AUTOMATIC TRANSAXLE UNIT REASSEMBLY


  1. BEARING POSITION


    1. Check each bearing position and installation direction.

      A01HZ2SE01
      A01HXQRE01
      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 - 62.6 (2.46) / 82.4 (3.24) 65.9 (2.59) / 82.3 (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 COUNTER DRIVE GEAR BEARING

    Note

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


    1. A01I0VTE01

      Using SST and a press, install a new counter drive gear bearing (outer race) and snap ring to the transaxle case sub-assembly.

      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07100 )

  3. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01HYAJE01

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

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

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

      Note

      Check that the manual valve lever shaft oil seal installed in the correct direction.

  4. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01HZN4

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

      Note

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

    2. A01I1J1

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

  5. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01I1A4

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

  6. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01HYC1

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

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

      Note

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

  7. INSTALL NO. 3 BRAKE PISTON


    1. A01HY7S

      Coat 2 new O-rings with ATF and install them to the No. 3 brake piston.

      Note

      Ensure that the O-rings are not twisted.

    2. A01I0EIE02
      Text in Illustration
      *1 No. 3 Brake Piston

      Temporarily install the No. 3 brake piston to the transaxle case sub-assembly.

    3. A01I14SE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

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

      Note

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

    4. Press the No. 3 brake piston to the transaxle case sub-assembly.

      Note

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

      Tech Tips

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

    5. Remove the 2 bolts and pawl stopper plate from the transaxle case sub-assembly.

    6. A01I18CE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 No. 3 Brake Piston Return Spring Sub-assembly

      Install the No. 3 brake piston return spring sub-assembly to the transaxle case sub-assembly.

      Note

      Install the No. 3 brake piston return spring sub-assembly as shown in the illustration.

    7. A01I0ATE02
      Text in Illustration
      *1 Snap Ring

      Place SST on the No. 3 brake piston return spring sub-assembly and compress the No. 3 brake piston return spring sub-assembly with a press.

      SST
      09387-00070

      Note

      Stop the press when the No. 3 brake piston return spring sub-assembly is flush with the snap ring groove. This prevents the No. 3 brake piston return spring sub-assembly from being deformed.

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

      Note


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

      • Be sure to orient the snap ring so that the edges do not protrude into a cutout on the No. 3 brake piston return spring sub-assembly as shown in the illustration.

  8. INSTALL COUNTER DRIVE GEAR


    1. A01I20IE02

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

      SST
      09387-00020

    2. Install 2 new counter drive gear bearings (balls and cage) to the counter drive gear bearing (outer race).

    3. A01HY67E01

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

      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. A01HYAXE01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  10. INSTALL NO. 2 BRAKE PISTON


    1. A01HY9F

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

      Note

      Ensure that the O-rings are not twisted.

    2. A01I07W

      Install the No. 2 brake piston to the transaxle case sub-assembly.

      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 sub-assembly.

    2. A01I0RZE01

      Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring sub-assembly 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 sub-assembly as shown in the illustration.

      Note


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

      • Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case sub-assembly as shown in the illustration.

  12. INSTALL NO. 2 BRAKE DISC


    1. A01I0FNE01
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

      Install the 4 No. 2 brake discs, 4 No. 2 brake plates and No. 2 brake flange to the transaxle case sub-assembly.

      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. A01I0FW

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

      Note


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

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

  13. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01I0QSE01
      Text in Illustration
      *1 No. 2 Brake Piston
      *a Clearance

      Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 2 brake piston.

    2. Set a dial indicator as shown in the illustration.

    3. 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
      0.707 to 0.974 mm (0.0278 to 0.0383 in.)

      Tech Tips


      • Measure the clearance at 3 points where the No. 2 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.

      • 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. A01HXYZE02
      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. A01HY42E01
      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. A01HYBRE03
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 One-way Clutch Assembly
      *3 Outer Race Retainer
      *4 Transaxle Case Sub-assembly

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 56.1 (2.21) 81.1 (3.19)

      Note

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

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

      Note


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

      • Make sure that there is no clearance between the one-way clutch assembly and transaxle case sub-assembly.

    5. A01I0UK

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

      Note


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

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

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


    1. A01I11NE01

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

      SST
      09726-36010
      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.

    2. A01HYSGE01

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

      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 sub-assembly.

  17. INSTALL TRANSAXLE CASE OIL SEAL


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

    2. A01HY8EE01

      Using SST and a hammer, install the transaxle case oil seal to the transaxle case sub-assembly.

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

      Note


      • Make sure that the transaxle case oil seal is installed in the correct direction.

      • Do not damage the lip of the transaxle case oil seal.

  18. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)


    1. A01HXIAE01

      Using SST and a hammer, install a new differential drive pinion tapered roller bearing LH (outer race) to the transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00630 )
      09950-70010   ( 09951-07100 )

      Note

      Be sure to install the differential drive pinion tapered roller bearing LH (outer race) so that there is no clearance between the differential drive pinion tapered roller bearing LH (outer race) and transaxle case sub-assembly. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  19. INSTALL PARKING LOCK PAWL


    1. A01HXURE02
      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 sub-assembly with the parking lock pawl shaft.

    2. Install the parking lock pawl pin to the transaxle case sub-assembly.

    3. A01HYJX

      Install the spring to the parking lock pawl pin.

      Note

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

  20. INSTALL PARKING LOCK SLEEVE


    1. A01HXIP

      Install the parking lock sleeve to the transaxle case sub-assembly.

  21. INSTALL PAWL STOPPER PLATE


    1. A01I0UN

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

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

  22. INSTALL NO. 1 TRANSMISSION CASE PLATE


    1. A01I1IOE01

      Clean and degrease the bolt and installation hole in the transaxle case sub-assembly.

    2. Apply adhesive to 2 or 3 threads on the end of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

    3. Install the No. 1 transmission case plate to the transaxle case sub-assembly with the 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 sub-assembly as shown in the illustration.

  23. INSTALL PAWL SHAFT CLAMP


    1. A01HXO2

      Install the pawl shaft clamp to the transaxle case sub-assembly with the bolt.

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

  24. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (INNER RACE)


    1. A01I0N7E01

      Using SST and a press, install a new differential drive pinion tapered roller bearing RH (inner race) to the counter driven gear.

      SST
      09950-60010   ( 09951-00490 )

      Note

      Be sure to install the differential drive pinion tapered roller bearing RH (inner race) so that there is no clearance between the differential drive pinion tapered roller bearing RH (inner race) and counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  25. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (INNER RACE)


    1. A01HXTQE01

      Using SST and a press, install a new differential drive pinion tapered roller bearing LH (inner race) to the counter driven gear.

      SST
      09950-60010   ( 09951-00400 )

      Note

      Be sure to install the differential drive pinion tapered roller bearing LH (inner race) so that there is no clearance between the differential drive pinion tapered roller bearing LH (inner race) and 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. A01I1XA

      Install the counter driven gear to the transaxle case sub-assembly.

  27. INSTALL COUNTER DRIVE GEAR NUT


    1. A01HYTXE01

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

    2. A01I24QE01

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 88 ft.*lbf }
    3. A01HYRME01

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

    4. A01I24QE01

      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 nut until the turning torque falls within the specified range.

      Maximum Torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)
    5. A01HZM3E01

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

      SST
      09930-00010

  28. INSPECT FRONT DIFFERENTIAL PINION BACKLASH


    1. Install SST as shown in the illustration and tighten it.

      A01I171E01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Secure the front differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. A01HZQ5E01
      Text in Illustration
      *1 Front No. 1 Differential Pinion Shaft

      Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

    4. Using a dial indicator, measure the front differential pinion backlash.

      Standard Backlash
      0.20 mm (0.00787 in.) or less

      Tech Tips

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

      If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select front No. 1 differential side gear thrust washers which will ensure that the backlash is within the specification.

      Front No. 1 Differential Side Gear Thrust Washer Thickness:
      Part No. Thickness (mm (in.))
      41361-73050 0.90 (0.0354)
      41361-73010 1.00 (0.0394)
      41361-73020 1.10 (0.0433)
      41361-73030 1.20 (0.0472)

  29. INSTALL FRONT DIFFERENTIAL CASE


    1. A01HZ5B

      Install the front differential case to the transaxle case sub-assembly.

  30. INSTALL NO. 1 BRAKE PISTON


    1. A01I099E04

      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. A01HYE1

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01HZMB

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

      Note

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

  32. INSTALL NO. 1 BRAKE DISC


    1. A01HYAVE01
      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 front oil pump assembly.

      Note


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

      • Be sure to install the No. 1 brake flange in the correct direction.

    2. Place SST on the No. 1 brake flange and compress the No. 1 brake flange with a press.

      SST
      09387-00070
      09495-65040

      Note

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

    3. A01HZ4AE02

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

      Note


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

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

    4. A01I1WA

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

      Note

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

    5. A01I07UE02

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

      Note


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

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

    6. A01HXUNE01
      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 a snap ring may not have been completely located in the groove on the front oil pump assembly. Remove and reinstall the snap ring and brake snap ring stopper.

  33. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A01HYMOE01
      Text in Illustration
      *1 No. 1 Brake Piston
      *a Clearance

      Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 1 brake piston.

    2. Set a dial indicator as shown in the illustration.

    3. 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 No. 1 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.

      • 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. A01HYIGE01
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 57.7 (2.27) 75.2 (2.96)

      Note

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

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

  35. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01HXTLE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller 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 thrust needle roller bearing and thrust bearing race with ATF and install them on the input shaft sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 29.1 (1.15) 48.6 (1.91)
      Thrust bearing race 30.7 (1.21) 48.3 (1.90)

      Note

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

    3. A01HZ4W

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

  36. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01I172E02
      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 UNDERDRIVE PLANETARY RING GEAR

    Tech Tips

    Perform this procedure only when replacement of the underdrive planetary ring gear or No. 3 brake hub is necessary.


    1. A01HXVH

      Install the snap ring to the underdrive planetary ring gear.

    2. A01I16A

      While compressing the snap ring with a screwdriver, install the underdrive planetary ring gear to the No. 3 brake hub.

      Note

      Confirm that the snap ring is correctly located in the groove of the No. 3 brake hub.

  38. INSTALL NO. 3 BRAKE HUB


    1. A01HZZRE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 62.6 (2.46) 82.4 (3.24)
      Thrust bearing race 65.9 (2.59) 82.3 (3.24)

      Note

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

    2. A01HXW7

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

  39. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01HY3N

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

  40. INSTALL NO. 3 BRAKE DISC


    1. A01HZY8E01
      Text in Illustration
      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc

      Install the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates to the front oil pump assembly.

      Note

      Make sure that the No. 3 brake discs, No. 3 brake plates, and No. 3 brake flanges are installed in the correct order.

    2. A01HZA5E02

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

      Note


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

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

  41. INSPECT CLEARANCE OF NO. 3 BRAKE


    1. A01HY7ZE01
      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 No. 3 brake flange.

      Tech Tips

      Measure dimension A at 3 points where the No. 3 brake 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 piston 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 No. 3 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)

  42. INSTALL FRONT OIL PUMP ASSEMBLY


    1. A01HXR2E01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 O-ring

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

    2. Coat the thrust needle roller bearing with ATF.

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 53.46 (2.10) 79 (3.11)

      Note

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

    4. Coat the thrust bearing race with MP grease.

    5. A01HYKVE01
      Text in Illustration
      *1 Thrust Bearing Race

      Install the thrust bearing race to the underdrive planetary gear assembly.

      Thrust Bearing Race Diameter: mm (in.)
      - Inside Outside
      Thrust bearing race 59.4 (2.34) 76 (2.99)
    6. A01HZSH

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

      Note

      Make sure that the O-ring is installed correctly with the identification line facing outward and check that it is not twisted, protruding or damaged.

    7. A01I0BUE02
      Text in Illustration
      *1 Gasket

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

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

    8. Coat a new gasket with ATF and install it to the front oil pump assembly.

  43. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. A01HYWR

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

    2. Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 3 bolts, apply adhesive to the 3 bolts and install them within 10 minutes of adhesive application.

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

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

  44. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01HXZ4

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

      Note

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

    2. Clean and degrease the bolt and installation hole in the transaxle housing.

    3. Apply adhesive to 2 or 3 threads on the end of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

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

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

      Note

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

  45. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)


    1. A01I1TJE01

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

      SST
      09523-36010
      09950-60010   ( 09951-00540 )
      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.

    2. Install the shim to the transaxle housing.

    3. A01HZZHE01

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

      SST
      09950-60020   ( 09951-00790 )
      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.

  46. INSTALL FRONT TRANSAXLE CASE OIL SEAL


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

    2. A01HXE6E01

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

      SST
      09308-14010
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note


      • Make sure that the front transaxle case oil seal is installed in the correct direction.

      • Do not damage the lip of the front transaxle case oil seal.

  47. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (OUTER RACE)


    1. A01I19DE01

      Install the shim to the transaxle housing.

    2. Using SST, install a new differential drive pinion tapered roller bearing RH (outer race) to the transaxle housing.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

      Note

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

  48. ADJUST COUNTER DRIVEN GEAR PRELOAD


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

    2. A01I1YUE01

      Install the transaxle housing to the transaxle case sub-assembly with the 20 bolts.

      Torque:
      Bolt (A)
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }
    3. A01I1PUE01

      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 to 6 N*m (31 to 61 kgf*cm, 27 to 53 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim of the differential drive pinion tapered roller bearing RH (outer race) so that the turning torque is within the specified range.

      Shim Thickness: mm (in.)
      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.275 (0.0896) 2.525 (0.0994) 2.775 (0.109)
      2.025 (0.0797) 2.300 (0.0906) 2.550 (0.100) 2.800 (0.110)
      2.050 (0.0807) 2.325 (0.0915) 2.575 (0.101) 2.825 (0.111)
      2.075 (0.0817) 2.350 (0.0925) 2.600 (0.102) 2.850 (0.112)
      2.100 (0.0827) 2.375 (0.0935) 2.625 (0.103) 2.875 (0.113)
      2.125 (0.0837) 2.400 (0.0945) 2.650 (0.104) 2.900 (0.114)
      2.150 (0.0846) 2.425 (0.0955) 2.675 (0.105) 2.925 (0.115)
      2.175 (0.0856) 2.450 (0.0965) 2.700 (0.106) 2.950 (0.116)
      2.200 (0.0866) 2.475 (0.0974) 2.725 (0.107) 2.975 (0.117)
      2.225 (0.0876) 2.500 (0.0984) 2.750 (0.108) 3.000 (0.118)
      2.250 (0.0886) - - -
    4. A01I0BO

      Remove the 20 bolts and transaxle housing.

  49. INSTALL TRANSAXLE HOUSING


    1. A01HYJJ

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

    2. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case sub-assembly.

      Note

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

    3. A01HXIWE01
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case sub-assembly.

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

      Note


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

      • After applying FIPG, install the transaxle housing to the transaxle case sub-assembly within 3 minutes and tighten the bolts within 20 minutes.

    4. A01HY75

      Install the transaxle housing to the transaxle case sub-assembly with the 17 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    5. A01HZH0

      Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 3 bolts, apply adhesive to the 3 bolts and install them within 10 minutes of adhesive application.

    6. Install the 3 bolts.

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

  50. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC


    1. A01HZXW

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

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

    3. A01HYUOE03
      Text in Illustration
      *a Feeler Gauge

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

      Tech Tips

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

      Standard Pack Clearance
      0.601 to 0.819 mm (0.0237 to 0.0322 in.)

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

  51. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01HY9SE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 28 (1.10) 47.1 (1.85)
      Thrust bearing race 26.1 (1.03) 44 (1.73)

      Note

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

    2. A01HZW3E02
      Text in Illustration
      *1 Rear Planetary Sun Gear Assembly

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

    3. A01HYR0

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

    4. A01HZXKE01
      Text in Illustration
      *1 O-ring
      *2 Oil Seal Ring

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

    5. Coat a new oil seal ring with ATF and install it to the rear multiple disc clutch assembly.

  52. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC


    1. A01I02R

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

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

    3. 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.

      Standard Pack Clearance
      0.394 to 0.605 mm (0.0155 to 0.0238 in.)

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

  53. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01HYRYE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Multiple Disc Clutch Assembly

      Coat the thrust needle roller bearing with ATF and install it to the transaxle case sub-assembly.

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 61.2 (2.41) 79 (3.11)

    2. Install the rear multiple disc clutch assembly to the transaxle case sub-assembly.

  54. INSPECT INTERMEDIATE SHAFT END PLAY


    1. A01I12LE01
      Text in Illustration
      *a Dimension A

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

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

    3. A01I09AE03
      Text in Illustration
      *a Dimension B

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

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

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

      Standard End Play
      0.022 to 1.099 mm (0.000867 to 0.0432 in.)

  55. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01HZKOE01

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

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Standard Depth
      21.5 to 21.9 mm (0.846 to 0.862 in.)
    2. A01I285

      Clean and degrease the 2 "TORX" screws and installation holes in the rear transaxle cover sub-assembly.

    3. Apply adhesive to 2 or 3 threads on the ends of the 2 "TORX" screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 2 "TORX" screws, apply adhesive to the 2 "TORX" screws and install them within 10 minutes of adhesive application.

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A01HXJNE01
      Text in Illustration
      *1 Oil Seal Ring

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

    6. A01HZKGE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

      Coat the thrust needle roller bearing and thrust bearing race with MP grease and install them on the rear transaxle cover sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 48.9 (1.93) 72.0 (2.84)
      Thrust bearing race 52.2 (2.06) 70.4 (2.77)
    7. A01HXG5E01

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

    8. A01HZ4F

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

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

      Note

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

    10. A01I1FEE07
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case sub-assembly.

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

      Note


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

      • After applying FIPG, install the rear transaxle cover sub-assembly to the transaxle case sub-assembly within 3 minutes and tighten the bolts within 20 minutes.

    11. A01I1ALE03

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

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

    12. Apply adhesive to 2 or 3 threads on the ends of the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 2 bolts, apply adhesive to the 2 bolts and install them within 10 minutes of adhesive application.

    13. A01I1ALE04

      Install the 2 bolts.

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

  56. INSTALL REAR TRANSAXLE COVER PLUG


    1. A01I0TU

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

      Note

      Ensure that the 3 O-rings are not twisted.

    2. Install the 3 rear transaxle cover plugs to the rear transaxle cover sub-assembly.

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

  57. INSTALL REFILL PLUG


    1. A01HYMV

      Install a new gasket to the refill plug.

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

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

  58. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY


    1. A01I20A

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

      Standard End Play
      0.020 to 1.242 mm (0.000788 to 0.0488 in.)

  59. INSTALL NO. 1 GOVERNOR APPLY GASKET


    1. A01I1V9

      Coat 2 new No. 1 governor apply gaskets with ATF.

    2. Install the 2 No. 1 governor apply gaskets to the transaxle case sub-assembly.

  60. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


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

    2. A01HZEEE01
      Text in Illustration
      *1 Manual Valve Lever Shaft Sub-assembly
      *2 Manual Valve
      *a Positioning Bolt

      Insert the pin of the manual valve lever shaft sub-assembly into the groove on the end of the manual valve and install the transmission valve body assembly to the transaxle case sub-assembly with the 11 bolts.

      Bolt

      Bolt Length
      (A) 25 mm (0.984 in.)
      (B) 30 mm (1.18 in.)
      (C) and (D) 35 mm (1.38 in.)
      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 }

      Note


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

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

      • First, temporarily install the bolts marked (*a) in the illustration because they are positioning bolts.

  61. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01I0ZUE02
      Text in Illustration
      *1 O-ring

      Coat a new O-ring with ATF.

    2. Install the O-ring to the valve body oil strainer assembly.

      Note

      Ensure that the O-ring is not twisted.

    3. A01HY4D

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

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

  62. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. A01HXF6E01
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

      Install the 4 transmission oil cleaner magnets to the automatic transaxle oil pan sub-assembly as shown in the illustration.

  63. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET


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

  64. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01I0YS

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

    2. A01HZ7X

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

    3. Apply adhesive to 2 or 3 threads on the ends of the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      In order to ensure proper sealing of the 2 bolts, apply adhesive to the 2 bolts and install them within 10 minutes of adhesive application.

    4. A01HXEB

      Install the 2 bolts.

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

  65. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE


    1. A01HYF6

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

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

  66. INSTALL OVERFLOW PLUG


    1. A01HY02

      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, 29 ft.*lbf }

  67. INSTALL NO. 2 TRANSAXLE CASE PLUG


    1. Clean and degrease the 3 No. 2 transaxle case plugs and installation holes in the transaxle housing.

    2. A01HY73

      Install 3 new gaskets to the 3 No. 2 transaxle case plugs.

    3. Apply adhesive to 2 or 3 threads on the ends of the 3 No. 2 transaxle case plugs.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      In order to ensure proper sealing of the 3 No. 2 transaxle case plugs, apply adhesive to the 3 No. 2 transaxle case plugs and install them within 10 minutes of adhesive application.

    4. Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs to the transaxle housing.

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

  68. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A01I0MC

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

      Note

      Ensure that the O-rings are not twisted.

    2. Install the 3 No. 1 transaxle case plugs to the transaxle case sub-assembly.

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

  69. INSTALL OIL COOLER TUBE UNION (INLET)


    1. A01I1UD

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  70. INSTALL OIL COOLER TUBE UNION (OUTLET)


    1. A01I120

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  71. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01HZOO

      Temporarily install the park/neutral position switch assembly to the transaxle case sub-assembly with the 2 bolts.

      Note

      Before installing the park/neutral position switch assembly, remove any dirt or rust on the manual valve lever shaft sub-assembly. Be sure to install the park/neutral position switch assembly straight along the manual valve lever shaft sub-assembly while being careful not to deform the plate spring that supports the manual valve lever shaft sub-assembly. If the plate spring is deformed, the park/neutral position switch assembly cannot be reinstalled correctly.

    2. A01HYF4E16
      Text in Illustration
      *a Protrusion

      Align the protrusions of the park/neutral position switch assembly as shown in the illustration.

    3. Tighten 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 park/neutral position switch assembly are aligned.

  72. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. A01I1OT

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

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

  73. INSTALL BREATHER PLUG HOSE


    1. A01I1PHE04
      Text in Illustration
      *1 No. 1 Breather Plug
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug
      *4 O-ring

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

      Note

      Ensure that the O-ring is not twisted.

    2. Install the No. 2 breather plug to the breather plug hose.

    3. Install the No. 1 breather plug to the breather plug hose.

    4. A01HZRIE01
      Text in Illustration
      *1 No. 2 Breather Plug
      *a Boss

      Install the No. 2 breather plug to the transaxle case sub-assembly.

      Note

      Ensure that the stopper of the No. 2 breather plug is in contact with the side of the boss on the transaxle case sub-assembly.