AUTOMATIC TRANSAXLE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Check each bearing position and installation direction.

B003ZCXN01
B003YXGE01
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) -

PROCEDURE


  1. INSTALL COUNTER DRIVE GEAR BEARING

    Tech Tips

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


    1. B003YZ7N01

      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 DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)


    1. B003YX2N02

      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.

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


    1. B004023N01

      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.

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


    1. B003ZGGN01

      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.

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


    1. B00406VN01

      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.

  6. 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. B003Z0J

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

    3. B003ZLR

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

    4. B003Z8GN03

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

      Torque:
      Bolt (A)
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
      except Bolt (A)
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
    5. B003ZIYN02

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

      SST
      09564-33010
      Turning Torque
      Differential side bearing preload + 3.0 to 6.9 N*m (31 to 70 kgf*cm, 27 to 61 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
      No. Thickness No. Thickness
      2.000 (0.0787) 2.275 (0.0896) 2.550 (0.100) 2.825 (0.111)
      2.025 (0.0797) 2.300 (0.0906) 2.575 (0.101) 2.850 (0.112)
      2.050 (0.0807) 2.325 (0.0915) 2.600 (0.102) 2.875 (0.113)
      2.075 (0.0817) 2.350 (0.0925) 2.625 (0.103) 2.900 (0.114)
      2.100 (0.0827) 2.375 (0.0935) 2.650 (0.104) 2.925 (0.115)
      2.125 (0.0837) 2.400 (0.0945) 2.675 (0.105) 2.950 (0.116)
      2.150 (0.0846) 2.425 (0.0955) 2.700 (0.106) 2.975 (0.117)
      2.175 (0.0856) 2.450 (0.0965) 2.725 (0.107) 3.000 (0.118)
      2.200 (0.0866) 2.475 (0.0974) 2.750 (0.108) -
      2.225 (0.0876) 2.500 (0.0984) 2.775 (0.109) -
      2.250 (0.0886) 2.525 (0.0994) 2.800 (0.110) -

    6. Remove the 20 bolts and the transaxle housing.

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

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

  7. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B003ZHNN05

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

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

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

      Note

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

  8. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B003YZX

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

      Note

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

    2. B003Z4G

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

  9. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. B003ZUH

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

  10. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B00402E

      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.

  11. INSTALL NO. 3 BRAKE PISTON


    1. B003ZPV

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

      Note

      Ensure that the O-rings are not twisted.

    2. B003YXTC01
      *1 No. 3 Brake Piston

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

    3. B003ZPRC01
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

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

      Note

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

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

      Note

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

      Tech Tips

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

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

    6. B003ZYYC01
      *1 No. 3 Brake Piston
      *2 Brake Piston Return Spring

      Install the brake piston return spring to the transaxle case sub-assembly.

      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.

      B003Z4AC02
      *1 Snap Ring - -
      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 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 brake piston return spring as shown in the illustration.

  12. INSTALL COUNTER DRIVE GEAR


    1. B003ZC2N01

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

      SST
      09387-00020

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

    3. B003Z0UN02

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

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

      Note

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

  13. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B004000N02

      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

  14. INSTALL NO. 2 BRAKE PISTON


    1. B003ZZE

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

      Note

      Ensure that the O-rings are not twisted.

    2. B003Z3D

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

      Note

      Be careful not to damage the O-rings.

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


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

      B003ZSON02

    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.

      SST
      09387-00060

      Note

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

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

      Note


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

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

  16. INSTALL NO. 2 BRAKE DISC


    1. B003ZICC06
      *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 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. B004054

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

      Note


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

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

  17. INSPECT CLEARANCE OF NO. 2 BRAKE

    Click here

  18. INSTALL PLANETARY RING GEAR FLANGE


    1. B003Z7NC01
      *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.

  19. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. B003Z9HC01
      *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. B003ZPTC01
      *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 will be visible.

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

      Note


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

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

    5. B00406X

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

      Note


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

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

  20. INSTALL PARKING LOCK PAWL


    1. B003Z0IC01
      *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. B003Z12

      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.

  21. INSTALL PARKING LOCK SLEEVE


    1. B003Z9G

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

  22. INSTALL PAWL STOPPER PLATE


    1. B004058

      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 }

  23. INSTALL NO. 1 TRANSMISSION CASE PLATE


    1. B003YWSN02

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

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

      Torque:
      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 sub-assembly as shown in the illustration.

  24. INSTALL PAWL SHAFT CLAMP


    1. B004098

      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 }

  25. INSTALL COUNTER DRIVEN GEAR


    1. B003ZKA

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

  26. INSTALL COUNTER DRIVE GEAR NUT


    1. B003ZQDN01

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

    2. B003Z7JE04

      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, 88 ft.*lbf }
    3. B003ZHAN01

      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. B003ZHMN01

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

      SST
      09387-00130
      Turning Torque
      0.1 to 0.8 N*m (1 to 8 kgf*cm, 1 to 7 in.*lbf)

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

      Maximum Torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)
    6. B003YYEN02

      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.

  27. INSTALL FRONT DIFFERENTIAL CASE


    1. B003ZEK

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

  28. INSTALL NO. 1 BRAKE PISTON


    1. B003ZX0

      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. B003ZYG

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

      Note

      Be careful not to damage the O-rings.

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


    1. B003ZFB

      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.

  30. INSTALL NO. 1 BRAKE DISC


    1. B003YYIC01
      *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. B003ZRON02

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

      Note


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

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

    4. B00409C

      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. B003ZZTN06

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

      Note


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

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

    6. B003ZABC01
      *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.

  31. INSPECT CLEARANCE OF NO. 1 BRAKE

    Click here

  32. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. B003ZKNC01
      *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 properly so that the temper colored side of the race will be visible.

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

  33. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. B003ZP2C01
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Sub-assembly
      *4 Oil Seal Ring

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

      Note

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

    2. Coat the thrust needle roller bearing and thrust bearing race with ATF and install them 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. B003ZM4

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

  34. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B003ZQAC01
      *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.

  35. 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. B004062

      Install the snap ring to the underdrive planetary ring gear.

    2. B003ZMO

      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.

  36. INSTALL NO. 3 BRAKE HUB


    1. B003ZKIC01
      *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 (2.47) 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. B003ZOI

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

  37. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. B004092

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

  38. INSTALL NO. 3 BRAKE DISC


    1. B003Z7OC01
      *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. B003ZKVN05

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

      Note


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

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

  39. INSPECT CLEARANCE OF NO. 3 BRAKE

    Click here

  40. INSTALL FRONT OIL PUMP ASSEMBLY


    1. B00409PC03
      *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 properly so that the temper colored side of the race is visible.

    4. Coat the thrust bearing race with MP grease.

    5. B003ZCAC01
      *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. B003ZDQ

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

      Note

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

    7. B003Z4DC08
      *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.

  41. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. B003ZTA

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

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

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

  42. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. B00403Q

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

      Note

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

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

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

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

      Note

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

  43. INSTALL TRANSAXLE HOUSING


    1. B003ZDI

      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. B003ZDXC02
      *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. B003ZKF

      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. B003ZM2

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    6. Install the 3 bolts.

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

  44. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    Click here

  45. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. B003ZL9C01
      *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. B003ZM3C01
      *1 Rear Planetary Sun Gear Assembly

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

    3. B003Z4W

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

    4. B003ZFFC01
      *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.

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

  46. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

    Click here

  47. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY


    1. B003ZZ8C01
      *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)

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

  48. INSPECT INTERMEDIATE SHAFT END PLAY

    Click here

  49. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. B003ZC3N01

      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. B00400Z

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. B003ZYBC01
      *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. B003Z1JC01
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      - 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. B003Z5T

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

    8. B003ZPD

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

    9. B003Z9OC02
      *a FIPG

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

      Note

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

    10. 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. B003ZOR

      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. 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. B003Z5E

      Install the 2 bolts.

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

  50. INSTALL REAR TRANSAXLE COVER PLUG


    1. B003YWZ

      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 }

  51. INSTALL REFILL PLUG


    1. B003ZPH

      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 }

  52. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY

    Click here

  53. INSTALL NO. 1 GOVERNOR APPLY GASKET


    1. B003ZKL

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

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

  54. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


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

    2. B003ZBCC01
      *1 Manual Valve Lever Shaft Sub-assembly
      *2 Manual Valve
      *a Positioning Bolt

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

      Bolt Length
      Bolt Length [mm (in.)]
      (A) 25 (0.984)
      (B) 30 (1.18)
      (C) and (D) 35 (1.38)
      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 sub-assembly to interfere with each other.

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

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

  55. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. B003ZWPC03
      *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. B003ZE1

      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 }

  56. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. B003YWXC01
      *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.

  57. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET


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

  58. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. B003Z8K

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

    2. B003ZI9

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

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

      Note

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

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

      Adhesive
      Toyota Genuine Adhesive 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.

    4. B003Z4X

      Install the 2 bolts.

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

  59. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE


    1. B003ZST

      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 }

  60. INSTALL OVERFLOW PLUG


    1. B003ZBN

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

      Torque:
      40 N*m  { 408 kgf*cm, 29 ft.*lbf }

  61. INSTALL NO. 2 TRANSAXLE CASE PLUG


    1. B00409U

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

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

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

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

  62. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. B003Z9W

      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 }

  63. INSTALL OIL COOLER TUBE UNION (INLET)


    1. B003ZK7

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  64. INSTALL OIL COOLER TUBE UNION (OUTLET)


    1. B003ZHL

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  65. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B003Z7L

      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. B003Z21C29
      *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.

  66. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. B003YZ0

      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 }

  67. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B003ZS4C01
      *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. B003ZXAC08
      *1 No. 2 Breather Plug
      *a Boss

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

      Note

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