AUTOMATIC TRANSAXLE UNIT REASSEMBLY

Tech Tips

Check each bearing position and installation direction.

B000N14E01
B000L7AE01
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) -

  1. INSTALL COUNTER DRIVE GEAR BEARING

    Note

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


    1. B000JUSE04

      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 )

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


    1. B000J60E01

      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

      Make sure to install the front differential case rear tapered roller bearing (outer race) so that there is no clearance between the front differential case rear tapered roller bearing (outer race) and transaxle case sub-assembly.

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


    1. Install the shim to the transaxle housing.

    2. B000KVOE01

      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

      Make sure to install the front differential case front tapered roller bearing (outer race) so that there is no clearance between the front differential case front tapered roller bearing (outer race), shim and transaxle housing.

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


    1. B000HNDE02

      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).

      • Make sure to install the front differential case rear tapered roller bearing (inner race) so 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. B000HGME02

      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).

      • Make sure to install the front differential case front tapered roller bearing (inner race) so that there is no clearance between the front differential case front tapered roller bearing (inner race) and front differential case.

  6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


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

    2. B000NGS

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

    3. B000MUNE01

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

      Torque:
      Bolt (A)
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
    4. B000NLWE01

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

      SST
      09564-33010

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

      SST
      09564-33010
      Turning Torque
      1.3 to 1.7 N*m (13 to 17 kgf*cm, 12 to 15 in.*lbf)

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

      Shim Thickness
      Part No.

      Thickness

      (mm (in.))
      90564-69001 2.000 (0.0787)
      90564-69002 2.025 (0.0797)
      90564-69003 2.050 (0.0807)
      90564-69004 2.075 (0.0817)
      90564-69005 2.100 (0.0827)
      90564-69006 2.125 (0.0837)
      90564-69007 2.150 (0.0846)
      90564-69008 2.175 (0.0856)
      90564-69009 2.200 (0.0866)
      90564-69010 2.225 (0.0876)
      90564-69011 2.250 (0.0886)
      90564-69012 2.275 (0.0896)
      90564-69013 2.300 (0.0906)
      90564-69014 2.325 (0.0915)
      90564-69015 2.350 (0.0925)
      90564-69016 2.375 (0.0935)
      90564-69017 2.400 (0.0945)
      90564-69020 2.425 (0.0955)
      90564-69021 2.450 (0.0965)
      90564-69022 2.475 (0.0974)
      90564-69023 2.500 (0.0984)
      90564-69024 2.525 (0.0994)
      90564-69025 2.550 (0.100)
      90564-69026 2.575 (0.101)
      90564-69027 2.600 (0.102)
      90564-69028 2.625 (0.103)
      90564-69029 2.650 (0.104)
      90564-69030 2.675 (0.105)
      90564-69031 2.700 (0.106)
      90564-69032 2.725 (0.107)
      90564-69033 2.750 (0.108)
      90564-69034 2.775 (0.109)
      90564-69035 2.800 (0.110)
      90564-69036 2.825 (0.111)
      90564-69037 2.850 (0.112)
      90564-69038 2.875 (0.113)

    6. Remove the 20 bolts and transaxle housing from the transaxle case sub-assembly.

    7. Remove the front differential case from the transaxle case sub-assembly.

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


    1. B000LJ8E01

      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

      Make 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 driven gear cannot be measured correctly.

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


    1. B000J24E01

      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

      Make 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 driven gear cannot be measured correctly.

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


    1. B000IJ9E01

      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

      Make 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 driven gear cannot be measured correctly.

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


    1. B000H8LE01

      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

      Make 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 driven gear cannot be measured correctly.

  11. 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. B000J2I

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

    3. B000JYP

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

    4. B000MUNE01

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

      Torque:
      Bolt (A)
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
    5. B000H6OE01

      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 + 2.9 to 6.1 N*m (30 to 62 kgf*cm, 26 to 54 in.*lbf)

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

      Shim Thickness
      Part No.

      Thickness

      (mm (in.))
      90564-61022 2.000 (0.0787)
      90564-61023 2.025 (0.0797)
      90564-61024 2.050 (0.0807)
      90564-61025 2.075 (0.0817)
      90564-61026 2.100 (0.0827)
      90564-61027 2.125 (0.0837)
      90564-61028 2.150 (0.0846)
      90564-61029 2.175 (0.0856)
      90564-61030 2.200 (0.0866)
      90564-61031 2.225 (0.0876)
      90564-61032 2.250 (0.0886)
      90564-61033 2.275 (0.0896)
      90564-61034 2.300 (0.0906)
      90564-61035 2.325 (0.0915)
      90564-61036 2.350 (0.0925)
      90564-61037 2.375 (0.0935)
      90564-61038 2.400 (0.0945)
      90564-61039 2.425 (0.0955)
      90564-61040 2.450 (0.0965)
      90564-61041 2.475 (0.0974)
      90564-61042 2.500 (0.0984)
      90564-61043 2.525 (0.0994)
      90564-61044 2.550 (0.100)
      90564-61045 2.575 (0.101)
      90564-61046 2.600 (0.102)
      90564-61047 2.625 (0.103)
      90564-61048 2.650 (0.104)
      90564-69049 2.675 (0.105)
      90564-61050 2.700 (0.106)
      90564-61051 2.725 (0.107)
      90564-61052 2.750 (0.108)
      90564-61053 2.775 (0.109)
      90564-61054 2.800 (0.110)
      90564-61055 2.825 (0.111)
      90564-61056 2.850 (0.112)
      90564-61057 2.875 (0.113)
      90564-61058 2.900 (0.114)
      90564-61059 2.925 (0.115)
      90564-61060 2.950 (0.116)
      90564-61061 2.975 (0.117)
      90564-61062 3.000 (0.118)

    6. Remove the 20 bolts and transaxle housing from the transaxle case sub-assembly.

    7. Remove the front differential case from the transaxle case sub-assembly.

    8. Remove the counter driven gear from the transaxle case sub-assembly.

  12. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B000LHTE06
      Text in Illustration
      *a Depth

      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

      Make sure the manual valve lever shaft oil seal is installed in the correct direction.

  13. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B000NBV

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

    2. B000LUI

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

  14. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. B000LXT

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

  15. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B000GZ4

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

      Torque:
      22.7 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.

  16. INSTALL NO. 3 BRAKE PISTON


    1. B000HZME01
      Text in Illustration
      *1 O-ring

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. B000L28E01
      Text in Illustration
      *1 No. 3 Brake Piston

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

    3. B000JD0E01
      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 into the transaxle case sub-assembly.

      Note

      Make sure that the O-rings of the No. 3 brake piston are not twisted or caught on 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 into the transaxle case sub-assembly.

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

    6. B000JZLE01
      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. 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.

      B000L4CE01
      Text in Illustration
      *1 Snap Ring - -
      *a Protective Tape - -
      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 with its tip wrapped with protective tape, 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.

  17. INSTALL COUNTER DRIVE GEAR


    1. B000NJUE02

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

      SST
      09387-00020

      Note

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

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

    3. B000LQOE01

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

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

  18. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B000MDEE01

      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

  19. INSTALL NO. 2 BRAKE PISTON


    1. B000L0KE01
      Text in Illustration
      *1 O-ring

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. B000ICZ

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

      Note

      Be careful not to damage the 2 O-rings.

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


    1. B000MPI

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

    2. 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.

      B000H9ME01
      Text in Illustration
      *a Protective Tape *b Snap Ring End Position
      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 with its tip wrapped with protective tape, 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 one of the cutouts on the transaxle case sub-assembly as shown in the illustration.

      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

  21. INSTALL NO. 2 BRAKE DISC


    1. B000LK5E01
      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. B000I08E01
      Text in Illustration
      *a Protective Tape
      *b Snap Ring End Position

      Using a screwdriver with its tip wrapped with protective tape, 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.

      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

  22. INSPECT CLEARANCE OF NO. 2 BRAKE PISTON


    1. B000NH9E01
      Text in Illustration
      *1 No. 2 Brake Piston
      *a Clearance

      Apply compressed air to the oil 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 the dial indicator, measure the clearance of the No. 2 brake piston while applying compressed air (350 kPa 3.6 kgf/cm2, 51 psi).

      Standard Clearance
      0.966 to 1.234 mm (0.0380 to 0.0486 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.

      Tech Tips

      There are 5 No. 2 brake flanges of different thicknesses.

      No. 2 Brake Flange Thickness
      Part No. Mark

      Thickness

      (mm (in.))
      35678-33140 40A 4.0 (0.157)
      35678-33150 41A 4.1 (0.161)
      35678-33160 42A 4.2 (0.165)
      35678-33170 43A 4.3 (0.169)
      35678-33180 44A 4.4 (0.173)

  23. INSTALL PLANETARY RING GEAR FLANGE


    1. B000JWJE02
      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 with its tip wrapped with protective tape, 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.

  24. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. B000LIIE01
      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 installed in the correct direction as shown in the illustration.

    3. B000K6AE03
      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
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      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 is 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 will be deformed.

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

    5. B000HMAE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, 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.

  25. INSTALL PARKING LOCK PAWL


    1. B000JHGE02
      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. B000HU5

      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 the other end is positioned on the parking lock pawl as shown in the illustration.

  26. INSTALL PARKING LOCK SLEEVE


    1. B000HRQ

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

  27. INSTALL PAWL STOPPER PLATE


    1. B000KOR

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

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

  28. INSTALL NO. 1 TRANSMISSION CASE PLATE


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

    2. B000H8PE22
      Text in Illustration
      *a Adhesive

      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. B000KSUE01

      Install the No. 1 transmission case plate to the transaxle case sub-assembly with the bolt.

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

      Tech Tips

      Tighten the bolt with the part (A) of the No. 1 transmission case plate contacting the transaxle case sub-assembly as shown in the illustration.

  29. INSTALL PAWL SHAFT CLAMP


    1. B000JEW

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

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

  30. INSTALL COUNTER DRIVEN GEAR


    1. B000KYO

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

  31. INSTALL COUNTER DRIVE GEAR NUT


    1. B000HLME01

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

    2. B000NDLE01

      Using SST, install a new counter drive gear nut to the front planetary gear assembly.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. B000NCPE01

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

    4. Remove the counter driven gear from the transaxle case sub-assembly.

    5. B000LCDE01

      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, 133 ft.*lbf)
    6. B000L2PE01

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

      SST
      09930-00010

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

  32. INSTALL FRONT DIFFERENTIAL CASE


    1. B000LH1

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

  33. INSTALL NO. 1 BRAKE PISTON


    1. B000KETE01
      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 2 O-rings are not twisted.

    2. B000KZ8

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

      Note

      Be careful not to damage the 2 O-rings.

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


    1. B000M4A

      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.

  35. INSTALL NO. 1 BRAKE DISC


    1. B000KOME01
      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. B000HHCE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, 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. B000KQR

      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. B000M9NE02

      Using a screwdriver with its tip wrapped with protective tape, 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. B000LO0E01
      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.

  36. INSPECT CLEARANCE OF NO. 1 BRAKE PISTON


    1. B000N0BE01
      Text in Illustration
      *1 No. 1 Brake Piston
      *a Clearance

      Apply compressed air to the oil 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 the dial indicator, measure the clearance of the No. 1 brake piston while applying compressed air (350 kPa 3.6 kgf/cm2, 51 psi).

      Standard Clearance
      0.729 to 0.951 mm (0.0287 to 0.0374 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.

      Tech Tips

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

      No. 1 Brake Flange Thickness
      Part No. Mark

      Thickness

      (mm (in.))
      35676-73010 30 3.0 (0.118)
      35676-73020 31 3.1 (0.122)
      35676-73030 32 3.2 (0.126)
      35676-73040 33 3.3 (0.130)
      35676-73050 34 3.4 (0.134)
      35676-73060 35 3.5 (0.138)

  37. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. B000NM1E01
      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
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 57.7 (2.27) 75.2 (2.96)

      Note

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

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

  38. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. B000K6DE02
      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 excessively.

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      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. B000H4D

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

  39. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B000M6JE02
      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.

  40. 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. B000LXP

      Install the snap ring to the underdrive planetary ring gear.

    2. B000H6JE01
      Text in Illustration
      *a Protective Tape

      While compressing the snap ring with a screwdriver with its tip wrapped with protective tape, 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.

  41. INSTALL NO. 3 BRAKE HUB


    1. B000KPRE02
      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
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      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. B000IZM

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

  42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. B000HVU

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

  43. INSTALL NO. 3 BRAKE DISC


    1. B000MM3E01
      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. B000H20E02

      Using a screwdriver with its tip wrapped with protective tape, 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).

  44. INSPECT CLEARANCE OF NO. 3 BRAKE PISTON


    1. 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.

      B000NKAE01
      Text in Illustration
      *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
      *3 No. 3 Brake Flange - -
      *a Dimension (A) *b Dimension (B)
      *c Contact Surface of Front Oil Pump Assembly - -

      Tech Tips

      Measure the distance (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 the distance (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 using the following formula:

      Clearance = Dimension (B) - Dimension (A)

      Standard Clearance
      0.727 to 0.927 mm (0.0286 to 0.0365 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.

    4. Adjust clearance of No. 3 brake piston:


      1. B000KNPE01
        Text in Illustration
        *a Protective Tape

        Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front oil pump assembly.

      2. B000MD7E01
        Text in Illustration
        *1 No. 3 Brake Flange

        Remove the No. 3 brake flange from the front oil pump assembly.

      3. 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 disc.

        B000HFLE01
        Text in Illustration
        *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
        *3 No. 3 Brake Disc - -
        *a Dimension (A) *b Dimension (B)
        *c Contact Surface of Front Oil Pump Assembly - -

        Tech Tips

        Measure the distance (Dimension(A)) at 3 points where the No. 3 brake disc diameter is approximately 166 mm (6.54 in.) and calculate the average.

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

        Tech Tips

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

      5. Calculate the thickness of the replacement No. 3 brake flange using the following formula:

        Thickness of Replacement No. 3 Brake Flange
        Dimension (B) - Dimension (A) - (0.727 to 0.927 mm (0.0286 to 0.0365 in.))

        Tech Tips

        There are 6 No. 3 brake flanges of different thicknesses.

        No. 3 Brake Flange Thickness
        Part No. Mark

        Thickness

        (mm (in.))
        35679-73020 38 3.8 (0.150)
        35679-73030 39 3.9 (0.154)
        35679-73040 40 4.0 (0.157)
        35679-73050 41 4.1 (0.161)
        35679-73060 42 4.2 (0.165)
        35679-73070 43 4.3 (0.169)
        35679-73080 44 4.4 (0.173)
      6. B000MD7E01
        Text in Illustration
        *1 No. 3 Brake Flange

        Install the No. 3 brake flange to the front oil pump assembly.

      7. B000IWRE01

        Using a screwdriver with its tip wrapped with protective tape, 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).

  45. INSTALL FRONT OIL PUMP ASSEMBLY


    1. B000KPTE01
      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
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 53.46 (2.10) 79 (3.11)

      Note

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

    4. Coat the thrust bearing race with MP grease.

    5. B000IQNE01
      Text in Illustration
      *1 Thrust Bearing Race

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

      Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust bearing race 59.4 (2.34) 76 (2.99)
    6. B000LOP

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

      Note

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

    7. B000KMRE02
      Text in Illustration
      *1 Gasket

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

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

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

  46. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


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

    2. B000H8PE22
      Text in Illustration
      *a Adhesive

      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. B000LCS

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

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

  47. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


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

    2. B000H8PE22
      Text in Illustration
      *a Adhesive

      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. B000ML7

      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.

    4. Install the clamp to the transaxle housing with the bolt.

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

      Note

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

  48. INSTALL TRANSAXLE HOUSING


    1. B000LN5

      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. B000L8OE01
      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. B000JDT

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

      Torque:
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
    5. B000H8PE22
      Text in Illustration
      *a Adhesive

      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. B000JQF

      Install the 3 bolts.

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

  49. INSPECT CLEARANCE OF NO. 1 CLUTCH


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

    2. B000GZY

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

    3. B000JYFE01
      Text in Illustration
      *a Feeler Gauge

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

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

      Tech Tips

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

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

  50. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. B000L6KE02
      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
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      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. B000M7ME02
      Text in Illustration
      *1 Rear Planetary Sun Gear Assembly

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

    3. B000MAFE01
      Text in Illustration
      *1 Snap Ring

      Using a brass bar and a hammer, install the snap ring to the rear multiple disc clutch assembly.

      Tech Tips

      Use a piece of cloth to keep the snap ring from flying off.

  51. INSPECT CLEARANCE OF NO. 2 CLUTCH


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

    2. B000MJBE01
      Text in Illustration
      *1 No. 2 Direct Clutch Piston

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

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

      Tech Tips

      Measure the clearance at 3 points where the diameter of the No. 2 direct clutch piston is approximately 152 mm (5.98 in.) and calculate the average.

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

  52. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY


    1. B000KPUE01
      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.

      Note

      Ensure that the O-ring is not twisted.

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

    3. B000NQRE02
      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
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 61.2 (2.41) 79 (3.11)

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

  53. INSPECT INTERMEDIATE SHAFT END PLAY


    1. B000HQSE01
      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 (Dimension (A)) using a vernier caliper.

    3. B000LPHE03
      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 using the following formula:

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

      Standard End Play
      0.022 to 1.099 mm (0.000866 to 0.0433 in.)

  54. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. B000J9AE06
      Text in Illustration
      *a Depth

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

    3. B000K39E02
      Text in Illustration
      *a Adhesive

      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. B000MEU

      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. B000NFLE01
      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.

      Note

      Confirm that the 2 oil seal rings are correctly located in the grooves of the rear transaxle cover sub-assembly.

    6. B000IWHE01
      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 to the rear transaxle cover sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      -

      Inside

      (mm (in.))

      Outside

      (mm (in.))
      Thrust needle roller bearing 48.9 (1.93) 72.0 (2.83)
      Thrust bearing race 52.2 (2.06) 70.4 (2.77)
    7. B000KNN

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

    8. B000IBL

      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 of the rear transaxle cover sub-assembly and transaxle case sub-assembly.

      Note

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

    10. B000K36E07
      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. B000MWO

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

      Torque:
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
    12. B000H8PE22
      Text in Illustration
      *a Adhesive

      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. B000J8E

      Install the 2 bolts.

      Torque:
      16.9 N*m  { 172 kgf*cm, 12 ft.*lbf }

  55. INSTALL REAR TRANSAXLE COVER PLUG


    1. B000KTU

      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 }

  56. INSTALL REFILL PLUG


    1. B000JVH

      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 }

  57. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY


    1. B000JW8

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

      Standard End Play
      0.020 to 1.242 mm (0.000787 to 0.0489 in.)

  58. INSTALL TRANSAXLE CASE GASKET


    1. B000J1P

      Coat 2 new transaxle case gaskets with ATF.

    2. Install the 2 transaxle case gaskets to the transaxle case sub-assembly.

  59. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


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

    2. B000LXAE01
      Text in Illustration
      *1 Manual Valve Lever Shaft Sub-assembly Pin
      *2 Manual Valve
      *a Positioning Bolt

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

      Bolt Length
      Bolt

      Bolt Length

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

      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 pin into the groove on the end of the manual valve.

    3. Fully tighten the 2 positioning bolts shown in the illustration.

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

    4. Fully tighten the 9 bolts to install the transmission valve body assembly.

      Torque:
      Bolt (A), (B), (C)
      10.8 N*m  { 110 kgf*cm, 8 ft.*lbf }
      Bolt (D)
      9.6 N*m  { 98 kgf*cm, 85 in.*lbf }

  60. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. B000KC2E01
      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. B000JJY

      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 }

  61. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. B000LG7E01
      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.

  62. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET


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

  63. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. B000ISM

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

    2. B000L0V

      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. B000H8PE22
      Text in Illustration
      *a Adhesive

      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. B000JTS

      Install the 2 bolts.

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

  64. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE


    1. B000JAE

      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 }

  65. INSTALL OVERFLOW PLUG


    1. B000M1O

      Using a 6 mm hexagon socket wrench, install the overflow plug and a new gasket to the automatic transaxle oil pan sub-assembly.

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

  66. INSTALL FRONT DRIVE SHAFT OIL SEAL LH


    1. Coat the lip of a new front drive shaft oil seal LH with MP grease.

    2. B000MLDE02
      Text in Illustration
      *a Depth

      Using SST and a hammer, install the front drive shaft oil seal LH 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 front drive shaft oil seal LH is installed in the correct direction.

      • Do not damage the lip of the front drive shaft oil seal LH.

  67. INSTALL FRONT DRIVE SHAFT OIL SEAL RH


    1. Coat the lip of a new front drive shaft oil seal RH with MP grease.

    2. B000J4DE02
      Text in Illustration
      *a Depth

      Using SST and a hammer, install the front drive shaft oil seal RH to the transaxle housing.

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

      Note


      • Make sure that the front drive shaft oil seal RH is installed in the correct direction.

      • Do not damage the lip of the front drive shaft oil seal RH.

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

    3. B000N2EE01
      Text in Illustration
      *a Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 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. B000HW3

      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, 13 ft.*lbf }

  69. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. B000JOV

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

      Note

      Ensure that the 3 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 }

  70. INSTALL OIL COOLER INLET ELBOW


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

      Note

      Ensure that the O-ring is not twisted.

    2. B000MWNE01
      Text in Illustration
      *a Turn
      *b Hold
      *c 20 to 24°
      *d Torque Wrench Fulcrum Length

      Using SST, install the oil cooler inlet elbow to the transaxle case sub-assembly so that it is positioned as shown in the illustration.

      SST
      09922-10010
      Torque
      Specified tightening torque
      27 N*m (275 kgf*cm, 20 ft.*lbf)

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here

      • When using SST (fulcrum length of 137 mm (5.39 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 15.3 N*m (156 kgf*cm, 11 ft.*lbf)

  71. INSTALL OIL COOLER UNION SUB-ASSEMBLY


    1. B000NLHE01
      Text in Illustration
      *1 Union Bolt
      *2 Gasket

      Temporarily install the oil cooler union sub-assembly to the transaxle case sub-assembly with the bolt.

    2. Install the union bolt and 2 new gaskets to the transaxle case sub-assembly as shown in the illustration.

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

    3. Tighten the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  72. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B000JFQ

      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. B000KX4E17
      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.

  73. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. B000K3I

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

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

  74. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B000MHYE04
      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. B000JS9E01
      Text in Illustration
      *1 No. 2 Breather Plug
      *a Boss

      Install the transmission breather hose sub-assembly to the transaxle case sub-assembly.

      Note

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