AUTOMATIC TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION


    1. Check bearing position and installation direction.

      B002AGSN02
      B002AGEN01
      Mark

      Front Race Diameter

      Inside / Outside

      Thrust Bearing Diameter

      Inside / Outside

      Rear Race Diameter

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

  2. INSTALL COUNTER DRIVE GEAR BEARING

    Note

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


    1. B0029H2N02

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

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

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


    1. B002A3XN02

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

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07100 )

      Note

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

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


    1. B0029UKN02

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

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

      Note

      Ensure that there is no clearance between the bearing and transaxle case.

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


    1. B0029MLN01

      Install the shim to the transaxle housing.

    2. Using SST, install a new counter driven gear front tapered roller bearing outer race to the transaxle housing.

      SST
      09950-60020   ( 09951-00810 )
      09950-70010   ( 09951-07100 )

      Note

      Be sure to install the counter driven gear front tapered roller bearing outer race so that there is no clearance between the shim and the transaxle housing.

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


    1. Install the shim to the transaxle housing.

    2. B0029YZN02

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

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

      Note

      Ensure that there is no clearance between the bearing and transaxle housing.

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


    1. B0029GPN01

      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.

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


    1. B0029YAN01

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

      SST
      09316-12010
      09649-17010
      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.

  9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


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

    2. B002A60

      Install the front differential case to the transaxle case.

    3. B0029HHN01

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

      Torque:
      for Bolt A
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
      for Bolt B
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
    4. B00298XN01

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

      SST
      09564-33010
      Turning torque
      0.72 to 1.40 N*m (7.35 to 14.27 kgf*cm, 6.38 to 12.39 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      Shim Thickness:
      Thickness Thickness Thickness Thickness
      2.000 mm (0.0787 in.) 2.225 mm (0.0876 in.) 2.450 mm (0.0965 in.) 2.675 mm (0.105 in.)
      2.025 mm (0.0797 in.) 2.250 mm (0.0886 in.) 2.475 mm (0.0974 in.) 2.700 mm (0.106 in.)
      2.050 mm (0.0807 in.) 2.275 mm (0.0896 in.) 2.500 mm (0.0984 in.) 2.725 mm (0.107 in.)
      2.075 mm (0.0817 in.) 2.300 mm (0.0906 in.) 2.525 mm (0.0994 in.) 2.750 mm (0.108 in.)
      2.100 mm (0.0827 in.) 2.325 mm (0.0915 in.) 2.550 mm (0.100 in.) 2.775 mm (0.109 in.)
      2.125 mm (0.0837 in.) 2.350 mm (0.0925 in.) 2.575 mm (0.101 in.) 2.800 mm (0.110 in.)
      2.150 mm (0.0846 in.) 2.375 mm (0.0935 in.) 2.600 mm (0.102 in.) 2.825 mm (0.111 in.)
      2.175 mm (0.0856 in.) 2.400 mm (0.0945 in.) 2.625 mm (0.103 in.) 2.850 mm (0.112 in.)
      2.200 mm (0.0866 in.) 2.425 mm (0.0955 in.) 2.650 mm (0.104 in.) 2.875 mm (0.113 in.)
    5. B002AHS

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

    6. B002A60

      Remove the front differential case from the transaxle case.

  10. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. B002AOTN01

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

      SST
      09950-60010   ( 09951-00530 )

      Note

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

  11. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. B0029VZN01

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

      SST
      09950-60010   ( 09951-00420 )

      Note

      Be sure to install the counter driven gear rear tapered roller bearing so that there is no clearance between each of them and the counter driven gear.

  12. ADJUST COUNTER DRIVEN GEAR PRELOAD


    1. B002A8Q

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

    2. B0029HHN01

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

      Torque:
      for Bolt A
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
      for Bolt B
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
    3. B00298YN01

      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 + 2.38 to 4.69 N*m (24.28 to 47.82 kgf*cm, 21.07 to 41.50 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim of the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range.

      Shim Thickness:
      Thickness Thickness Thickness Thickness
      2.000 mm (0.0787 in.) 2.275 mm (0.0896 in.) 2.525 mm (0.0994 in.) 2.775 mm (0.109 in.)
      2.025 mm (0.0797 in.) 2.300 mm (0.0906 in.) 2.550 mm (0.100 in.) 2.800 mm (0.110 in.)
      2.050 mm (0.0807 in.) 2.325 mm (0.0915 in.) 2.575 mm (0.101 in.) 2.825 mm (0.111 in.)
      2.075 mm (0.0817 in.) 2.350 mm (0.0925 in.) 2.600 mm (0.102 in.) 2.850 mm (0.112 in.)
      2.100 mm (0.0827 in.) 2.375 mm (0.0935 in.) 2.625 mm (0.103 in.) 2.875 mm (0.113 in.)
      2.125 mm (0.0837 in.) 2.400 mm (0.0945 in.) 2.650 mm (0.104 in.) 2.900 mm (0.114 in.)
      2.150 mm (0.0846 in.) 2.425 mm (0.0955 in.) 2.675 mm (0.105 in.) 2.925 mm (0.115 in.)
      2.175 mm (0.0856 in.) 2.450 mm (0.0965 in.) 2.700 mm (0.106 in.) 2.950 mm (0.116 in.)
      2.200 mm (0.0866 in.) 2.475 mm (0.0974 in.) 2.725 mm (0.107 in.) 2.975 mm (0.117 in.)
      2.225 mm (0.0876 in.) 2.500 mm (0.0984 in.) 2.750 mm (0.108 in.) 3.000 mm (0.118 in.)
      2.250 mm (0.0886 in.) - - -
    4. B002AHS

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

    5. B002A60

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

  13. INSTALL TRANSAXLE CASE OIL SEAL LH


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

    2. B0029MKN01

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

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

      Note

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

  14. INSTALL TRANSAXLE CASE OIL SEAL RH (OUTER)


    1. Coat the lip of a new transaxle case oil seal RH (outer) with MP grease.

    2. B002A4YN01

      Using SST and a hammer, tap in the transaxle case oil seal RH (outer).

      SST
      09649-17010   ( 09951-07200 )
      Standard depth
      5.5 to 6.5 mm (0.217 to 0.255 in.)

      Note

      Make sure that the transaxle case oil seal RH (outer) is installed in the correct direction.

  15. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B002A61N01

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

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

      SST
      09950-60010   ( 09951-00230 )
      09950-70010   ( 09951-07100 )
      Oil seal driven in depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  16. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B0029SX

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

      Note

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

    2. B0029QC

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

  17. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. B0029DXC01
      *1 Parking Lock Rod Sub-assembly
      *2 Manual Valve Lever Shaft Sub-assembly

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

  18. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B002A7W

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

  19. INSTALL NO. 3 BRAKE PISTON


    1. B0029I1

      Coat the contact surface of the transaxle case with ATF.

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

    3. B0029QG

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

    4. Press the No. 3 brake piston into the transaxle case.

      Note


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

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

      Tech Tips

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

    5. B0029VEC01
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

      Install the brake piston return spring to the transaxle case.

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

    7. B002ACJC01
      *a Protective Tape

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

      SST
      09387-00070

      Note

      Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.

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

      Note


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

      • Be sure to align the opening of the snap ring with one of the protrusions on the brake piston return spring as shown in the illustration.


      • Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

  20. INSTALL COUNTER DRIVE GEAR


    1. Install 2 new balls of the counter drive gear bearing to the counter drive gear bearing.

    2. B0029EBN01

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

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

      Note

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

  21. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B002AH4N01

      Using SST and a press, press the front planetary gear assembly onto the transaxle case.

      SST
      09223-15030
      09527-17011
      09951-01100

  22. INSTALL NO. 2 BRAKE PISTON


    1. B0029VJC02
      *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. B002A79

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

      Note

      Be careful not to damage the O-rings.

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


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

    2. Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring sub-assembly using a press.

      SST
      09387-00060
      B002ACKC01
      *a Protective Tape - -

      Note

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

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

      Note


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

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


      • Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

  24. INSTALL NO. 2 BRAKE DISC


    1. B0029YNC02
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

      Install the 5 No. 2 brake discs, 5 No. 2 brake plates and No. 2 brake flange to the transaxle case.

      Note

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

    2. B0029U5C01
      *a Protective Tape

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

      Note


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

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


      • Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

  25. INSPECT CLEARANCE OF NO. 2 BRAKE

    Click here

  26. INSTALL PLANETARY RING GEAR FLANGE


    1. B002A5SC03
      *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.


      • Be careful not to damage the planetary ring gear.

      Tech Tips

      Tape the screwdriver tip before use.

  27. INSTALL PLANETARY RING GEAR


    1. B0029EZC01
      *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 planetary ring gear to the one-way clutch assembly.

      Note

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

  28. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. B002A9M

      Coat the thrust needle roller bearing with ATF, and install it onto the planetary gear assembly.

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

      Note

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

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

      Note

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

    3. B0029M2C01
      *a Protective Tape

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

      Note


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

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


      • Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

  29. INSTALL PARKING LOCK PAWL


    1. B0029SNC01
      *1 Parking Lock Pawl Shaft
      *2 Parking Lock Pawl
      *3 Spring
      *4 Parking Lock Pawl Pin

      Install the parking lock pawl to the transaxle case with the parking lock pawl shaft.

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

    3. B002ADM

      Install the spring to the parking lock pawl.

      Note

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

  30. INSTALL PARKING LOCK SLEEVE


    1. B002AL3

      Install the parking lock sleeve to the transaxle case.

  31. INSTALL PAWL STOPPER PLATE


    1. B0029AW

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

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

  32. INSTALL PAWL SHAFT CLAMP


    1. B0029OQ

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

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

  33. INSTALL COUNTER DRIVEN GEAR


    1. B0029LW

      Install the counter driven gear to the transaxle case.

  34. INSTALL COUNTER DRIVE GEAR NUT


    1. B0029QNN02

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

    2. B002A1ON02

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. B002AK9N02

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

    4. B002A8KN02

      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 0.2 N*m (1 to 2 kgf*cm, 0.9 to 1.9 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)

    5. Using a chisel and hammer, securely stake the counter drive gear nut.

  35. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

    Click here

  36. INSTALL FRONT DIFFERENTIAL CASE


    1. B002A0J

      Install the front differential case to the transaxle case.

  37. INSTALL NO. 1 BRAKE PISTON


    1. B0029ZYC02
      *1 O-ring

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

      Note

      Ensure that the O-rings are not twisted.

    2. B002A7C

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

      Note

      Be careful not to damage the O-rings.

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


    1. B002AGC

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

      Note

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

  39. INSTALL NO. 1 BRAKE DISC


    1. B0029CJC01
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

      Install the 4 No. 1 brake discs, 4 No. 1 brake plates and No. 1 brake flange to the oil pump assembly.

      Note


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

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

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

      SST
      09387-00070
      09495-65040

      Note

      Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.

    3. B002AK7C01
      *a Protective Tape

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

      Note


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

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


      • Be careful not to damage the oil pump assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    4. B002ADA

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

      Note

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

    5. B002ANGC01
      *a Protective Tape

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

      Note


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

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


      • Be careful not to damage the oil pump assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    6. B0029RQC02
      *1 Snap Ring
      *2 Brake Snap Ring Stopper
      *a Correctly installed

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

      Note

      If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or the snap ring may not have been completely located in the groove on the oil pump. Remove and reinstall the snap ring and the brake snap ring stopper.

  40. INSPECT CLEARANCE OF NO. 1 BRAKE

    Click here

  41. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. B0029VQC01
      *1 Thrust Needle Roller Bearing
      *2 Underdrive Planetary Sun Gear

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

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

      Note

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

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

  42. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. B0029Y7C02
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring
      *4 Input Shaft Sub-assembly

      Coat 3 new input shaft 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 needle roller race with ATF, and install them on the oil pump assembly.

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

      Note

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

    3. B002A71

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

  43. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B002AJEC02
      *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.

  44. INSTALL UNDERDRIVE PLANETARY RING GEAR


    1. B0029SSC02
      *1 Snap Ring
      *2 Underdrive Planetary Ring Gear

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

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

      Note

      Confirm that the snap ring is correctly located in the groove of the underdrive planetary ring gear.

  45. INSTALL NO. 3 BRAKE HUB


    1. B002AACC01
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing

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

      Thrust Needle Roller Bearing and Thrust Needle Roller Race Diameter:
      - Inside Outside
      Thrust needle roller bearing 62.6 mm (2.46 in.) 82.9 mm (3.26 in.)
      Thrust needle roller race 65.9 mm (2.59 in.) 80.3 mm (3.16 in.)

      Note

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

    2. B002AK2

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

  46. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. B002AC3

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

  47. INSTALL NO. 3 BRAKE DISC


    1. B0029HFC03
      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc

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

      Note

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

    2. B002AB4N03

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

      Note


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

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


      • Be careful not to damage the oil pump assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  48. INSPECT CLEARANCE OF NO. 3 BRAKE

    Click here

  49. INSTALL FRONT OIL PUMP BODY O-RING


    1. B0029LL

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

  50. INSTALL OIL PUMP ASSEMBLY


    1. B0029M4C05
      *1 Thrust Needle Roller Bearing
      *2 O-ring

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

    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 Outside
      Thrust needle roller bearing 53.1 mm (2.09 in.) 79 mm (3.11 in.)

      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 needle roller race with MP grease.

    5. B0029KAC06
      *1 Thrust Needle Roller Race

      Install the thrust needle roller race to the underdrive planetary gear assembly.

      Thrust Needle Roller Race Diameter:
      - Inside Outside
      Thrust needle roller race 59.4 mm (2.34 in.) 77 mm (3.03 in.)
    6. B002A48C01
      *1 Gasket

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

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

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

  51. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. B002A40

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

      Note

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

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

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

      Note

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

  52. INSTALL TRANSAXLE HOUSING


    1. Clean and degrease the contact surfaces between the transaxle housing and transaxle case.

      Note

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

    2. B00298AC01
      *a Seal Packing

      Apply seal packing to the transaxle case.

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

      Note


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


      • After applying seal packing, install the transaxle housing to the transaxle case within 3 minutes and tighten the bolts within 10 minutes.

    3. B0029BU

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

      Torque:
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
    4. B002A9G

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the 3 bolts.

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

  53. INSTALL NO. 1 CLUTCH DISC


    1. B0029XNC02
      *1 No. 1 Clutch Flange
      *2 No. 1 Clutch Plate
      *3 No. 1 Clutch Disc

      Install the No. 1 clutch flange, 4 No. 1 clutch discs and 4 No. 1 clutch plates to the direct multiple disc clutch assembly.

      Note

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

    2. B0029H7

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

      Note


      • Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.


      • Be careful not to damage the direct multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  54. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    Click here

  55. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. B002A2GC01
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

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

      Bearing and Race Diameter:
      - Inside Outside
      Bearing 28 mm (1.10 in.) 47.1 mm (1.85 in.)
      Race 26.1 mm (1.03 in.) 44 mm (1.73 in.)

      Note

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

    2. B002A6X

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

    3. B0029Q0

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

  56. INSTALL NO. 2 CLUTCH DISC


    1. B0029Q3C02
      *1 No. 2 Clutch Plate
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Flange

      Install the No. 2 clutch flange, 3 No. 2 clutch discs and 3 No. 2 clutch plates to the direct multiple disc clutch assembly.

      Note

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

  57. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING


    1. B00299FC02
      *1 Intermediate Shaft Oil Seal
      *2 O-ring

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

    2. Coat a new intermediate shaft oil seal with ATF and install it to the direct multiple disc clutch assembly.

    3. B002AK4

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

      Note

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

    4. B002989C01
      *a Protective Tape

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

      Note


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

      • Confirm that the snap ring is correctly located in the groove of the direct multiple disc clutch assembly.


      • Be careful not to damage the direct multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  58. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

    Click here

  59. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. B0029BZC01
      *1 Thrust Needle Roller Bearing
      *2 Direct Multiple Disc Clutch Assembly

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

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

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

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

    4. B0029XUC01
      *a Dimension A

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

    5. B002A5KC02
      *a Dimension B

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

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

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

      End play
      0.007 to 1.113 mm (0.000276 to 0.0438 in.)

  60. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. B002A1EN01

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

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Installation depth
      21.5 to 21.9 mm (0.847 to 0862 in.)

    2. Clean and degrease the 2 "TORX" screws and the 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
    4. B002AOQ

      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. B002AGXC08
      *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. B002AB7C08
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

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

      Thrust Needle Roller Bearing and Thrust Needle Roller Race Diameter:
      - Inside Outside
      Thrust needle roller bearing 48.9 mm (1.93 in.) 72.0 mm (2.84 in.)
      Thrust needle roller race 52.2 mm (2.06 in.) 70.4 mm (2.77 in.)
    7. B002A6T

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

      Note

      Ensure that the O-rings are not twisted.

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

      Note

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

    9. B002ANTC01
      *a Seal Packing

      Apply seal packing to the transaxle case.

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

      Note


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


      • After applying seal packing, install the rear transaxle cover sub-assembly to the transaxle case within 3 minutes and tighten the bolts within 10 minutes.

    10. B0029T3

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

      Torque:
      for bolt A
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
    11. B0029RM

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the 2 bolts.

      Torque:
      for bolt B
      16.9 N*m  { 172 kgf*cm, 12 ft.*lbf }
    14. B002AMY

      Install a new gasket to the refill plug.

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

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

  61. INSPECT INPUT SHAFT END PLAY

    Click here

  62. INSTALL TRANSAXLE CASE GASKET


    1. B002AM6

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

  63. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


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

    2. B002AALC04
      *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 with the 11 bolts.

      Item Bolt Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 30 mm (1.18 in.)
      Bolt C 35 mm (1.38 in.)
      Bolt D 45 mm (1.77 in.)
      Bolt E 55 mm (2.17 in.)

      Note


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

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

    3. Tighten the 2 positioning bolts shown in the illustration.

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

    4. Tighten the 9 bolts to install the transmission valve body assembly.

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

  64. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. B0029SUC03
      *1 O-ring

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

      Note

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

    2. B002AAJ

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

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

  65. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. B002986C04
      *1 Transmission Oil Cleaner Magnet

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

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

    3. B002A1F

      Install the automatic transaxle oil pan sub-assembly to the automatic transaxle assembly with the 17 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. B0029NR

      Clean and degrease the bolt and the installation hole in the automatic transaxle.

    5. Apply adhesive to the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Install the bolt.

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

      Note


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

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

    7. B0029NH

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

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }
    8. B002AMM

      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 TRANSAXLE CASE PLUG


    1. Install 3 new gaskets to the 3 hexagon bolts.

    2. Apply adhesive to the 3 hexagon bolts.

      Adhesive
      Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent

      Note

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

    3. B002AH9

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

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    4. B002AKP

      Coat 6 new O-rings with ATF and install them to the 6 transaxle case plugs.

    5. Install the 6 transaxle case plugs to the transaxle case and rear transaxle cover sub-assembly.

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

  67. INSTALL OIL COOLER TUBE UNION


    1. B002ALS

      Coat 2 new O-rings with ATF and install them to the 2 oil cooler tube unions.

    2. Using a 19 mm union nut wrench, install the 2 oil cooler tube unions as shown in the illustration.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  68. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B002A25

      Temporarily install the park/neutral position switch assembly to the transaxle case 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 switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral position switch assembly cannot be reinstalled correctly.

    2. Temporarily install the control shaft lever.

    3. B0029YLN01

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

    4. Remove the control shaft lever.

    5. B002AO6C05
      *a Protrusion

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

    6. Hold the switch in that position and 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.

    7. B002ACT

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

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

  69. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B0029PTC01
      *1 Breather Plug Hose
      *2 Breather Plug
      *3 O-ring

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

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

    3. B0029GA

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