AUTOMATIC TRANSAXLE UNIT REASSEMBLY


  1. BEARING POSITION


    1. Check bearing position and installation direction.

      A01EM1GE01
      A01EM4IE01
      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) / 82.3 (3.24) 62.6 (2.46) / 82.4 (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) -

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01EJR2E01

      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 )
      Oil seal driven in depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01EM6R

      Install the manual valve lever shaft 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. A01ELWQ

      Using needle-nose pliers, install the manual valve shaft retainer spring to the transaxle case.

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01EM0W

      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. A01EKYU

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

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

      Note

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

  6. INSTALL COUNTER DRIVE GEAR BEARING

    Note

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


    1. A01EKIHE01

      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 )

  7. INSTALL NO. 3 BRAKE PISTON


    1. A01ELOZ

      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. A01EL3FE02
      Text in Illustration
      *1 No. 3 Brake Piston

      Temporarily install the No. 3 brake piston to the transaxle case.

    3. A01EMOQE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

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

      Note

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

    4. 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.

      Tech Tips

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

    5. A01EMOQE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

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

    6. A01EK38E02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Brake Piston Return Spring

      Install the brake piston return spring to the transaxle case.

      Note

      Install the brake piston return spring as shown in the illustration.

    7. A01EMQTE02
      Text in Illustration
      *1 Snap Ring

      Place SST on the brake piston return spring and compress the brake piston return spring with 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 align the opening of the snap ring with one of the protrusions on the brake piston return spring as shown in the illustration.

  8. INSTALL COUNTER DRIVE GEAR


    1. A01EKP6E02

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

      SST
      09387-00020
    2. A01EJVIE01

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

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

      Note

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

  9. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01EJWCE01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  10. INSTALL NO. 2 BRAKE PISTON


    1. A01EL6O

      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. A01ELHI

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

      Note

      Be careful not to damage the O-rings.

  11. 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. A01EL16E01

      Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring with 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 align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

  12. INSTALL NO. 2 BRAKE DISC


    1. A01EL3WE02
      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. A01EJQ7

      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 align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

  13. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01EJI5

      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 No. 2 brake 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)

  14. INSTALL PLANETARY RING GEAR FLANGE


    1. A01ELKNE02
      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.

  15. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A01EJP1E02
      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 positioned in the correct direction as shown in the illustration.

    3. A01EMQZE02
      Text in Illustration
      *1 Bearing

      Coat the bearing with ATF, and install it onto the front planetary gear assembly.

      Bearing Diameter: mm (in.)
      - Inside Outside
      Bearing 56.1 (2.21) 81.1 (3.19)

      Note

      Be sure to install the bearing properly so that the temper colored side of the race will be visible.

    4. Install the one-way clutch assembly 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 will be deformed.

    5. A01EMNQ

      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 align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.

  16. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE


    1. A01ELW5E01

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

      SST
      09710-30012   ( 09710-04081 )
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )

      Note


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


      • Ensure that there is no clearance between the front differential case rear tapered roller bearing and differential case.

    2. A01ELJDE01

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

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

      Note

      Ensure that there is no clearance between the front differential case rear tapered roller bearing outer race and transaxle case.

  17. INSTALL TRANSAXLE CASE OIL SEAL


    1. A01ELZCE01

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

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

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

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


    1. A01ELICE01

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

      SST
      09950-60010   ( 09951-00630 )
      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.

  19. INSTALL PARKING LOCK PAWL


    1. A01ELM4E02
      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 with the parking lock pawl shaft.

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

    3. A01EKTG

      Install the spring to the parking lock pawl.

      Note

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

  20. INSTALL PARKING LOCK SLEEVE


    1. A01EM6S

      Install the parking lock sleeve to the transaxle case.

  21. INSTALL PAWL STOPPER PLATE


    1. A01ELY9

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

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  22. INSTALL NO. 1 TRANSMISSION CASE PLATE


    1. A01EKH2E01

      Install the No. 1 transmission case plate to the transaxle case with a new bolt.

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Tighten the bolt while part A of the No. 1 transmission case plate contacts the transaxle case as shown in the illustration.

  23. INSTALL PAWL SHAFT CLAMP


    1. A01EL9B

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

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  24. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. A01EJ5KE01

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

      SST
      09950-60010   ( 09951-00490 )

      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.

  25. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. A01EM10E01

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

      SST
      09950-60010   ( 09951-00400 )

      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.

  26. INSTALL COUNTER DRIVEN GEAR


    1. A01EMAT

      Install the counter driven gear to the transaxle case.

  27. INSTALL COUNTER DRIVE GEAR NUT


    1. A01EJR5E01

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

    2. A01EK9UE01

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      150 N*m  { 1530 kgf*cm, 110 ft.*lbf }
    3. A01ELD8E01

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

    4. A01EKHOE01

      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 not within the specified range, gradually tighten the counter drive gear nut until the turning toque falls within the specified range.

      Maximum torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)
    5. A01ELZNE01

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

      SST
      09930-00010

  28. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01EL6X

      Hold the differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. Place a dial indicator on the tip of the differential side gear tooth at a right angle.

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

      Standard backlash
      0 to 0.15 mm (0 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 greater than the standard range, select another No. 1 front differential side gear thrust washer.

  29. INSTALL FRONT DIFFERENTIAL CASE


    1. A01EJJ9

      Install the front differential case to the transaxle case.

  30. INSTALL NO. 1 BRAKE PISTON


    1. A01EM3YE04

      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. A01EJ4N

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01EISB

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

      Note

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

  32. INSTALL NO. 1 BRAKE DISC


    1. A01ELHUE03
      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 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 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 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. A01ELXYE01

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

      Note


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

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

    4. A01EJGV

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

      Note

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

    5. A01EL9SE01

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

      Note


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

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

    6. A01EKIZE03
      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 the snap ring may not have been completely located in the groove on the oil pump assembly. Remove and reinstall the snap ring and the brake snap ring stopper.

  33. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A01EM6Q

      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
      0.601 to 0.819 mm (0.0237 to 0.0322 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 No. 1 brake 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)

  34. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. A01EKR4E02
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Bearing

      Coat the bearing with ATF, and install it to the oil pump assembly.

      Bearing Diameter: mm (in.)
      - Inside Outside
      Bearing 57.7 (2.27) 75.2 (2.96)

      Note

      Be sure to install the bearing properly so that the temper colored side of the race will be visible.

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

  35. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01EKOPE02
      Text in Illustration
      *1 Race
      *2 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 too much.

    2. Coat the bearing and race with ATF, and install them on the oil pump assembly.

      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 29.1 (1.15) 48.6 (1.91)
      Race 30.7 (1.21) 48.3 (1.90)

      Note

      Be sure to install the bearing in the correct direction.

    3. A01EJAZ

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

  36. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01ELW6E02
      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.

  37. INSTALL NO. 3 BRAKE HUB


    1. A01ELSDE02
      Text in Illustration
      *1 Race
      *2 Bearing

      Coat the bearing with ATF and install it on the underdrive planetary gear assembly.

      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 62.6 (2.46) 82.4 (3.24)
      Race 65.9 (2.59) 82.3 (3.24)

      Note

      Be sure to install the bearing properly so that the temper colored side of the race will be visible.

    2. Coat the race with MP grease and install it to the No. 3 brake hub.

    3. A01EK1K

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

  38. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01EM35

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

  39. INSTALL NO. 3 BRAKE DISC


    1. A01ELY8E02
      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 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. A01EL9HE02

      Using a screwdriver, install the snap ring to the oil pump assembly.

      Note


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

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

  40. INSPECT CLEARANCE OF NO. 3 BRAKE


    1. A01EKT2E01
      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 - Flange Thickness

      Standard clearance
      0.599 to 0.799 mm (0.0236 to 0.0315 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 No. 3 brake 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)

  41. INSTALL OIL PUMP ASSEMBLY


    1. A01EMGKE01
      Text in Illustration
      *1 Race
      *2 Bearing
      *3 O-ring

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

    2. Coat the bearing and race with ATF and install them on the underdrive planetary gear assembly.

      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 53.46 (2.10) 79 (3.11)
      Race 59.4 (2.34) 76 (2.99)

      Note

      Be sure to install the bearing properly so that the temper colored side of the race will be visible.

    3. A01EJ7O

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

    4. A01EK13E01
      Text in Illustration
      *1 O-ring

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

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

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

  42. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. A01EJJ1

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

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  43. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01EJGE

      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 apply tube clamp to the differential gear lube apply tube with a new bolt.

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

      Note

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

  44. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE


    1. A01EJTJE01

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

      SST
      09316-12010
      09649-17010
      09950-70010   ( 09951-07100 )

      Note


      • Do not damage the front differential case front tapered roller bearing cage when installing front differential case front tapered roller bearing.


      • Ensure that there is no clearance between the front differential case front tapered roller bearing and differential case.

    2. Install the shim to the transaxle housing.

    3. A01ELFXE01

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

      SST
      09950-60010   ( 09951-00910 )
      09950-70010   ( 09951-07150 )

      Note

      Ensure that there is no clearance between the front differential case front tapered roller bearing outer race, shim and transaxle housing.

  45. INSTALL FRONT TRANSAXLE CASE OIL SEAL


    1. A01EKPSE01

      Inside:


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

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

        SST
        09950-60010   ( 09951-00410 )
        09950-70010   ( 09951-07200 )
        Standard Depth
        21.5 to 22.5 mm (0.846 to 0.886 in.)
    2. A01ELQ4E01

      Outside:


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

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

        SST
        09649-17010
        09950-70010   ( 09951-07200 )
        Standard Depth
        5.5 to 6.5 mm (0.217 to 0.256 in.)

        Note

        Check that the front transaxle case oil seal is installed in the correct direction.

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


    1. A01EIUKE01

      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   ( 09951-00710 )
      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.

  47. ADJUST COUNTER DRIVEN GEAR PRELOAD


    1. Remove the seal packing from the contact surfaces between the transaxle housing and transaxle case.

    2. A01EJ85

      Install the transaxle housing to the transaxle case with the 17 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    3. A01EK2V

      Install the transaxle housing to the transaxle case with 3 bolts.

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }
    4. A01EJLFE01

      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 + 3.5 to 7.0 N*m (35 to 71 kgf*cm, 31 to 62 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim of 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) - - -
    5. A01EL31

      Remove the 20 bolts and the transaxle housing.

  48. INSTALL TRANSAXLE HOUSING


    1. Remove the seal packing from the contact surfaces between the transaxle housing and transaxle case.

      Note

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

    2. A01EIVA

      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.

    3. A01EJ85

      Install the transaxle housing to the transaxle case with the 17 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    4. A01EK2V

      Install the transaxle housing to the transaxle case with 3 new bolts.

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  49. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC


    1. A01EL0N

      Install the direct multiple disc clutch assembly onto 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. A01EIMZE02
      *1 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
      0.601 to 0.819 mm (0.0237 to 0.0322 in.)

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

  50. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING


    1. A01EKWGE02
      Text in Illustration
      *1 O-ring
      *2 Intermediate Shaft Oil Seal

      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. A01EK66E02
      Text in Illustration
      *1 Rear Planetary Sun Gear Thrust Needle Roller Bearing
      *2 Race

      Coat the rear planetary sun gear thrust needle roller bearing and 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

      Install the rear planetary sun gear thrust needle roller bearing properly so that the temper colored side of the race will be visible.

    4. A01EMI3E02
      Text in Illustration
      *1 Rear Planetary Sun Gear Assembly

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

    5. A01EIX6

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

  51. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC


    1. A01ELM1

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

    2. Using a dial indicator, measure the No. 2 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 diameter of the No. 2 direct multiple clutch piston is approximately 152 mm (5.98 in.) and calculate the average.

      Pack clearance
      0.394 to 0.605 mm (0.0155 to 0.0238 in.)

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

  52. INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING


    1. A01EJ8LE02
      Text in Illustration
      *1 Rear No. 2 Planetary Sun Gear Thrust Needle Roller Bearing
      *2 Direct Multiple Disc Clutch Assembly

      Coat the rear No. 2 planetary sun gear thrust needle roller bearing with ATF and install it on the transaxle case.

      Bearing Diameter: mm (in.)
      - Inside Outside
      Bearing 61.2 (2.41) 79 (3.11)

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

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

    4. A01EMS7E02
      Text in Illustration
      *a Dimension A

      As shown in the illustration, 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).

    5. A01EKZSE02
      Text in Illustration
      *a Dimension B

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

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

      End play = Dimension B - Dimension A - Bearing Thickness

      End play
      0.022 to 1.099 mm (0.000866 to 0.0433 in.)

  53. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01EJGGE01

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

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Installation depth
      21.5 to 21.9 mm (0.846 to 0862 in.)
    2. A01EKPL

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    3. A01EKBAE02
      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 on the transaxle case.

      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 48.9 (1.93) 72.0 (2.83)
      Race 52.2 (2.06) 70.4 (2.77)

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

    5. A01ELDJE01

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

      Note

      Ensure that the O-rings are not twisted.

    6. A01EIVB

      Remove the seal packing from the contact surfaces between the rear transaxle cover sub-assembly and transaxle case.

      Note

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

      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent.
    7. A01EK39E03

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

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }
    8. A01EK39E04

      Install the rear transaxle cover sub-assembly to the transaxle case with 2 new bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }
    9. A01ELAL

      Install a new gasket to the refill plug.

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

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    11. A01EK2L

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

    12. 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 }

  54. INSPECT INPUT SHAFT END PLAY


    1. A01EK2W

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

      End play
      0.020 to 1.242 mm (0.000787 to 0.0489 in.)

  55. INSTALL TRANSAXLE CASE GASKET


    1. A01EJG6

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

  56. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A01EME6E01

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

      Torque:
      Bolt A, B, C
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Bolt D
      9.6 N*m  { 98 kgf*cm, 85 in.*lbf }

      -

      Bolt Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 30 mm (1.18 in.)
      Bolt C, D 35 mm (1.38 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 tighten the bolts marked *1 in the illustration because they are positioning bolts.

  57. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01EKLLE02
      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. A01ELEW

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

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

  58. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01EKZ6

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

    2. A01EJT5

      Install the automatic transaxle oil pan sub-assembly and a new automatic transaxle oil pan gasket 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 surfaces of the transaxle case and automatic transaxle oil pan sub-assembly with the gasket before installation.

    3. Apply adhesive to the 2 new bolts.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A01EMEN

      Install the automatic transaxle oil pan sub-assembly with the 2 bolts.

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

      Note

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

    5. A01EKHA

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

      Torque:
      0.8 N*m  { 8 kgf*cm, 7 in.*lbf }
    6. A01EJR0

      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 }

  59. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A01EKFD

      Install the 3 new gaskets to the 3 hexagon bolts.

    2. Apply adhesive to the 3 hexagon bolts.

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

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

    3. Using a 6 mm hexagon socket wrench, install the 3 hexagon bolts to the transaxle housing with the gaskets.

      Torque:
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }
    4. A01EKZ4

      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 }

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


    1. A01EKB6

      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 }

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


    1. A01EK0T

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

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

  62. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01EJLLE06
      Text in Illustration
      *1 Protrusion

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

    2. A01EKLK

      Install the park/neutral position switch assembly to the transaxle case with 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 switch are aligned.

    3. A01EK77

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  63. INSTALL BREATHER PLUG HOSE


    1. A01EJDRE04
      Text in Illustration
      *1 Breather Plug Cap
      *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. 2 breather plug (ATM) to the breather plug hose.

    3. Install the breather plug cap to the breather plug hose.

    4. A01EJN1

      Install the breather plug hose to the transaxle case.