AUTOMATIC TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION


    1. Check each bearing position and installation direction.

      B003ZOPN02
      B003ZRGN01
      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 (2.47) / 82.4 (3.24) 65.9 (2.59) / 80.3 (3.16)
      D 59.4 (2.34) / 77 (3.03) 53.1 (2.09) / 79 (3.11) -
      E - 56.1 (2.21) / 80.9 (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 (2.84) -

  2. INSTALL COUNTER DRIVE GEAR BEARING

    Note

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


    1. B003YZ7N09

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

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

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


    1. B003ZSEN01

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

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

      Note

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

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


    1. B00409QN02

      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

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

  5. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. B003ZOEN03

      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

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

  6. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. B003ZI1N02

      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

      Make sure to install the counter driven gear front tapered roller bearing so that there is no clearance between the counter driven gear front tapered roller bearing and transaxle case sub-assembly. If there is any clearance, the turning torque of the counter driven gear cannot be measured correctly.

  7. 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. A002BPY

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

    4. B003ZUEN01

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

      Torque:
      Bolt (A)
      30.6 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      22.7 N*m  { 231 kgf*cm, 17 ft.*lbf }
    5. B00409GN01

      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 + 2.5 to 4.9 N*m (26 to 49 kgf*cm, 23 to 43 in.*lbf)

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

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

    6. Remove the 20 bolts and 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.

  8. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B003ZHNN04

      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 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.)

  9. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A002AVK

      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.

  10. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A0027VO

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

  11. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B00402E

      Install the manual detent spring sub-assembly and 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 cover.

  12. INSTALL NO. 3 BRAKE PISTON


    1. A0026ZX

      Coat the contact surface of the transaxle case sub-assembly with ATF.

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

    3. A002B9L

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

    4. B003ZKPC02
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

      Press the No. 3 brake piston into 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.

      • 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 sub-assembly.

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

    6. A0028UJ

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

    7. B003ZGJN01

      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 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 brake piston return spring as shown in the illustration.

  13. INSTALL COUNTER DRIVE GEAR


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

    2. B003ZHBN01

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

      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.

  14. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B003ZH9N01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  15. INSTALL NO. 2 BRAKE PISTON


    1. B00401LC04
      *1 O-ring

      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.

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


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

    2. 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.

      B003Z5QN01
      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.

  17. INSTALL NO. 2 BRAKE DISC


    1. B003ZICC04
      *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. A0027OB

      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.

  18. INSPECT CLEARANCE OF NO. 2 BRAKE

    Click here

  19. INSTALL PLANETARY RING GEAR FLANGE


    1. B003Z7NC09
      *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.

  20. INSTALL PLANETARY RING GEAR


    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 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.

  21. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. 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: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 56.1 (2.21) 80.9 (3.19)

      Note

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

    2. 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 the claw on the one-way clutch assembly. If there is any clearance, the spring of the retainer should be deformed.

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

    3. 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.

  22. INSTALL PARKING LOCK PAWL


    1. B00400EC04
      *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 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.

      Note

      Make sure that one end of the spring is set 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.

  23. INSTALL PARKING LOCK SLEEVE


    1. A00286K

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

  24. INSTALL PAWL STOPPER PLATE


    1. A0027N6

      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 }

  25. INSTALL PAWL SHAFT CLAMP


    1. A00288J

      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 }

  26. INSTALL COUNTER DRIVEN GEAR


    1. A002CM8

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

  27. INSTALL COUNTER DRIVE GEAR NUT


    1. B003ZD3N01

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

    2. B003Z7JE04

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. B003ZFYN01

      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. B003ZNNN01

      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 1.7 in.*lbf)

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

      Maximum Torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)
    6. B003ZZBN04

      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.

  28. INSPECT FRONT DIFFERENTIAL PINION BACKLASH

    Click here

  29. INSTALL FRONT DIFFERENTIAL CASE


    1. A002BPY

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

  30. INSTALL NO. 1 BRAKE PISTON


    1. B004067C04
      *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. B003ZYG

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

      Note

      Be careful not to damage the O-rings.

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


    1. A002B30

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

      Note

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

  32. INSTALL NO. 1 BRAKE DISC


    1. B003Z17C01
      *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 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. B003ZQEN01

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

      SST
      09387-00070
      09495-65040

      Note

      Stop the press when the 2nd brake piston return spring sub-assemblies is 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 (#1).

      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. A0029AG

      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. B003ZDCN01

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

      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. B00408HC05
      *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 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 the brake snap ring stopper.

  33. INSPECT CLEARANCE OF NO. 1 BRAKE

    Click here

  34. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. B003ZCZC02
      *1 Thrust Needle Roller Bearing
      *2 Underdrive Planetary Sun Gear

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

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

      Note

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

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

  35. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. B004070C03
      *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 input shaft oil seal rings excessively.

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

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

      Note

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

    3. A002CEL

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

  36. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B00408WC02
      *1 Planetary Sun Gear Sub-assembly
      *2 Underdrive Planetary Gear Assembly
      *3 Snap Ring

      Using a snap ring expander, install the snap ring to the underdrive planetary gear assembly.

    2. Using a snap ring expander, install the planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded.

  37. INSTALL UNDERDRIVE PLANETARY RING GEAR

    Tech Tips

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


    1. 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.

  38. INSTALL NO. 3 BRAKE HUB


    1. B003ZKIC01
      *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: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 62.6 (2.46) 82.9 (3.26)
      Thrust needle roller race 65.9 (2.59) 80.3 (3.16)

      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.

  39. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A0026WB

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

  40. INSTALL NO. 3 BRAKE DISC


    1. B003Z2NC09
      *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. B003ZKVN02

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

      Note


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

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

  41. INSPECT CLEARANCE OF NO. 3 BRAKE

    Click here

  42. INSTALL FRONT OIL PUMP BODY O-RING


    1. A002C5Y

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

  43. INSTALL FRONT OIL PUMP ASSEMBLY


    1. B003Z61C01
      *1 Thrust Needle Roller Bearing
      *2 O-ring

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

    2. Coat the thrust needle roller bearing with ATF.

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 53.1 (2.09) 79 (3.11)

      Note

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

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

    5. B003ZEXC03
      *1 Thrust Needle Roller Race

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

      Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller race 59.4 (2.34 in.) 77 (3.03 in.)
    6. B004069C01
      *1 Gasket

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

    7. 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 }

  44. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A002B8W

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

      Note

      Insert the differential gear lube apply tube to the transaxle case housing 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 gear lube apply tube and clamp.

  45. INSTALL TRANSAXLE HOUSING


    1. B003ZDI

      Clean and degrease the 3 bolts and the 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 of the transaxle housing and transaxle case sub-assembly.

    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.

    4. A002B8H

      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. A0029J8

      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 installation 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 }

  46. INSTALL NO. 1 CLUTCH DISC


    1. B003ZB5C04
      *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 No. 1 clutch flange, No. 1 clutch discs and No. 1 clutch plates are installed in the correct order.

    2. A01QVWM

      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.

  47. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    Click here

  48. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. B003ZD0C02
      *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.

      Thrust Needle Roller Bearing and Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 28 (1.10) 47.1 (1.85)
      Thrust needle roller 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. A01QWDW

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

    3. A01QVS3

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

  49. INSTALL NO. 2 CLUTCH DISC


    1. B003ZLOC04
      *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 No. 2 clutch flange, No. 2 clutch discs and No. 2 clutch plates are installed in the correct order.

  50. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING


    1. A01QV65

      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.

    2. A01QWAC

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

      Note


      • Position the opening of the direct multiple disc clutch snap ring as shown in the illustration.

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

  51. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

    Click here

  52. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. B003ZIZC02
      *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. B003ZC1C02
      *1 Thrust Needle Roller Bearing
      *2 Direct Multiple Disc Clutch Assembly

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

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

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

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

    6. B00403WC02
      *a Dimension A

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

    7. B003ZUQC05
      *a Dimension B

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

    8. 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.)

  53. 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 0862 in.)

    2. Apply adhesive to the 2 "TORX" screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    3. A0026VR

      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 }
    4. 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.

    5. B003Z1JC04
      *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 to the rear transaxle cover sub-assembly.

      Thrust Needle Roller Bearing and Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 48.9 (1.93) 72.0 (2.84)
      Thrust needle roller race 52.2 (2.06) 70.4 (2.77)
    6. A002ANP

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

      Note

      Ensure that the O-rings are not twisted.

    7. B003ZPD

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

    8. B003Z9OC03
      *a FIPG

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

      Note

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

    9. 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 rear transaxle cover sub-assembly.

    10. B003ZOR

      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. 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 installation of the 2 bolts, apply adhesive to the 2 bolts and install them within 10 minutes of adhesive application.

    12. B003Z5E

      Install the 2 bolts.

      Torque:
      16.9 N*m  { 172 kgf*cm, 12 ft.*lbf }
    13. B003ZPH

      Install a new gasket to the refill plug.

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

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    15. A002B6G

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

    16. Install the 3 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.

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

  54. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY

    Click here

  55. INSTALL TRANSAXLE CASE GASKET


    1. A002AGS

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

  56. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


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

    2. B003ZF2C01
      *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.

      Torque:
      10.8 N*m  { 110 kgf*cm, 8 ft.*lbf }
      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 sub-assembly to interfere with each other.

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

  57. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. B003ZLEC06
      *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. A0029T7

      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 }

  58. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. B003ZLGC08
      *1 Transmission Oil Cleaner Magnet

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

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

    3. A002CBK

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

    4. A002BRQ

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

      Note

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A002A3C

      Apply adhesive to the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    6. Install the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    7. A002BK9

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

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }
    8. A0028L4

      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 }

  59. INSTALL NO. 2 TRANSAXLE CASE PLUG


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

    2. Apply adhesive to the 3 No. 2 transaxle case plugs.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper installation 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.

    3. B00409U

      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 }

  60. 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.

    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 }

  61. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION)


    1. B003ZK7

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

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

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

  62. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)


    1. B003ZHL

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

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

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

  63. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B003Z21C19
      *a Protrusion

      Align the protrusions of the park/neutral position switch assembly.

    2. B003Z7L

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      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.

      • After installing the park/neutral position switch assembly, confirm that the 2 protrusions on the park/neutral position switch assembly are aligned.

    3. 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 }

  64. INSTALL BREATHER PLUG HOSE


    1. B003ZS4C08
      *1 No. 1 Breather Plug (ATM)
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug (ATM)
      *4 O-ring

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

    2. Install the No. 1 breather plug (ATM) and No. 2 breather plug (ATM) to the breather plug hose.

    3. A002AMW

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