AUTOMATIC TRANSAXLE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Check bearing position and installation direction.

A01V9BZN01
A01V7ZBN01
Mark

Front Race Diameter

Inside / Outside

Thrust Bearing Diameter

Inside / Outside

Rear Race Diameter

Inside / Outside
A - 57.7 mm (2.27 in.) / 75.2 mm (2.96 in.) -
B - 29.1 mm (1.15 in.) / 48.6 mm (1.91 in.) 30.7 mm (1.21 in.) / 48.3 mm (1.90 in.)
C - 62.6 mm (2.46 in.) / 82.4 mm (3.24 in.) 65.9 mm (2.59 in.) / 82.3 mm (3.24 in.)
D 59.4 mm (2.34 in.) / 76 mm (2.99 in.) 53.46 mm (2.10 in.) / 79 mm (3.11 in.) -
E - 56.1 mm (2.21 in.) / 81.1 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 (2.83 in.) -

PROCEDURE


  1. INSTALL COUNTER DRIVE GEAR BEARING

    Tech Tips

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


    1. A01V7YEN07

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

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

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


    1. A01VAIIN03

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

      SST
      09950-60010   ( 09951-00630 )
      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.

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


    1. A01V7OUN04

      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   ( 09951-00810 )
      09950-70010   ( 09951-07150 )

      Note

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

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


    1. Install the shim to the transaxle housing.

    2. A01V8J5N05

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

      SST
      09950-60020   ( 09951-00710 )
      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.

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


    1. Install the shim to the transaxle housing.

    2. A01V76BN05

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

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

      Note

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

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


    1. A01VAYVN01

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

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

      Note


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

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

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


    1. A01V6ZTN01

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

      SST
      09523-36010
      09950-60010   ( 09951-00540 )
      09950-70010   ( 09951-07100 )

      Note


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

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

  8. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD


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

    2. A01V9GM

      Install the front differential case to the transaxle case.

    3. A01VA1DN01

      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. A01V7T0N01

      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
      1.23 to 1.65 N*m (12.55 to 16.82 kgf*cm, 10.89 to 14.60 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. A01V9V7

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

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

  9. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. A01V8T8N05

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

      SST
      09950-60010   ( 09951-00490 )

      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.

  10. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. A01V8ENN05

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

      SST
      09950-60010   ( 09951-00400 )

      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.

  11. ADJUST COUNTER DRIVEN GEAR PRELOAD


    1. A01V9XH

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

    2. A01VA1DN01

      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. A01V82IN01

      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 + 2.96 to 6.54 N*m (30.19 to 66.68 kgf*cm, 26.20 to 57.88 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. A01V9V7

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

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

  12. INSTALL TRANSAXLE CASE OIL SEAL LH


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

    2. A01V6ZAN05

      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.

  13. INSTALL TRANSAXLE CASE OIL SEAL RH (OUTER)


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

    2. A01VAI1N01

      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 is installed in the correct direction.

  14. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01V9QTN02

      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, tap in the manual valve lever shaft oil seal.

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

      Note

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

  15. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01V8WS

      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. A01VAL7

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

  16. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01V8DU

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

  17. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01V8X5

      Install the manual detent spring sub-assembly and manual detent spring 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 manual detent spring cover.

  18. INSTALL NO. 3 BRAKE PISTON


    1. A01VAK0

      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. A01V9JQC01
      *1 No. 3 Brake Piston

      Temporarily install the No. 3 brake piston to the transaxle.

    3. A01V9EDC01
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

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

      Note

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

    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.

      Tech Tips

      Use the installation surface of the return spring to press the piston into the transaxle case.

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

    6. A01VAGDC01
      *1 No. 3 Brake Piston
      *2 Brake Piston Return Spring

      Install the brake piston return spring to the transaxle case.

      Note

      Install the brake piston return spring as shown in the illustration.

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

      A01V9AVC01
      *1 Snap Ring - -
      *a Protective Tape - -
      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.

  19. INSTALL COUNTER DRIVE GEAR


    1. A01V9DJN01

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

      SST
      09387-00020
    2. A01VAALN02

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

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

      Note

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

  20. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01VAWZN02

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

      SST
      09223-15030
      09527-17011
      09951-01100

  21. INSTALL NO. 2 BRAKE PISTON


    1. A01V7RI

      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. A01V6Z9

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

      Note

      Be careful not to damage the O-rings.

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


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

      A01V9IHC01
      *a Protective Tape - -

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

      SST
      09387-00060

      Note

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

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

  23. INSTALL NO. 2 BRAKE DISC


    1. A01V8LIC01
      *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.

      Note

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

    2. A01VAZLC01
      *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.

  24. INSPECT CLEARANCE OF NO. 2 BRAKE

    Click here

  25. INSTALL PLANETARY RING GEAR FLANGE


    1. A01VAPCC01
      *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.

  26. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A01V8QTC01
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

      Install the outer race retainer to the one-way clutch assembly.

    2. Install the one-way clutch assembly to the planetary ring gear.

      Note

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

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

      A01V8OEC02
      *1 Thrust Needle Roller Bearing - -
      Bearing Diameter
      - Inside Outside
      Bearing 56.1 mm (2.21 in.) 81.1 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.

    4. Install the one-way clutch assembly with the planetary ring gear 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.

    5. A01V7GTC01
      *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.

  27. INSTALL PARKING LOCK PAWL


    1. A01VAP5C01
      *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 with the parking lock pawl shaft.

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

    3. A01V7E9

      Install the spring to the parking lock pawl.

      Note

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

  28. INSTALL PARKING LOCK SLEEVE


    1. A01V7MD

      Install the parking lock sleeve to the transaxle case.

  29. INSTALL PAWL STOPPER PLATE


    1. A01V6XR

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

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

  30. INSTALL NO. 1 TRANSMISSION CASE PLATE


    1. A01V7TKN02

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Install the No. 1 transmission case plate to the transaxle case with the bolt.

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

      Tech Tips

      Tighten the bolt while part A of the No. 1 transmission case plate contacts the transaxle case as shown in the illustration.

  31. INSTALL PAWL SHAFT CLAMP


    1. A01V7IF

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

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

  32. INSTALL COUNTER DRIVEN GEAR


    1. A01V80K

      Install the counter driven gear to the transaxle case.

  33. INSTALL COUNTER DRIVE GEAR NUT


    1. A01V7VXN01

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

    2. A01V8VQN02

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. A01V7F6N01

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

    4. A01V6SDN01

      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, 0.9 to 7.1 in.*lbf)

      If the measured value is not within the specified range, gradually tighten the counter drive gear 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.

  34. INSTALL FRONT DIFFERENTIAL CASE


    1. A01V9MX

      Install the front differential case to the transaxle case.

  35. INSTALL NO. 1 BRAKE PISTON


    1. A01V9T9

      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. A01V6YY

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01V97F

      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.

  37. INSTALL NO. 1 BRAKE DISC


    1. A01V87XC01
      *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 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. A01VA9MC01
      *a Protective Tape

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

      SST
      09387-00070
      09495-65040

      Note

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

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

      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 (#1) of the front oil pump and gear body 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. A01V8XP

      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. A01VAZPN01

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

      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. A01V8OPC02
      *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 the snap ring may not have been completely located in the groove on the oil pump assembly. Remove and reinstall the snap ring and the brake snap ring stopper.

  38. INSPECT CLEARANCE OF NO. 1 BRAKE DISC

    Click here

  39. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. A01V7AKC01
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

      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.

  40. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01V8CXC01
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Sub-assembly
      *4 Oil Seal Ring

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

      Note

      Do not expand the gap of the oil seal ring too much.

    2. Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them on the input shaft sub-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. A01V9O2

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

  41. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01V8IFC01
      *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.

  42. 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. A01VAP3

      Install the snap ring to the underdrive planetary ring gear.

    2. A01V8ZTC02
      *a Protective Tape

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

      Note

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

      Tech Tips

      tape the screwdriver tip before use.

  43. INSTALL NO. 3 BRAKE HUB


    1. A01V7FYC01
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing

      Coat the thrust needle roller bearing with ATF and install it on the underdrive planetary gear assembly.

      Bearing and Race Diameter
      - Inside Outside
      Bearing 62.6 mm (2.47 in.) 82.4 mm (3.24 in.)
      Race 65.9 mm (2.59 in.) 82.3 mm (3.24 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. Coat the thrust needle roller race with MP grease and install it to the No. 3 brake hub.

    3. A01V87J

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

  44. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01V6WA

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

  45. INSTALL NO. 3 BRAKE DISC


    1. A01V8YMC01
      *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. A01VALEN02

      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.

  46. INSPECT CLEARANCE OF NO. 3 BRAKE DISC

    Click here

  47. INSTALL OIL PUMP ASSEMBLY


    1. A01VAF8C06
      *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 53.46 mm (2.10 in.) 79 mm (3.11 in.)

      Note

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

    4. Coat the thrust needle roller race with MP grease.

    5. A01V6VCC03
      *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.) 76 mm (2.99 in.)
    6. A01V7YI

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

    7. A01V7HAC01
      *1 O-ring

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

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

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

  48. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. A01V9U6

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. 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 }

  49. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01V7ED

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

      Note

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

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the apply tube 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 apply tube clamp.

  50. INSTALL TRANSAXLE HOUSING


    1. A01VB32

      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. 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. A01V8PZ

      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 }
    4. A01V6TR

      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 }

  51. INSPECT CLEARANCE OF NO. 1 CLUTCH

    Click here

  52. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01V8H7C01
      *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. A01V8X9C01
      *1 Rear Planetary Sun Gear

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

    3. A01V86S

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

    4. A01V9XNC01
      *1 O-ring
      *2 Oil Seal Ring

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

      Note

      Ensure that the O-ring is not twisted.

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

  53. INSPECT CLEARANCE OF NO. 2 CLUTCH

    Click here

  54. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01V94MC01
      *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.

  55. INSPECT INTERMEDIATE SHAFT END PLAY

    Click here

  56. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01V92CN05

      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 0.862 in.)
    2. A01V8GU

      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. 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. A01V9Y5C01
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 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.

      Bearing and Race Diameter
      - Inside Outside
      Bearing 48.9 mm (1.93 in.) 72.0 mm (2.83 in.)
      Race 52.2 mm (2.06 in.) 70.4 mm (2.77 in.)

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

    7. A01V9A7

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

    8. A01V8V9

      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. 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. A01V9C5

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

      Torque:
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
    11. A01V8JQ

      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.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the 2 bolts.

      Torque:
      16.9 N*m  { 172 kgf*cm, 12 ft.*lbf }
    14. A01V8WB

      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 }

  57. INSPECT INPUT SHAFT END PLAY

    Click here

  58. INSTALL TRANSAXLE CASE GASKET


    1. A01V7C8

      Coat 2 new transaxle case gaskets with ATF.

    2. Install the 2 transaxle case gaskets onto the transaxle case.

  59. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A01V7VMC01
      *a Positioning Bolt

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

    2. Insert the pin of the manual valve lever into the groove on the end of the manual valve and install the transmission valve body assembly onto the transaxle case with the 11 bolts.

      Bolt Length
      Bolt Length
      A 25 mm (0.984 in.)
      B 30 mm (1.18 in.)
      C and D 35 mm (1.38 in.)
      Torque:
      Bolt A, B, C
      10.8 N*m  { 110 kgf*cm, 8 ft.*lbf }
      Bolt D
      9.6 N*m  { 98 kgf*cm, 85 in.*lbf }

      Note


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

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

  60. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01VAPU

      Coat a new O-ring with ATF.

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

      Note

      Ensure that the O-ring is not twisted.

    3. A01V910

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

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

  61. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01V9OGC01
      *1 Transmission Oil Cleaner Magnet

      Install the 2 transmission oil cleaner magnets onto the automatic transaxle oil pan sub-assembly as shown in the illustration.

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

    3. A01V91W

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

    4. A01V8R0

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    7. A01VAVU

      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 }
    8. A01VAHV

      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 }

  62. INSTALL TRANSAXLE CASE PLUG


    1. A01V8M6

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

    2. Apply adhesive to 2 or 3 threads on the ends of the 3 transaxle case plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    5. A01V9MY

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

    6. 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 }

  63. INSTALL OIL COOLER TUBE UNION


    1. A01V7OZ

      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.

  64. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01V7Q6

      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. A01V9KTC14
      *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.

    4. A01VAHA

      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 }

  65. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A01V7C5C01
      *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. A01V9AKC05
      *1 No. 2 Breather Plug
      *a Boss

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

      Note

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