38 in.)
      Bolt (D) 45 mm (1.77 in.)
      Bolt (E) 55 mm (2.17 in.)

      Note


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

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

      • First, temporarily install the bolts marked by *1 in the illustration because they are positioning bolts.

  55. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01HNFAE05
      Text in Illustration
      *1 O-ring

      Coat a new O-ring with ATF and install it to the valve body oil strainer assembly.

      Note

      Ensure that the O-ring is not twisted or pinched.

    2. A01HMNP

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

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  56. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01HMVZE04
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

      Install the 2 transmission oil cleaner magnets to the automatic transaxle oil pan sub-assembly.

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

    3. A01HME1

      Install the automatic transaxle oil pan sub-assembly to the transaxle case 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 surface of the transaxle case sub-assembly and automatic transaxle oil pan sub-assembly with the gasket before installation.

    4. A01HPA2

      Clean and degrease the bolt and the installation hole in the transaxle case.

    5. Apply adhesive to the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Install the bolt.

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

      Note

      In order to ensure proper sealing of the automatic transaxle oil pan sub-assembly bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

    7. A01HQF9

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

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }
    8. A01HMVL

      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 }

  57. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. Install 3 new gaskets to the 3 No. 1 transaxle case plugs.

    2. Apply adhesive to the 3 No. 1 transaxle case plugs.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      In order to ensure proper sealing of the No. 1 transaxle case plugs, apply adhesive to the bolts and install them within 10 minutes of adhesive application.

    3. A01HNQX

      Using a 6 mm hexagon socket wrench, install the 3 No. 1 transaxle case plugs to the transaxle housing.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    4. A01HPV4

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

    5. Install the 3 No. 1 transaxle case plugs to the transaxle case.

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

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


    1. A01HOGM

      Coat a new O-ring with ATF and install it to the oil cooler tube union (inlet oil cooler union).

    2. Install the oil cooler tube union (inlet oil cooler union) to the transaxle case.

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

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


    1. A01HMQA

      Coat a new O-ring with ATF and install it to the oil cooler tube union (outlet oil cooler union).

    2. Install the oil cooler tube union (outlet oil cooler union) to the transaxle case.

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

  60. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01HQTHE11
      Text in Illustration
      *a Protrusion

      Align the protrusions of the park/neutral position switch assembly.

    2. A01HQ6O

      Install the park/neutral position switch assembly to the automatic transaxle assembly with the 2 bolts.

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

      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 switch 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.

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

    3. A01HOCK

      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 }

  61. INSTALL BREATHER PLUG HOSE


    1. A01HMEEE04
      Text in Illustration
      *1 No. 1 Breather Plug (ATM)
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug (ATM)
      *4 O-ring

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

    2. Install the No. 1 breather plug (ATM) and No. 2 breather plug (ATM) to the breather plug hose.

    3. A01HOAW

      Install the breather plug hose to the transaxle case.