AUTOMATIC TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION


    1. Check the position and installation direction of the bearing.

      A004OUFE01
      A004SOUE01
      Bearing Position
      Mark

      Front Race Diameter

      Inside/Outside

      Thrust Bearing Diameter

      Inside/Outside

      Rear Race Diameter

      Inside/Outside
      A - 57.7 mm (2.27 in.)/75.2 mm (2.96 in.) -
      B - 29.1 mm (1.15 in.)/48.6 mm (1.91 in.) 30.7 mm (1.21 in.)/48.3 mm (1.90 in.)
      C 65.9 mm (2.59 in.)/80.3 mm (3.16 in.) 62.6 mm (2.47 in.)/82.4 mm (3.24 in.) -
      D 59.4 mm (2.34 in.)/77 mm (3.03 in.) 53.1 mm (2.09 in.)/79 mm (3.11 in.) -
      E - 56.1 mm (2.21 in.)/80.9 mm (3.19 in.) -
      F - 61.2 mm (2.41 in.)/79 mm (3.11 in.) -
      G - 28 mm (1.10 in.)/47.1 mm (1.85 in.) 26.1 mm (1.03 in.)/44 mm (1.73 in.)
      H 52.2 mm (2.06 in.)/70.4 mm (2.77 in.) 48.9 mm (1.93 in.)/72.0 mm (2.84 in.) -

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

    A004S5SE05

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

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

      Note

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

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

    A004MOOE10

    1. Install the shim to the transaxle housing.

    2. Using SST and a hammer, tap in a new differential case bearing outer race to the transaxle housing.

      SST
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07150 )

      Note

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

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


    1. A004QRGE01

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

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

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


    1. A004RYPE01

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

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

      Note


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

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

  6. ADJUST FRONT DIFFERENTIAL CASE BEARING PRELOAD

    A004RW9

    1. Install the front differential case to the transaxle case.

    2. Clean the contact surfaces of the transaxle case and transaxle housing.

    3. A004P9PE02

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

      Torque:
      for bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      for bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

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

      SST
      09564-33010
    5. A004PGXE05

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

      SST
      09564-33010
      Standard turning torque
      1.05 to 1.93 N*m (10.7 to 19.7 kgf*cm, 9.29 to 17.1 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim of a different thickness so that the turning torque is within the specified range, and replace the installed shim with the selected shim.

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

    6. Remove the 20 bolts and transaxle housing from the transaxle case.

    7. Remove the front differential case from the transaxle case.

  7. INSTALL COUNTER DRIVEN GEAR BEARING OUTER RACE (REAR)

    A004RZ7E07

    1. Using SST and a hammer, tap in a new counter driven gear 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 bearing outer race so that there is no clearance between the bearing outer race and the transaxle case. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  8. INSTALL COUNTER DRIVEN GEAR BEARING OUTER RACE (FRONT)

    A004PMBE12

    1. Install the shim to the transaxle housing.

    2. Using SST, install a new counter driven gear 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 bearing outer race so that there is no clearance between the bearing outer race and the transaxle housing. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  9. INSTALL COUNTER DRIVEN GEAR BEARING (FRONT)

    A004MLGE02

    1. Using SST and a press, install a new counter driven gear bearing to the counter driven gear.

      SST
      09950-60010   ( 09951-00530 )

      Note

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

  10. INSTALL COUNTER DRIVEN GEAR BEARING (REAR)

    A004T0KE03

    1. Using SST and a press, install a new counter driven gear bearing to the counter driven gear.

      SST
      09950-60010   ( 09951-00420 )

      Note

      Be sure to install the counter driven gear bearing and the differential drive pinion so that there is no clearance between each of them and the counter driven gear.

  11. ADJUST COUNTER DRIVEN GEAR BEARING PRELOAD

    A004QLL

    1. Install the counter driven gear and front differential case to the transaxle case.

    2. A004P9PE02

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

      Torque:
      for bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      for bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    3. A004T3DE05

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

      SST
      09564-33010
      Standard turning torque
      Front differential case bearing preload + 3.29 to 6.07 N*m (33.5 to 61.9 kgf*cm, 29.1 to 53.7 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim of a different thickness so that the turning torque is within the specified range, and replace the installed shim with the selected shim.

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

    4. Remove the 20 bolts and transaxle housing from the transaxle case.

    5. Remove the front differential case and counter driven gear from the transaxle case.

  12. INSTALL TRANSAXLE CASE OIL SEAL LH

    A004R03E03

    1. Using SST and a hammer, tap in a new transaxle case oil seal.

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

      Note

      Check that the oil seal is installed in the correct direction.

    2. Coat the lip of the transaxle case oil seal with MP grease.

  13. INSTALL TRANSAXLE CASE OIL SEAL RH

    A004RYCE02

    1. Using SST and a hammer, tap in a new front transaxle case oil seal.

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

      Note

      Check that the oil seal is installed in the correct direction.

    2. Coat the lip of the front transaxle case oil seal with MP grease.

  14. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    A004QURE13

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

    2. Using SST and a hammer, tap in 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.)

  15. INSTALL MANUAL VALVE LEVER SHAFT


    1. Install a new spacer to the parking lock lever.

    2. Install the parking lock lever to the manual valve lever shaft.

    3. Install a new spacer to the manual valve lever.

    4. Install the manual valve lever to the manual valve lever shaft.

    5. A004TLL

      Install the manual valve lever shaft to the transaxle case.

      Note

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

    6. A004QIB

      Using a 3 mm pin punch and hammer, install a new slotted spring pin to the parking lock lever.

    7. A004OB7

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

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

    9. Check that the spacer does not turn.

    10. A004QSV

      Using a 3 mm pin punch and hammer, install a new slotted spring pin to the manual valve lever.

    11. A004Q6N

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

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

    13. Check that the spacer does not turn.

    14. A004RCU

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

  16. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A004SHI

    1. Align the protrusions on the parking lock rod with the notches in the parking lock lever and install the parking lock rod.

  17. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

    A004ND5

    1. Install the manual detent spring and cover to the transaxle case with the bolt.

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

      Note

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

  18. INSTALL COUNTER DRIVE GEAR BEARING

    Note

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


    1. A004RYSE07

      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 )

  19. INSTALL NO. 3 BRAKE PISTON


    1. A004NZZ

      Coat the contact surface of the transaxle case with ATF.

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

    3. A004R60

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

    4. A004OC7

      Press the No. 3 brake piston into the transaxle case to install it.

      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 installing, 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 return spring to press the piston into the transaxle case.

    5. Install the return spring to the transaxle case.

    6. A004Q88

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

    7. A004Q32E01

      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


      • Make sure that the snap ring is seated properly 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.

  20. INSTALL COUNTER DRIVE GEAR

    A004RR7E02

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

      SST
      09387-00020

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

      A004MYNE01
      SST
      09223-15030
      09527-17011
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07100 )

      Note

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

  21. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. Using SST and a press, press in the planetary gear to the transaxle case.

      A004QHWE01
      SST
      09223-15030
      09527-17011
      09951-01100

  22. INSTALL NO. 2 BRAKE PISTON

    A004QKAE09

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

      Text in Illustration
      *1 O-ring

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A004SO1

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

      Note

      Be careful not to damage the O-rings.

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


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

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

      A004OA4E01
      SST
      09387-00060

      Note

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

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

      Note


      • Make sure that the snap ring is seated properly 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.

  24. INSTALL NO. 2 BRAKE DISC

    A004T4JE01

    1. Install the 5 brake plates, 5 brake discs, and brake flange to the transaxle case.

      Text in Illustration
      *1 Brake Flange
      *2 Brake Plate
      *3 Brake Disc

      Note


      • Make sure that the discs, plates, and flange are installed in the correct order.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. A004PII

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

      Note


      • Make sure that the snap ring is seated properly 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.

  25. INSPECT PISTON STROKE OF NO. 2 BRAKE

    Click here

  26. INSTALL PLANETARY RING GEAR FLANGE

    A004P1Q

    1. 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

      Make sure that the snap ring is seated properly in the groove of the planetary ring gear.

  27. INSTALL PLANETARY RING GEAR

    A004RO5

    1. Install the planetary ring gear to the one-way clutch.

      Note

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

  28. INSTALL ONE-WAY CLUTCH ASSEMBLY

    A004NA7

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

      Bearing Diameter
      Item Inside Outside
      Bearing 56.1 mm (2.21 in.) 80.9 mm (3.19 in.)

      Note

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

    2. Install the one-way clutch assembly to the transaxle case.

      Note

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

    3. A004RXZ

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

      Note


      • Make sure that the snap ring is seated properly 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.

  29. INSTALL PARKING LOCK PAWL

    A004P9GE04

    1. 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. A004Q25

      Install the spring to the parking lock pawl.

      Note

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

  30. INSTALL PARKING LOCK SLEEVE

    A004MUJ

    1. Install the parking lock sleeve to the transaxle case.

  31. INSTALL PAWL STOPPER PLATE

    A004OMS

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

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

  32. INSTALL PAWL SHAFT CLAMP

    A004T15

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

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

  33. INSTALL COUNTER DRIVEN GEAR

    A004OC2

    1. Install the counter driven gear to the transaxle case.

  34. INSTALL COUNTER DRIVE GEAR NUT

    A004S5IE01

    1. Turn the manual shaft lever 2 notches counterclockwise to set it to the P position as shown in the illustration.

    2. A004PFHE02

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1223 kgf*cm, 88 ft.*lbf }
    3. A004MZKE01

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

    4. A004RGTE06

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

      SST
      09387-00130
      Standard turning torque
      0.1 to 0.22 N*m (1.02 to 2.24 kgf*cm, 0.885 to 1.95 in.*lbf)

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

      Maximum torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)
    5. A004QQEE07

      Using SST and a hammer, stake the planetary gear.

      SST
      09930-00010

  35. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

    Click here

  36. INSTALL FRONT DIFFERENTIAL CASE

    A004OYR

    1. Install the differential case to the transaxle case.

  37. INSTALL NO. 1 BRAKE PISTON


    1. A004P1JE06
      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. A004Q3P

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

      Note

      Be careful not to damage the O-rings.

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

    A004NVS

    1. Install the 3 2nd brake piston return springs to the oil pump.

      Note

      Make sure that the 3 2nd brake piston return springs are installed to the protrusions on the oil pump.

  39. INSTALL NO. 1 BRAKE DISC

    A004OUVE03

    1. Install the 4 brake plates, 4 brake discs, and brake flange to the oil pump.

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

      Note


      • Make sure that the discs, plates, and flange are installed in the correct order.

      • Be sure to install the flange in the correct direction.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. Place SST on the flange and compress the flange with a press.

      SST
      09387-00070
      09495-65040

      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.

    3. A004NLYE08

      Using a screwdriver, install the snap ring to the oil pump as shown in the illustration.

      Note


      • Make sure that the snap ring is seated properly in the groove of the oil pump.

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

    4. A004Q92

      Install the brake snap ring stopper to the oil pump.

      Note

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

    5. A004NFFE06

      Using a screwdriver, install the snap ring to the oil pump as shown in the illustration.

      Note


      • Make sure that the snap ring is seated properly in the groove of the oil pump.

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

    6. A004OKKE14
      Text in Illustration
      *1 Snap Ring
      *2 Brake Snap Ring Stopper

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

      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. Remove and reinstall the snap ring and the brake snap ring stopper.

  40. INSPECT PISTON STROKE OF NO. 1 BRAKE

    Click here

  41. INSTALL UNDERDRIVE PLANETARY SUN GEAR

    A004P15

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

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

      Note

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

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

  42. INSTALL INPUT SHAFT SUB-ASSEMBLY

    A004QL5E03

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

      Note

      Do not expand the gaps of the oil seal rings too much.

    2. Coat the thrust needle roller bearing and thrust needle roller bearing race with ATF, and install them to the oil pump.

      Bearing Diameter
      Item Inside Outside
      Bearing 29.1 mm (1.15 in.) 48.6 mm (1.91 in.)
      Race 30.7 mm (1.21 in.) 48.3 mm (1.90 in.)
      Text in Illustration
      *1 Thrust Needle Roller Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring

      Note

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

    3. A004PZF

      Install the input shaft to the oil pump.

  43. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY

    A004RG5

    1. Using a snap ring expander, install the planetary sun gear and snap ring to the underdrive planetary gear.

  44. INSTALL UNDERDRIVE PLANETARY RING GEAR

    A004R8Y

    1. Install the underdrive planetary ring gear to the underdrive planetary gear.

    2. Using needle-nose pliers, install the snap ring to the underdrive planetary ring gear.

      Note

      Make sure that the snap ring is seated properly in the groove of the underdrive planetary ring gear.

  45. INSTALL NO. 3 BRAKE HUB

    A004RAK

    1. Coat the thrust needle roller bearing with ATF and install it to the underdrive planetary gear.

      Bearing Diameter
      Item Inside Outside
      Bearing 62.6 mm (2.46 in.) 82.9 mm (3.26 in.)

      Note

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

    2. A004TKY

      Coat the thrust needle roller bearing race with MP grease and install it to the No. 3 brake hub.

      Bearing Diameter
      Item Inside Outside
      Race 65.9 mm (2.59 in.) 80.3 mm (3.16 in.)
    3. A004TY3

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

  46. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

    A004OM3

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

  47. INSTALL NO. 3 BRAKE DISC

    A004S09E06

    1. Install the 2 brake flanges, 3 brake discs, and 2 brake plates to the oil pump.

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

      Note


      • Make sure that the discs, plates, and flanges are installed in the correct order.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. A004PMRE07

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

      Note


      • Make sure the snap ring is seated properly in the groove of the oil pump.

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

  48. INSPECT CLEARANCE OF NO. 3 BRAKE

    Click here

  49. INSTALL FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY

    A004N42E05

    1. 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 bearing race with ATF and install them to the counter drive gear nut.

      Bearing and Race Diameter
      Item Inside Outside
      Bearing 53.1 mm (2.09 in.) 79 mm (3.11 in.)
      Race 59.4 mm (2.34 in.) 77 mm (3.03 in.)
      Text in Illustration
      *1 Thrust Needle Roller Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 O-ring

      Note

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

    3. A004SH4

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

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

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

  50. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

    A004OS7

    1. 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  { 231 kgf*cm, 17 ft.*lbf }

      Note

      Make sure there is clearance between the differential lube apply tube and clamp.

  51. INSTALL TRANSAXLE HOUSING


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

      Note

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

    2. A004RVXE11
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the transaxle case.

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

      Note

      Apply seal packing in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

    3. A004P9PE02

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

      Torque:
      for bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      for bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

  52. INSTALL NO. 1 CLUTCH DISC

    A004RRRE01

    1. Install the 4 clutch plates, 4 clutch discs, and clutch flange to the direct multiple disc clutch.

      Text in Illustration
      *1 Clutch Flange
      *2 Clutch Plate
      *3 Clutch Disc

      Note


      • Make sure that the flange, discs, and plates are installed in the correct order.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. A004Q7C

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

      Note

      Make sure that the snap rings are seated properly in the groove of the direct multiple disc clutch.

  53. INSPECT PISTON STROKE OF NO. 1 CLUTCH DISC

    Click here

  54. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

    A004T4BE05

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

      Bearing and Race Diameter
      Item Inside Outside
      Bearing 28 mm (1.10 in.) 47.1 mm (1.85 in.)
      Race 26.1 mm (1.03 in.) 44 mm (1.73 in.)
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Bearing Race

      Note

      Install the thrust needle roller bearing properly so that the temper colored side of the race is visible.

    2. A004OQ7

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

    3. A004OH1

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

  55. INSTALL NO. 2 CLUTCH DISC

    A004QB8E03
    Text in Illustration
    *1 Clutch Plate
    *2 Clutch Disc
    *3 Clutch Flange

    1. Install the clutch flange, 3 clutch discs, and 3 clutch plates to the direct multiple disc clutch.

      Note


      • Make sure that the discs, plates, and flange are installed in the correct order.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  56. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING

    A004S1WE04

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

    2. Coat a new intermediate shaft oil seal with ATF and install it to the intermediate shaft.

      Text in Illustration
      *1 Intermediate Shaft Oil Seal
      *2 O-ring
    3. A004S7L

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

      Note

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

    4. A004RMB

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

      Note


      • Position the opening of the snap ring as shown in the illustration.

      • Make sure the snap ring is seated properly in the groove of the direct multiple disc clutch.

  57. INSPECT PISTON STROKE OF NO. 2 CLUTCH

    Click here

  58. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

    A004R3KE02
    Text in Illustration
    *1 Thrust Needle Roller Bearing
    *2 Direct Multiple Disc Clutch Assembly

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

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

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

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

    4. A004TJDE04
      Text in Illustration
      *a Dimension A

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

    5. A004PG4E05
      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

      Standard end play
      0.007 to 1.113 mm (0.000275 to 0.0438 in.)

  59. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY

    A004TGUE02

    1. Using SST and a hammer, install the needle roller bearing to the rear transaxle cover.

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

    2. Apply adhesive to the 2 screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A004OPL

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A004SEPE07
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Needle Roller Bearing Race

      Coat the thrust needle roller bearing and thrust needle roller bearing race with ATF and install them to the transaxle case.

      Bearing Diameter
      Item Inside Outside
      Bearing 48.9 mm (1.93 in.) 72.0 mm (2.84 in.)
      Race 52.2 mm (2.06 in.) 70.4 mm (2.77 in.)

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

    6. A004TGM

      Coat the 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 old seal packing material from the contact surfaces between the rear transaxle cover and transaxle case.

    8. A004QBIE07
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the transaxle case.

      Note

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

      Seal packing
      Toyota Genuine Seal Packing 1281,
      Three Bond 1281 or equivalent
    9. A004RF1E02

      Install the rear transaxle cover to the transaxle case with the 14 bolts.

      Torque:
      Bolt A
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
      Bolt B
      17 N*m  { 172 kgf*cm, 12 ft.*lbf }
    10. A004SGC

      Install a new gasket to the refill plug.

    11. Install the refill plug to the rear transaxle cover.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    12. A004SCK

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

    13. Install the 3 No. 1 automatic transaxle case plugs to the rear transaxle cover.

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

  60. INSPECT INPUT SHAFT END PLAY

    Click here

  61. INSTALL TRANSAXLE CASE GASKET

    A004S45

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

  62. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    A004Q0UE02

    1. Install the valve body to the transaxle case with the 11 bolts.

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

      Note


      • When installing the transmission valve body, 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 into the groove on the end of the manual valve.

      • Temporarily install the bolts marked by *1 in the illustration first because they are positioning bolts.

      Tech Tips

      Each bolt length is indicated below.

      for bolt A: 25 mm (0.984 in.)

      for bolt B: 30 mm (1.18 in.)

      for bolt C: 35 mm (1.38 in.)

      for bolt D: 45 mm (1.77 in.)

      for bolt E: 55 mm (2.17 in.)

  63. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    A004MV3

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

      Note

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

    2. A004RL7

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

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

  64. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

    A004NGPE05

    1. Install the 2 magnets in the automatic transaxle oil pan.

      Text in Illustration
      *1 Magnet

    2. Install a new gasket to the oil pan.

    3. A004T34E01

      Apply seal packing to the bolt labeled A in the illustration.

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

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

      Torque:
      for bolt labeled A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for other bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note


      • In order to ensure proper sealing of the transmission oil pan bolt, apply seal packing to the bolt and install it within 10 minutes of seal packing application.

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

    5. A004OPK

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

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

    6. Using a 6 mm hexagon wrench, install the a new gasket and the overflow plug to the oil pan.

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

  65. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. Install 3 new gaskets to the 3 transaxle case plugs.

    2. Apply adhesive to the 3 transaxle case plugs.

      Adhesive
      Toyota Genuine Seal Packing 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the transaxle case plugs, apply adhesive to the plugs and install them within 10 minutes of adhesive application.

    3. A004RGQ

      Using a 6 mm hexagon wrench, install the 3 gaskets and 3 transaxle case plug to the transaxle housing.

      Torque:
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }
    4. A004U3K

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

    5. Install the 3 transaxle case plugs to the transaxle case.

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

  66. INSTALL OIL COOLER TUBE UNION (INLET)

    A004NIX

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

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

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

  67. INSTALL OIL COOLER TUBE UNION (OUTLET)

    A004OUS

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

    2. Install the oil cooler tube union (outlet) to the transaxle case as shown in the illustration.

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

  68. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A004MNW

    1. Install the park/neutral position switch to the control shaft.

    2. Temporarily install the 2 bolts.

    3. Temporarily install the control shaft lever.

    4. A004QL1E01

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

    5. Remove the control shaft lever.

    6. A004O2ZE09

      Align the protrusions of the park/neutral position switch.

    7. Hold the switch in that position and tighten the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Text in Illustration
      *a Protrusion
    8. A004RG4

      Install the control shaft lever to the control shaft with the washer and nut.

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

  69. INSTALL BREATHER PLUG HOSE

    A004SFA

    1. Coat a new O-ring with ATF and install it to the breather plug.

    2. Install the breather plug to the breather plug hose.

    3. A004OA2

      Install the breather plug hose to the transaxle case.