AUTOMATIC TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    A0052BFE01
    Standard Bearing Position
    Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside
    A - 53.0 mm (2.09 in.)/78.2 mm (3.08 in.) 52.1 mm (2.05 in.)/75.5 mm (2.97 in.)
    B - 37.73 mm (1.49 in.)/58.0 mm (2.28 in.) 29.9 mm (1.18 in.)/55.5 mm (2.19 in.)
    C - 33.85 mm (1.33 in.)/52.2 mm (2.06 in.) -
    D - 23.5 mm (0.925 in.)/44.0 mm (1.73 in.) -
    E - 36.3 mm (1.49 in.)/52.2 mm (2.06 in.) 34.5 mm (1.36 in.)/48.5 mm (1.91 in.)
    F - 34.6 mm (1.36 in.)/52.2 mm (2.06 in.) -
    G 40.3 mm (1.59 in.)/58.0 mm (2.28 in.) 38.6 mm (1.52 in.)/60.0 mm (2.36 in.) 38.6 mm (1.52 in.)/58.0 mm (2.28 in.)
    H - 53.6 mm (2.11 in.)/69.6 mm (2.74 in.) -
    I - 33.7 mm (1.33 in.)/48.2 mm (1.90 in.) 30.3 mm (1.19 in.)/46.0 mm (1.81 in.)
    J - 53.6 mm (2.11 in.)/70.18 mm (2.76 in.) or 69.6 mm (2.74 in.) -

  2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

    A0053DV

    1. Install the apply tube and clamp to the transaxle housing with the bolt.

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

      Note

      Make sure the tube is completely inserted.

  3. INSTALL NO. 2 BREATHER PLUG

  4. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING

    A0053GP

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

  5. INSTALL COUNTER DRIVE GEAR

    A0057EKE01
    *1 Counter Drive Gear Side:
    *2 Front Planetary Gear Side:

    1. Using SST and a press, press in the 2 counter drive gear bearing outer races to the transaxle.

      SST
      09950-60020   ( 09951-00890, 09951-07150 )

      Note


      • Press-fit the bearing outer race until it contacts the snap ring.

      • Do not apply excessive pressure.

    2. A005326E06

      Using SST and a press, press the tapered roller bearing onto the counter drive gear.

      SST
      09649-17010

      Note


      • Press-fit the bearing until it contacts the counter drive gear.

      • Do not apply excessive pressure.

    3. A0057WCE06

      Using SST and a press, press in the counter drive gear and bearing to the transaxle.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07150 )

      Note

      Do not apply excessive pressure.

  6. INSTALL 1ST AND REVERSE BRAKE PISTON

    A00565U

    1. Coat 2 new O-rings with ATF WS.

    2. Install the 2 O-rings to the 1st and reverse brake piston.

    3. A00558V

      Coat the 1st and reverse brake piston with ATF WS and install it to the transaxle.

    4. A0053N7

      Install the 1st and reverse brake return spring to the 1st and reverse brake piston.

    5. A0056TME09

      Using SST, a press and snap ring expander, press the return spring and install the snap ring to the transaxle.

      Note


      • Stop the press when the spring sheet is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove, preventing the spring sheet from being deformed.

      • Do not expand the snap ring excessively.

  7. INSTALL FRONT PLANETARY RING GEAR

    A0056Y1

    1. Using a screwdriver, install the front planetary ring gear and brake hub snap ring to the brake hub.

  8. INSTALL FRONT PLANETARY GEAR ASSEMBLY

    A0056VH

    1. Install the front planetary gear to the brake hub.

    2. A00587RE01
      Text in Illustration
      *1 2nd Brake Hub with Front Planetary Gear
      *2 Transaxle Case
      *3 Counter Drive Gear

      Using SST and a press, press-fit the front planetary gear.

      Note

      Do not apply excessive pressure.

    3. A0056CP

      Install a new lock washer as shown in the illustration.

    4. A0058IFE14

      Using SST, install the lock nut.

      SST
      09387-00030
      09387-00080
      Torque:
      268 N*m  { 2728 kgf*cm, 196 ft.*lbf }
    5. A005352E09

      Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified range, gradually tighten the lock nut until the measured value is within the specified range.

      SST
      09950-60010   ( 09951-00400 )
      09950-70010   ( 09951-07100 )
      09387-00030
      09387-00080
      Standard turning torque at 60 rpm
      for new bearing
      0.5 to 1.0 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf)
      for used bearing
      0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to 4.4 in.*lbf)
    6. A00551H

      Using a chisel and hammer, stake all the claws of the lock washer.

  9. INSTALL INPUT SUN GEAR

    A0057T3

    1. Install the 2 thrust bearings, bearing race and input sun gear to the planetary gear.

      Bearing and Race Diameter
      Item Inside Outside
      Bearing 34.6 mm (1.36 in.) 52.2 mm (2.06 in.)
      Race 40.3 mm (1.58 in.) 58.0 mm (2.28 in.)
      Bearing 38.6 mm (1.52 in.) 60.0 mm (2.36 in.)

  10. INSTALL REAR PLANETARY GEAR ASSEMBLY

    A0057FF

    1. Install bearing race to the rear planetary gear.

      Bearing Race Diameter
      Item Inside Outside
      Race 38.6 mm (1.52 in.) 58.0 mm (2.28 in.)
    2. A0052DH

      Install the No. 2 thrust washer to the planetary gear.

    3. A0054XK

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

    4. A0056Z5

      Using a screwdriver, install the snap ring to the brake hub.

  11. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

    A0058MYE01

    1. Install the 5 plates and 5 discs.

      Install in order
      P - D - P - D - P - D - P - D - P - D

      Tech Tips

      P = Plate

      D = Disc

    2. A0058ZNE06

      Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).

    3. Select an appropriate flange so that the piston stroke is within the specified range.

      Standard pack clearance
      1.02 to 1.21 mm (0.0402 to 0.0476 in.)

      Tech Tips

      Piston stroke = Dimension A - Flange thickness

      Flange Thickness
      Mark Thickness
      1 1.8 mm (0.0709 in.)
      2 1.9 mm (0.0748 in.)
      3 2.0 mm (0.0787 in.)
      4 2.1 mm (0.0827 in.)
      5 2.2 mm (0.0866 in.)
      6 2.3 mm (0.0906 in.)
      7 2.4 mm (0.0945 in.)
      8 2.5 mm (0.0984 in.)
    4. A0058DI

      Install the selected flange.

  12. INSTALL 2ND BRAKE PISTON O-RING

    A0053VM

    1. Coat 2 new O-rings with ATF WS and install them to the 2nd brake piston.

  13. INSTALL 2ND BRAKE PISTON

    A0053O0

    1. Press the 2nd brake piston into the 2nd brake cylinder by hand.

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

    A00543K

    1. Install the piston return spring.

    2. A0053DSE20

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

      SST
      09387-00060

    3. Using a screwdriver, install the snap ring.

      Note

      Make sure the end gap of the snap ring is not aligned with the piston return spring claw.

  15. INSTALL 2ND BRAKE PISTON ASSEMBLY

    A0052CJ

    1. Install the 2nd brake piston to the transaxle.

    2. A0056LU

      Using a screwdriver, install the snap ring.

  16. INSTALL 1-WAY CLUTCH OUTER SLEEVE

    A0058KA

    1. Install the 1-way clutch outer sleeve to the 2nd brake cylinder.

      Note

      Check the direction of the outer sleeve.

  17. INSTALL 1-WAY CLUTCH ASSEMBLY

    A0054S0

    1. Install the inner race to the 1-way clutch.

      Note

      Check the direction of the inner race.

    2. A0053D6E02
      Text in Illustration
      *a Free

      Check that the 1-way clutch rotates freely in one direction and locks in the other direction, as shown in the illustration.

    3. A0057RV

      Install the 1-way clutch and thrust bearing to the 1-way clutch outer race sleeve.

      Bearing Diameter
      Item Inside Outside
      Bearing 53.6 mm (2.11 in.) 69.6 mm (2.74 in.)

      Note

      Make sure that the colored side of the bearing is facing the 1-way clutch.

  18. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

    A0058U3

    1. Coat the No. 1 thrust washer with petroleum jelly, and install it to the rear planetary sun gear.

    2. A00594Z

      Coat the thrust bearing with petroleum jelly, and install it to the rear planetary sun gear.

      Bearing Diameter
      Item Inside Outside
      Bearing 33.8 mm (1.33 in.) 48.2 mm (1.90 in.)
    3. A0053EX

      Install the rear planetary sun gear to the rear planetary gear.

  19. INSTALL 2ND BRAKE CLUTCH DISC

    A00590YE01

    1. Install the 3 discs and 3 plates to the transaxle.

      Install in order
      P - D - P - D - P - D

      Tech Tips

      P = Plate

      D = Disc

    2. Temporarily install the snap ring.

    3. A0057BU

      Using a vernier caliper, measure the distance between the disc surface and snap ring surface.

    4. Select an appropriate flange so that the piston stroke is within the specified range.

      Standard pack clearance
      0.62 to 0.91 mm (0.0244 to 0.0358 in.)

      Tech Tips

      Piston stroke = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.0630 in.)

      Flange Thickness
      Mark Thickness
      0 2.9 mm (0.114 in.)
      1 3.0 mm (0.118 in.)
      2 3.1 mm (0.122 in.)
      3 3.2 mm (0.126 in.)
      4 3.3 mm (0.130 in.)
      5 3.4 mm (0.134 in.)
      6 3.5 mm (0.138 in.)
      7 3.6 mm (0.142 in.)
      8 3.7 mm (0.146 in.)
    5. A00556J

      Remove the snap ring and install the selected flange, and then reinstall the snap ring.

      Note

      Install the snap ring so that its gap is visible through the groove of the transaxle case.

  20. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    A00539Q

    1. Coat the direct clutch piston with ATF WS and install it to the direct clutch drum.

      Note

      Be careful not to damage the lip seal of the direct clutch piston.

    2. A0054Z2

      Install the direct clutch return spring to the direct clutch drum.

    3. A0054L5

      Install the clutch balancer to the direct clutch drum.

      Note

      Be careful not to damage the lip seal of the direct clutch balancer.

    4. A00570ZE08

      Place SST on the clutch balancer and compress the return spring with a press.

      SST
      09387-00020

    5. Using a snap ring expander, install the snap ring to the direct clutch drum.

      Note


      • Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.

      • Stop the press when the spring sheet is lowered to a piston 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring sheet from being deformed.

      • Do not expand the snap ring excessively.

  21. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC

    A00552SE06

    1. Install the 3 plates, 3 discs and flange.

      Install in order
      P - D - P - D - P - D - F

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

    2. A0056F2

      Using a screwdriver, install the snap ring.

      Tech Tips

      Tape the screwdriver tip before use.

    3. Check that the end gap of the snap ring is not aligned with one of the cutouts.

  22. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

    A0058Z0

    1. Install the direct clutch to the transaxle rear cover.

    2. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Standard pack clearance
      0.605 to 0.825 mm (0.0238 to 0.0325 in.)

      If the pack clearance is less than the standard, parts may have been assembled incorrectly, so check and reassemble again.

      If the stroke is not as specified, select another flange.

      Tech Tips

      There are 6 flanges of differing thicknesses.

      Flange Thickness
      No. Thickness
      1 3.0 mm (0.118 in.)
      2 3.1 mm (0.122 in.)
      3 3.2 mm (0.126 in.)
      4 3.3 mm (0.130 in.)
      5 3.4 mm (0.134 in.)
      6 3.5 mm (0.138 in.)

  23. INSPECT DIRECT CLUTCH ASSEMBLY

    A005480

    1. Inspect the clutch disc rotation.


      1. Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.

        Note

        Do not place the rear planetary sun gear in a vise.

  24. INSTALL DIRECT CLUTCH ASSEMBLY

    A0057W4

    1. Install the bearing race to the direct clutch.

      Bearing Race Diameter
      Item Inside Outside
      Bearing race 30.3 mm (1.19 in.) 46.0 mm (1.81 in.)
    2. A0058CU

      Install the direct clutch and thrust bearing to the rear planetary sun gear.

      Note

      Make sure the teeth of the discs in the direct clutch completely mesh with the teeth of the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

    3. A005534E04

      Clean the contact surfaces of the transaxle case and rear cover.

    4. As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and straightedge using a vernier caliper (Dimension B).

    5. A0055RPE03
      Text in Illustration
      *1 Dimension (1)
      *2 Dimension (2)

      Measure the 2 distances as shown in the illustration and calculate dimension C using the following formula.

      Tech Tips

      Dimension C = Dimension (1) - Dimension (2)

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

      Tech Tips

      End play = Dimension C - Dimension B

      End play
      0.198 to 0.936 mm (0.00800 to 0.0369 in.)

      If the end play is not as specified, replace the thrust bearing with one of a different thickness and diameter so that the end play is within the specified range.

      Note

      Make sure that the colored side of the race is facing the direct clutch assembly.

      Bearing Thickness and Diameter
      Thickness Inside Outside
      3.58 mm (0.141 in.) 53.6 mm (2.11 in.) 69.6 mm (2.74 in.)
      3.88 mm (0.152 in.) 53.6 mm (2.11 in.) 70.18 mm (2.76 in.)

  25. INSTALL NO. 1 GOVERNOR APPLY GASKET

    A005323E02

    1. Install 2 new apply gaskets to the transaxle.

  26. INSTALL FRONT CLUTCH APPLY TUBE

    A0053CW

    1. Install the front clutch apply tube to the clamp.

      Note

      Be sure to install the apply tube to the clamp before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

  27. INSTALL BRAKE APPLY TUBE

    A0053CW

    1. Install the brake apply tube to the clamp.

      Note

      Be sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply pipe from being deformed or damaged.

    2. A00567J

      Install the 2 apply tubes to the transaxle with the bolt.

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

      Note

      Each pipe should be securely inserted until it reaches the stopper.

  28. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A00567Y

      Install 2 new O-rings to the 2 plugs.

    2. Install the 2 plugs to the transaxle rear cover.

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

  29. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

    A0054Y1

    1. Using SST and a press, press in the needle roller bearing.

      SST
      09950-60010   ( 09951-00230, 09951-00350 )
      Standard depth
      12.05 to 12.75 mm (0.474 to 0.502 in.)

      Note


      • Make sure the inscribed mark side of the bearing race faces upward.

      • Press in the bearing to the specified depth.

    2. Apply adhesive to the 2 screws.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A005724

      Using a T30 "TORX" socket, install the rear cover plate with the 2 screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A0058IP

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

    5. A0054RY

      Remove any old seal packing and be careful not to get oil on the contacting surfaces of the transaxle rear cover and transaxle.

    6. Apply seal packing to the cover.

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

    7. Coat the needle roller bearing with ATF WS.

    8. A00563EE03

      Apply adhesive to the threads of the bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    9. Install the rear cover with the 11 bolts.

      Torque:
      for bolt A
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      for bolt B
      19 N*m  { 190 kgf*cm, 14 ft.*lbf }

  30. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

    A0053N9

    1. Coat 2 new oil seal rings with ATF WS and install them to the transaxle.

  31. INSTALL UNDERDRIVE BRAKE PISTON

    A0055CJE22

    1. Wind vinyl tape around SST 4.0 mm (0.157 in.) above the bottom end until the thickness of the wound tape is approximately 5.0 mm (0.197 in.).

      SST
      09550-60010   ( 09951-00320 )
      Text in Illustration
      *1 Vinyl Tape

      Note

      Clean SST to remove deposited oil before winding vinyl tape.

    2. A0059FLE07

      Using SST and a press, press in the needle roller bearing to the transaxle until the wound vinyl tape contacts the transaxle case.

      SST
      09550-60010   ( 09951-00320 )
      09950-70010   ( 09951-07100 )
      09387-00020
    3. A0056RQ

      Coat 2 new O-rings with ATF WS and install them to the underdrive brake piston.

    4. A0058HO

      Install the underdrive brake piston to the transaxle.

  32. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

    A005799

    1. Install the underdrive brake return spring to the underdrive brake piston.

    2. A0053SWE09

      Using SST, a snap ring expander and press, compress the return spring and install the snap ring to the transaxle.

      SST
      09387-00020

      Note

      Do not apply excessive pressure.

  33. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

    A0057O1E02

    1. Install the 3 discs, 3 plates and flange to the transaxle.

      Install in order
      P - D - P - D - P - D - F

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

    2. A0055AT

      Using a screwdriver, install the snap ring.

    3. A00571P

      Using a dial indicator, measure the underdrive brake piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Standard piston stroke
      1.81 to 2.20 mm (0.0713 to 0.0866 in.)

      If the piston stroke is not as specified, replace the flange with one of a different thickness.

      Tech Tips

      Select an appropriate flange from the table below so that the piston stroke is within the specified range.

      Flange Thickness
      Mark Thickness
      1 3.0 mm (0.118 in.)
      2 3.2 mm (0.126 in.)
      3 3.4 mm (0.134 in.)

    4. When replacing the flange:

      Remove the snap ring and flange, and then install the selected flange. Then reinstall the snap ring.

  34. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

    A0052HC

    1. Install the outer race retainer to the 1-way clutch.

    2. A005790E12
      Text in Illustration
      *a Free

      Install the underdrive clutch assembly to the 1-way clutch. Rotate the underdrive clutch and check that it rotates freely in one direction and locks in the other direction.

    3. A0053PF

      Install the 1-way clutch to the transaxle.

      Note

      Make sure that the mark on the 1-way clutch outer race is visible.

    4. A00577G

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

  35. INSTALL UNDERDRIVE CLUTCH DRUM O-RING

    A0052QG

    1. Coat a new O-ring with ATF WS and install it to the underdrive clutch drum.

  36. INSTALL UNDERDRIVE CLUTCH PISTON SET

    A0059M0

    1. Coat the underdrive clutch piston with ATF WS and install it to the underdrive clutch piston drum.

      Note

      Be careful not to damage the O-ring.

    2. A0053ZB

      Install the piston return spring and clutch balancer to the underdrive clutch drum.

      Note

      Be careful not to damage the lip seal of the clutch balancer.

    3. A00597KE11

      Place SST on the clutch balancer and compress the piston return spring with a press.

      SST
      09350-32014   ( 09351-32070 )

    4. Using a snap ring expander, install the snap ring to the underdrive clutch drum.

      Note


      • Be sure the end gap of the snap ring is not aligned with the claw of the clutch balancer.

      • Stop the press when the spring sheet is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring sheet from being deformed.

      • Do not expand the snap ring excessively.

  37. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC

    A0055OKE07

    1. Install the 3 plates, 3 discs and flange.

      Install in order
      P - D - P - D - P - D - F

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

    2. A0058DH

      Using a screwdriver, install the snap ring.

      Tech Tips

      Tape the screwdriver tip before use.

    3. Check that the end gap of the snap ring is not aligned with one of the cutouts.

  38. INSPECT UNDERDRIVE PACK CLEARANCE


    1. Install the underdrive clutch to the transaxle case.

      Note

      Be careful not to damage the oil seal rings.

    2. A0056QB

      Set a dial indicator as shown in the illustration.

    3. A0057IQ

      Measure the underdrive clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Standard pack clearance
      1.51 to 1.90 mm (0.0594 to 0.0748 in.)

      If the pack clearance is less than the standard, parts may have been assembled incorrectly, so check and reassemble again.

      If the pack clearance is not as specified, select another flange.

      Tech Tips

      There are 3 flanges of differing thicknesses.

      Flange Thickness
      No. Thickness
      A 3.0 mm (0.118 in.)
      B 3.2 mm (0.126 in.)
      C 3.4 mm (0.134 in.)

    4. Remove the underdrive clutch from the transaxle case.

  39. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

    A0054WJ

    1. Coat the thrust bearing and bearing race with petroleum jelly, and install them to the underdrive clutch.

      Race Diameter
      Item Inside Outside
      Bearing 37.73 mm (1.49 in.) 58.0 mm (2.28 in.)
      Race 29.9 mm (1.18 in.) 55.5 mm (2.19 in.)

    2. Install the underdrive clutch assembly to the transaxle.

  40. INSTALL PARKING LOCK PAWL

    A0052B9

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

    2. A0057HW

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

  41. INSTALL UNDERDRIVE PLANETARY RING GEAR

    A00584M

    1. Install a new snap ring to the outer race of a new underdrive bearing.

    2. A0058I1

      Using a piston ring compressor, squeeze the snap ring.

    3. A0055KQE05

      Using SST and a press, press in the outer race of the underdrive bearing.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07100 )
    4. A0055BT

      Install the underdrive planetary ring gear to the counter driven gear.

    5. A005922

      Using snap ring pliers, install the snap ring.

  42. INSTALL UNDERDRIVE PLANETARY GEAR

    A00559K

    1. Using a press, press in a new underdrive bearing.

    2. A0054DV

      Install the counter driven gear with underdrive planetary ring gear to the underdrive planetary gear.

    3. A0054WRE05

      Using SST and a press, press in a new underdrive bearing.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Press in the bearing while rotating the counter driven gear.

    4. A0057BQ

      Using a press, press in the parking lock gear.

    5. A005495E06

      Using SST and a press, press in the differential drive pinion.

      SST
      09506-35010
      09950-60010   ( 09951-00250 )
    6. A0054YWE06

      Using SST and a press, press in the cylindrical roller bearing inner race.

      SST
      09506-35010
      09950-60010   ( 09951-00250 )
    7. A00583YE16

      Clamp the underdrive planetary gear assembly between aluminum plates in a vise.

      Note

      Be careful not to damage the differential drive pinion.

    8. Using SST, install a new lock nut.

      SST
      09564-16020
      Torque:
      280 N*m  { 2855 kgf*cm, 207 ft.*lbf }
    9. A0056XRE09

      Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assembly while rotating the torque wrench at 60 rpm.

      SST
      09564-16020
      09387-00050
      Standard turning torque at 60 rpm
      0.23 to 5.01 N*m (2 to 51 kgf*cm, 2.0 to 44.3 in.*lbf)
    10. A0052I8

      Using a pin punch and hammer, stake the lock nut.

      Note

      Make sure that there are no cracks in the nut.

  43. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

    A0058SP

    1. Install the underdrive planetary gear assembly to the transaxle.

      Note

      Engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assembly firmly and assemble them securely.

    2. A0052YG

      Install the parking lock pawl shaft.

    3. A0057IN

      Install the parking lock pawl shaft clamp with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    4. A0052OTE11

      Using a straightedge and vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle (Dimension D).

      Note

      Note down the dimension D as it is necessary for a later step.

    5. A0053GOE12
      Text in Illustration
      *1 Dimension (1)
      *2 Dimension (2)

      Measure the 2 distances shown in the illustration. Calculate dimension E using the formula.

      Note

      Note down dimension E as it is necessary for a later step.

      Tech Tips

      Dimension E = Dimension (1) - Dimension (2)

  44. INSTALL MULTIPLE DISC CLUTCH HUB

    A0057S1

    1. Install the bearing race to the transaxle in the correct direction.

      Bearing Race Diameter
      Item Inside Outside
      Bearing race 34.5 mm (1.36 in.) 48.5 mm (1.91 in.)
    2. A0059LZ

      Coat the thrust bearing with petroleum jelly, and install it to the multiple disc clutch hub.

      Thrust Bearing Diameter
      Item Inside Outside
      Bearing 36.3 mm (1.43 in.) 52.25 mm (2.06 in.)
    3. A0055XL

      Install the thrust bearing to the multiple disc clutch hub.

      Bearing Diameter
      Item Inside Outside
      Bearing 23.5 mm (0.925 in.) 44.0 mm (1.73 in.)

    4. Install the multiple disc clutch hub to the transaxle.

  45. INSTALL INPUT SHAFT OIL SEAL RING

    A0053W3E05

    1. Compress a new oil seal ring from both sides to so that dimension A is as specified.

      Dimension A
      5.0 mm (0.197 in.)

    2. Coat the oil seal ring with ATF WS and install it to the input shaft.

  46. INSTALL FORWARD CLUTCH PISTON O-RING

    A0054KX

    1. Coat 2 new O-rings with ATF WS and install them to the forward clutch piston.

  47. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY

    A0058HU

    1. Install the forward clutch piston to the forward clutch drum.

  48. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

    A0055BL

    1. Place the forward clutch return spring onto the forward clutch piston.

    2. A0058TSE07

      Place SST on the return spring, and compress the return spring with a press.

      SST
      09350-32014   ( 09351-32070 )

    3. Install the snap ring with a snap ring expander. Make sure the end gap of the snap ring is not aligned with the spring retainer claw.

      Note


      • Stop the press when the spring sheet is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring sheet from being deformed.

      • Do not expand the snap ring excessively.

  49. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC

    A005458E04

    1. Install the 4 plates, 4 discs and flange.

      Install order
      P - D - P - D - P - D - P - D - F

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

    2. A0053UP

      Using a screwdriver, install the snap ring.

    3. Check that the end gap of the snap ring is not aligned with one of the cutouts.

  50. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

    A0052JB

    1. Install the forward clutch to the oil pump.

      Note

      Be careful not to damage the oil seal ring of the the oil pump.

    2. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Standard piston stroke
      1.74 to 2.08 mm (0.0685 to 0.0819 in.)

      If the piston stroke is less than the standard, the parts may have been assembled incorrectly. Check and reassemble again.

      If the clearance is not as specified, select another flange.

      Tech Tips

      There are 5 flanges of differing thicknesses.

      Flange Thickness
      No. Thickness
      1 3.00 mm (0.118 in.)
      2 3.15 mm (0.124 in.)
      3 3.30 mm (0.130 in.)
      4 3.45 mm (0.136 in.)
      5 3.60 mm (0.142 in.)

  51. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC

    A0058VL

    1. Inspect the clutch disc rotation.


      1. Insert the multiple disc clutch into the multiple disc clutch hub, rotate the forward clutch and check that the disc lightly rotates.

        Note

        Do not place the forward clutch in a vise.

  52. INSTALL FORWARD CLUTCH ASSEMBLY

    A0058ZPE10

    1. Install the thrust bearing to the forward clutch.

      Bearing Diameter
      Item Inside Outside
      Bearing 33.85 mm (1.33 in.) 52.2 mm (2.06 in.)
      Text in Illustration
      *1 Race "A"
      *2 Race "B"

      Note

      Install the thrust bearing properly so that the race "B" is visible.

    2. A0057XP

      Install the forward clutch to the multiple clutch hub.

      Note

      Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

  53. INSTALL OVERDRIVE BRAKE GASKET

    A0054PY

    1. Install 2 new overdrive brake gaskets to the transaxle.

  54. INSTALL FRONT DIFFERENTIAL ASSEMBLY

    A0052NG

    1. Install the front differential to the transaxle.

  55. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE

    A005838

    1. Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate No. 2 thrust bearing underdrive race so that the end play is within the specified range.

      Standard end play
      0.498 to 0.993 mm (0.0194 to 0.0390 in.)

      Tech Tips

      End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.129 in.) - underdrive thrust bearing race thickness.

      Standard Race Thickness
      E - D Thickness
      Less than 7.34 mm (0.289 in.) 3.5 mm (0.138 in.)
      7.34 mm (0.289 in.) 3.8 mm (0.150 in.)
      Bearing and Bearing Race Diameter
      Item Inside Outside
      Bearing 53.0 mm (2.09 in.) 78.2 mm (3.08 in.)
      Bearing race 52.1 mm (2.05 in.) 75.5 mm (2.97 in.)

    2. Install the selected thrust underdrive bearing race to the underdrive planetary gear.

  56. INSTALL THRUST NEEDLE ROLLER BEARING

    A0054FH

    1. Install the thrust needle roller bearing to the underdrive planetary gear.

  57. INSTALL OIL PUMP ASSEMBLY

    A0054I3

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

      Torque:
      22 N*m  { 225 kgf*cm, 16 ft.*lbf }

  58. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

    A0055H4

    1. Install a new oil seal ring to the transaxle housing.

  59. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

    A0055J3E08

    1. Using SST and a press, press in a new underdrive cylindrical roller bearing.

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

      Note

      Do not apply excessive pressure to it.

  60. INSTALL TRANSAXLE HOUSING

    A0053Z1

    1. Remove any old seal packing and be careful not to get oil on the contacting surfaces of the transaxle case and transaxle housing.

    2. Apply seal packing to the transaxle case.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Seal packing diameter
      1.2 mm (0.0472 in.)
    3. A00583DE02

      Install the transaxle housing to the transaxle with the 18 bolts.

      Torque:
      for bolt A
      22 N*m  { 225 kgf*cm, 16 ft.*lbf }
      for bolt B and C
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
      for bolt D
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
      for bolt E
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt F
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      for bolt A, B, E and F
      50 mm (1.969 in.)
      for bolt C and D
      42 mm (1.654 in.)

      Note

      Because the bolt labeled F is a seal bolt, apply the seal packing to the bolt and install it within 10 minutes after application.

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

  61. INSTALL NO. 1 TRANSAXLE CASE PLUG

    A0059HM

    1. Install 2 new O-rings to the 2 plugs.

    2. Install the 2 plugs to the transaxle housing.

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

  62. INSPECT INPUT SHAFT END PLAY

    Click here

  63. FIX AUTOMATIC TRANSAXLE ASSEMBLY

    A0054ZR

  64. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    A0056AL

    1. Coat a new oil seal with ATF WS and install it to the transaxle.

  65. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A005383

    1. Install the parking lock rod to the manual valve lever.

  66. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

    A0053O1

    1. Install a new spacer and the manual valve lever shaft to the transaxle.

    2. A0054Z9

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

    3. A0054KW

      Turn the spacer and lever shaft to align the small hole for locating the staking position of the spacer with the staking position mark on the lever shaft.

    4. Using a pin punch, stake the spacer through the small hole.

    5. Check that the spacer does not turn.

  67. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

    A00539R

    1. Using needle-nose pliers, install the retainer spring.

  68. INSTALL PARKING LOCK PAWL BRACKET

    A0059K8

    1. Install the parking lock pawl bracket with the 2 bolts.

      Torque:
      20 N*m  { 205 kgf*cm, 15 ft.*lbf }
      Bolt length
      25 mm (0.984 in.)

  69. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

    A005677E12

    1. Install the spring cover and manual detent spring with the 2 bolts.

      Note

      Make sure to install the spring cover and manual detent spring in this order.

      Torque:
      for bolt A
      20 N*m  { 205 kgf*cm, 15 ft.*lbf }
      for bolt B
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      for bolt A
      27 mm (1.06 in.)
      for bolt B
      16 mm (0.630 in.)

  70. INSTALL B-3 ACCUMULATOR PISTON

    A005864

    1. Coat a new O-ring with ATF WS and install it to the B-3 accumulator piston.

    2. A0057JR

      Coat the B-3 accumulator piston with ATF WS and install the 2 springs and B-3 accumulator piston to the transaxle.

      Spring
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-3 Inner

      60.24 mm (2.37 in.)

      15.9 mm (0.626)

      		 Yellowish green
      B-3 Outer

      74.61 mm (2.94 in.)

      21.7 mm (0.854 in.)

      		 Blue

  71. INSTALL C-1 ACCUMULATOR PISTON

    A0052VV

    1. Coat 2 new O-rings with ATF WS and install them to the C-1 accumulator piston.

    2. A005869

      Coat the C-1 accumulator piston with ATF WS and install the spring and C-1 accumulator piston to the transaxle.

      Spring
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-1

      81.53 mm (3.21 in.)

      18.5 mm (0.728 in.)

      		 Pink

  72. INSTALL C-3 ACCUMULATOR PISTON

    A0059GO

    1. Coat a new O-ring with ATF WS and install it to the C-3 accumulator piston.

    2. A0058BE

      Coat the C-3 accumulator piston with ATF WS and install it to the transaxle.

      Accumulator Spring
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-3

      90.49 mm (3.56 in.)

      19.20 mm (0.756 in.)

      		 White
    3. A0053M5

      Install the spring to the C-3 accumulator piston.

  73. INSTALL CHECK BALL BODY

    A0055WX

    1. Install the spring and check ball body.

  74. INSTALL TRANSMISSION WIRE

    A005621

    1. Coat a new O-ring with ATF WS and install it to the transmission wire connector.

    2. A0055VS

      Install the transmission wire with the bolt.

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

  75. INSTALL BRAKE DRUM GASKET

    A00552O

    1. Coat a new brake drum gasket with ATF WS and install it to the transaxle.

  76. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

    A0058ZI

    1. Coat a new transaxle case 2nd brake gasket with ATF WS and install it to the transaxle.

  77. INSTALL NO. 1 GOVERNOR APPLY GASKET

    A005961

    1. Coat a new No. 1 governor apply gasket with ATF WS and install it to the transaxle.

  78. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    A00547PE03

    1. Make sure that the manual valve lever position, install the valve body to the transaxle with the 17 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      for bolt A
      25 mm (0.984 in.)
      for bolt B
      41 mm (1.61 in.)
      for bolt C
      45 mm (1.77 in.)

      Note


      • Push the valve body against the accumulator piston spring and check ball body to install it.

      • When installing the valve body to the transaxle case, do not hold the solenoids.

      • Temporarily install the bolts marked by * in the illustration first because they are positioning bolts.

    2. A0058UKE03

      Connect the 5 solenoid connectors.

    3. Install the ATF temperature sensor with the lock plate and bolt.

      Torque:
      6.6 N*m  { 66 kgf*cm, 58 in.*lbf }
      Text in Illustration
      *1 Lock Plate

  79. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    A0056M8

    1. Coat a new O-ring with ATF WS and install it to the oil strainer.

    2. A0053C8

      Install the oil strainer to the valve body with the 3 bolts.

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

  80. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

    A0057R6E08

    1. Install the 2 magnets to the oil pan.

      Text in Illustration
      *1 Magnet

    2. Install a new oil pan gasket to the oil pan.

    3. A0053BR

      Install the oil pan to the transaxle with the 18 bolts.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  81. INSTALL SPEED SENSOR

    A0059DF

    1. Coat 2 new O-rings with ATF WS and install them to the 2 sensors.

    2. Install the 2 sensors to the transaxle with the 2 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  82. INSTALL OIL COOLER INLET TUBE UNION

    A0052M6

    1. Coat a new O-ring with ATF WS and install it to the union.

    2. Install the union to the transaxle.

      Torque:
      27 N*m  { 276 kgf*cm, 20 ft.*lbf }

  83. INSTALL OIL COOLER OUTLET TUBE UNION

    A0052ZV

    1. Coat a new O-ring with ATF WS and install it to the union.

    2. Install the union to the transaxle case.

      Torque:
      27 N*m  { 276 kgf*cm, 20 ft.*lbf }

  84. INSTALL NO. 1 TRANSAXLE CASE PLUG

    A0055E9

    1. Coat 3 new O-rings with ATF WS and install them to the 3 plugs.

    2. Install the 3 plugs to the transaxle.

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

  85. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A005552

    1. Install the park/neutral position switch to the manual valve lever shaft and temporarily install the 2 bolts.

    2. Install a new lock plate and the lock nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }
    3. A00536W

      Temporarily install the control shaft lever.

    4. A00572WE06

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

    5. Remove the control shaft lever.

    6. A0055XK

      Align the groove with neutral basic line.

    7. Tighten the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    8. A0053X5

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

    9. A00558A

      Install the control shaft lever with the washer and nut.

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