AUTOMATIC TRANSAXLE UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    Check bearing position and installation direction.

    B006LRAN01
    B006KJCN01
    Thrust Needle Roller Bearing and Bearing Race Diameter
    Mark

    Front Side Thrust Bearing Race Diameter Inside / Outside

    mm (in.)

    Thrust Bearing Diameter Inside / Outside

    mm (in.)

    Rear Side Thrust Bearing Race Diameter Inside / Outside

    mm (in.)
    A 32.6 (1.28) / 54.2 (2.13) 31.7 (1.25) / 52.3 (2.06) 31.7 (1.25) / 52.3 (2.06)
    B 59.8 (2.35) / 77.0 (3.03) 58.3 (2.30) / 75.0 (2.95) -
    C - 39.2 (1.54) / 52.6 (2.07) 38.1 (1.50) / 50.2 (1.98)
    D - 33.3 (1.31) / 46.3 (1.82) 34.2 (1.35) / 47.3 (1.86)
    E 34.4 (1.35) / 48.7 (1.92) 33.2 (1.31) / 47.7 (1.88) 33.2 (1.31) / 47.7 (1.88)
    F 25.58 (1.01) / 43.7 (1.72) 24.2 (0.953) / 43.7 (1.72) 24.2 (0.953) / 43.7 (1.72)
    G - 50.5 (1.99) / 74.5 (2.93) 52.8 (2.08) / 76.4 (3.01)

  2. INSTALL AUTOMATIC TRANSMISSION CASE STRAIGHT PIN

    Note

    It is not necessary to remove the automatic transmission case straight pins unless they are being replaced.


    1. B006P5F

      Using a plastic hammer, tap in 2 new automatic transmission case straight pins to the specified protrusion height.

      Protrusion Height
      7.0 to 8.0 mm (0.276 to 0.315 in.)

  3. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (INNER RACE)


    1. B006KTFN01

      Using SST and a press, install a new counter driven gear front tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.

      SST
      09950-60011   ( 09951-00550 )
      09950-70010   ( 09951-07150 )

      Note

      Be sure to install the counter driven gear front tapered roller bearing (inner race) so that there is no clearance between the counter driven gear front tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

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


    1. B006MX7N01

      Using SST and a hammer, install a new counter driven gear front tapered roller bearing (outer race) and pinion and counter driven gear shim to the transaxle housing.

      SST
      09950-60021   ( 09951-00780 )
      09950-70010   ( 09951-07150 )

      Note

      Be 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), pinion and counter driven gear shim and the transaxle housing. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  5. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (INNER RACE)


    1. B006PYLN01

      Using SST and a press, install a new counter driven gear rear tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.

      SST
      09506-30012
      09950-60011   ( 09951-00420, 09951-00550 )
      09950-70010   ( 09951-07150 )

      Note

      Be sure to install the counter driven gear rear tapered roller bearing (inner race) so that there is no clearance between the counter driven gear rear tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  6. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (OUTER RACE)


    1. B006RG6N01

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

      SST
      09950-60021   ( 09951-00680 )
      09950-70010   ( 09951-07150 )

      Note

      Be 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 the automatic transaxle case sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  7. ADJUST FRONT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD


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

    2. Coat the front differential case front tapered roller bearing (inner race) and the front differential case rear tapered roller bearing (inner race) with a sufficient amount of Toyota Genuine ATF WS.

    3. B006QSM

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

    4. B006MYWN01

      Install the transaxle housing to the automatic transaxle case sub-assembly with the 21 bolts (A and B).

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
      Bolt Length
      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 35 mm (1.38 in.)
    5. B006KSYN01

      Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.

      SST
      09564-33010
    6. B006P6WN01

      Using SST and a torque wrench, measure the turning torque of the front differential case tapered roller bearing while rotating SST at 10 rpm.

      SST
      09564-33010
      Standard Turning Torque
      0.69 to 1.02 N*m (8 to 10 kgf*cm, 7 to 9 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.

      Differential Drive Pinion Shim Thickness
      Part Number

      Thickness

      mm (in.)

      		 Mark
      90564-75002 1.10 (0.0433) 50
      90564-75003 1.13 (0.0445) 51
      90564-75004 1.16 (0.0457) 52
      90564-75005 1.19 (0.0469) 53
      90564-75006 1.22 (0.0480) 54
      90564-75007 1.25 (0.0492) 55
      90564-75008 1.28 (0.0504) 56
      90564-75009 1.31 (0.0516) 57
      90564-75010 1.34 (0.0528) 58
      90564-75011 1.37 (0.0539) 59
      90564-75012 1.40 (0.0551) 60
      90564-75013 1.43 (0.0563) 61
      90564-75014 1.46 (0.0575) 62
      90564-75015 1.49 (0.0587) 63
      90564-75016 1.52 (0.0598) 64
      90564-75017 1.55 (0.0610) 65
      90564-75018 1.58 (0.0622) 66
      90564-75019 1.61 (0.0634) 67
      90564-75023 1.64 (0.0646) 68
      90564-75024 1.67 (0.0657) 69
      90564-75025 1.70 (0.0669) 70
      90564-75026 1.73 (0.0681) 71
      90564-75027 1.76 (0.0693) 72
      90564-75028 1.79 (0.0705) 73
      90564-75029 1.82 (0.0717) 74
      90564-75030 1.85 (0.0728) 75
      90564-75031 1.88 (0.0740) 76
      90564-75032 1.91 (0.0752) 77
      90564-75033 1.94 (0.0764) 78
      90564-75034 1.97 (0.0776) 79
      90564-75035 2.00 (0.0787) 80

    7. Remove the 21 bolts and transaxle housing from the automatic transaxle case sub-assembly.

  8. ADJUST PINION AND COUNTER DRIVEN GEAR TAPERED ROLLER BEARING PRELOAD


    1. Coat the counter driven gear front tapered roller bearing (inner race) and the counter driven gear rear tapered roller bearing (inner race) with a sufficient amount of Toyota Genuine ATF WS.

    2. B006NIM

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

    3. B006MYWN01

      Install the transaxle housing to the automatic transaxle case sub-assembly with the 21 bolts (A and B).

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
      Bolt Length
      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 35 mm (1.38 in.)
    4. B006KSYN01

      Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.

      SST
      09564-33010
    5. B006P6WN01

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

      SST
      09564-33010
      Standard Turning Torque
      Front differential case tapered roller bearing preload + 0.99 to 2.26 N*m (11 to 23 kgf*cm, 9 to 20 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.

      Pinion and Counter Driven Gear Shim Thickness
      Part Number

      Thickness

      mm (in.)

      		 Mark
      90564-67047 1.19 (0.0469) AA
      90564-67048 1.22 (0.0480) AB
      90564-67049 1.25 (0.0492) AC
      90564-67050 1.28 (0.0504) AD
      90564-67051 1.31 (0.0516) AE
      90564-67052 1.34 (0.0528) AF
      90564-67053 1.37 (0.0539) AG
      90564-67054 1.40 (0.0551) AH
      90564-67055 1.43 (0.0563) AJ
      90564-67056 1.46 (0.0575) AK
      90564-67057 1.49 (0.0587) AL
      90564-67058 1.52 (0.0598) AM
      90564-67059 1.55 (0.0610) AN
      90564-67060 1.58 (0.0622) AP
      90564-67061 1.61 (0.0634) AR
      90564-67062 1.64 (0.0646) AS
      90564-67063 1.67 (0.0657) AT
      90564-67064 1.70 (0.0669) AU
      90564-67065 1.73 (0.0681) AV
      90564-67066 1.76 (0.0693) AW
      90564-67067 1.79 (0.0705) AX
      90564-67068 1.82 (0.0717) AY
      90564-67069 1.85 (0.0728) AZ
      90564-67071 1.88 (0.0740) BA
      90564-67072 1.91 (0.0752) BB
      90564-67073 1.94 (0.0764) BC
      90564-67074 1.97 (0.0776) BD
      90564-67075 2.00 (0.0787) BE
      90564-67076 2.03 (0.0799) BF
      90564-67077 2.06 (0.0811) BG
      90564-67078 2.09 (0.0823) BH
      90564-67079 2.12 (0.0835) BJ
      90564-67080 2.15 (0.0846) BK
      90564-67081 2.18 (0.0858) BL
      90564-67082 2.21 (0.0870) BM

    6. Remove the 21 bolts and transaxle housing from the automatic transaxle case sub-assembly.

    7. Remove the pinion and counter driven gear sub-assembly from the automatic transaxle case sub-assembly.

    8. Remove the differential case assembly from the automatic transaxle case sub-assembly.

  9. INSTALL NO. 2 TRANSAXLE CASE PLUG


    1. Clean the 6 No. 2 transaxle case plugs and 6 installation holes.

    2. B006OVF

      Apply adhesive to 2 or 3 threads on the end of the No. 2 transaxle case plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Make sure to install the No. 2 transaxle case plug immediately after applying adhesive to prevent foreign matter from attaching to them.

    3. B006NXI

      Using a 6 mm socket hexagon wrench, install the 3 No. 2 transaxle case plugs and 3 new gaskets to the automatic transaxle case sub-assembly.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    4. B006KKF

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

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

  10. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. B006L2T

      Coat 8 new O-rings with Toyota Genuine ATF WS and install them to the 8 No. 1 transaxle case plugs.

    2. B006QOG

      Install the 4 No. 1 transaxle case plugs to the automatic transaxle case sub-assembly.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    3. B006LCK

      Install the 4 No. 1 transaxle case plugs to the transaxle housing.

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

  11. INSTALL NEEDLE ROLLER BEARING


    1. B006PGMN01

      Using SST and a press, install a new needle roller bearing to the transaxle housing.

      SST
      09950-60011   ( 09951-00560 )
      09950-70010   ( 09951-07200 )

      Note

      Be careful not to damage the transaxle housing.

  12. INSTALL FRONT DRIVE SHAFT OIL SEAL LH


    1. B006RIYN01

      Using SST and a hammer, install a new front drive shaft oil seal LH to the automatic transaxle case sub-assembly.

      SST
      09649-17010
      09950-70010   ( 09951-07200 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  13. INSTALL FRONT DRIVE SHAFT OIL SEAL RH


    1. B006PT1N01

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

      SST
      09316-10010
      09950-70010   ( 09951-07200 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  14. INSTALL TRANSAXLE CASE OIL SEAL


    1. Clean and degrease the oil seal press-in surface.

    2. B006OE3E01

      Using SST and a hammer, install a new transaxle case oil seal to the transaxle housing.

      SST
      09950-60011   ( 09951-00640 )
      09950-70010   ( 09951-07200 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

    3. Apply MP grease to the lip of the transaxle case oil seal.

  15. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B006OSXN01

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

      SST
      09950-60011   ( 09951-00210 )
      09950-70010   ( 09951-07200 )
      Standard Depth
      -0.3 to 0.4 mm (-0.0118 to 0.0157 in.)

    2. Apply MP grease to the lip of the manual valve lever shaft oil seal.

  16. INSTALL NEEDLE ROLLER BEARING


    1. B006N3YN01

      Using SST and a press, install a new needle roller bearing to the automatic transaxle case sub-assembly.

      SST
      09950-60011   ( 09951-00210 )
      09950-70010   ( 09951-07150 )
      Standard Depth
      2.1 to 2.5 mm (0.0827 to 0.0984 in.)

      Note

      Install the needle roller bearing with its supplier name mark facing the front of the automatic transaxle assembly.

  17. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. B006NY8

      Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install them to the 1st and reverse brake piston.

      Note


      • Make sure to correctly distinguish between the inner side and outer side O-rings.

      • Be careful not to damage or twist the O-rings.

    2. B006QDNC01
      *1 1st And Reverse Brake Return Spring Sub-assembly
      *2 1st And Reverse Brake Piston

      Set the 1st and reverse brake return spring sub-assembly on the 1st and reverse brake piston.

    3. B006MOB

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

      Note

      Make sure that the O-rings are not damaged or do not jump out of position during installation.

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


    1. B006QJVC01
      *a Snap ring opening within this area.

      Set the snap ring on the automatic transaxle case sub-assembly as shown in the illustration.

      Note

      The opening of the snap ring should be within the area shown in the illustration (spline portion).

    2. B006R0HN01

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

      SST
      09380-60011   ( 09381-06020, 09381-06050, 09381-06060, 09381-06100, 09381-06110 )
      09950-70010   ( 09951-07200 )

      Note

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

    3. B006RL5

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring into the snap ring groove of the automatic transaxle case sub-assembly.

      Note


      • Be careful not to damage the automatic transaxle case sub-assembly.

      • Make sure that the snap ring is installed in the groove of the automatic transaxle case sub-assembly correctly.

  19. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON


    1. B006PB3

      Install the No. 2 1st and reverse brake piston to the automatic transaxle case sub-assembly.

  20. INSTALL 2ND BRAKE BRAKE DISC


    1. B006LCNC01
      *1 2nd Brake Brake Flange
      *2 2nd Brake Brake Disc
      *3 2nd Brake Brake Plate
      *a Snap Ring Side
      *b 2nd Brake Brake Disc Side

      Install the 5 2nd brake brake plates, 5 2nd brake brake discs and 2nd brake brake flange to the automatic transaxle case sub-assembly.

      Note

      Assemble the 2nd brake brake flange with its tapered surface facing toward the 2nd brake brake disc.

    2. B006OSRC01
      *a Snap ring opening within this area.

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the automatic transaxle case sub-assembly.

      Note

      The opening of the snap ring should be within the area shown in the illustration (spline portion).

  21. INSPECT CLEARANCE OF B-2 BRAKE

    Click here

  22. INSTALL DIRECT CLUTCH DRUM OIL SEAL RING


    1. Apply a small amount of MP grease to the entire circumference of the direct clutch drum oil seal ring installation groove portion.

      Tech Tips

      By applying MP grease, the wobble within the direct clutch drum oil seal ring installation groove will be eliminated, preventing damage to the direct clutch drum oil seal ring at the time of front planetary gear assembly installation.

    2. B006MXA

      Coat 2 new direct clutch drum oil seal rings with Toyota Genuine ATF WS and install them to the automatic transaxle case sub-assembly.

      Note

      While making the spread of the opening of the direct clutch drum oil seal ring as small as possible, install it to the automatic transaxle case sub-assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  23. INSTALL C-2 CLUTCH PISTON


    1. B006RDC

      Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install it to the intermediate shaft sub-assembly.

      Note

      Be careful not to damage or twist the O-ring.

    2. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the C-2 clutch piston.

    3. B006QBA

      Install the C-2 clutch piston to the intermediate shaft sub-assembly.

      Note


      • Make sure the lip is not cut or folded.

      • Be careful not to damage the lip seal of the C-2 clutch piston.

  24. INSTALL CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. B006P82

      Install the clutch return spring sub-assembly to the intermediate shaft sub-assembly.

  25. INSTALL C-2 CLUTCH BALANCER


    1. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the C-2 clutch balancer.

    2. B006OWR

      Install the C-2 clutch balancer to the intermediate shaft sub-assembly.

      Note

      Be careful not to damage the lip seal of the C-2 clutch balancer.

      Note


      • Make sure the lip is not cut or folded.

      • Be careful not to damage the lip seal of the C-2 clutch balancer.

    3. B006RLVN01

      Place SST on the C-2 clutch balancer and compress the clutch return spring sub-assembly with a press.

      SST
      09387-00020

      Note

      Stop the press when the clutch return spring sub-assembly is flush with the snap ring groove.

    4. Using SST, install the snap ring to the intermediate shaft sub-assembly.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Make sure that the snap ring is installed in the groove of the intermediate shaft sub-assembly correctly.

  26. INSTALL NO. 2 CLUTCH DISC


    1. B006KQQC01
      *1 Direct Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate
      *a Snap Ring Side
      *b No. 2 Clutch Disc Side

      Install the 4 No. 2 clutch plates, 4 No. 2 clutch discs and direct clutch flange to the intermediate shaft sub-assembly.

      Note


      • Be careful during assembly because there are 2 types of No. 2 clutch plate with different thicknesses.

      • Assemble the direct clutch flange with its tapered surface facing toward the No. 2 clutch disc.

    2. B006MFB

      Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the intermediate shaft sub-assembly.

      Note


      • Be careful not to damage the intermediate shaft sub-assembly.

      • Make sure that the snap ring is installed in the groove of the intermediate shaft sub-assembly correctly.

  27. INSTALL NO. 1 THRUST BEARING RACE


    1. B006QXR

      Coat the No. 1 thrust bearing race with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

      No. 1 Thrust Bearing Race Diameter
      Inside Outside
      52.8 mm (2.08 in.) 76.4 mm (3.01 in.)

      Note

      Securely insert the claw of the No. 1 thrust bearing race into the hole of the automatic transaxle case sub-assembly.

  28. INSTALL THRUST NEEDLE ROLLER BEARING


    1. B006MAL

      Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      50.5 mm (1.99 in.) 74.5 mm (2.93 in.)

      Note

      Make sure to assemble the thrust needle roller bearing in the correct direction.

      Tech Tips

      When installing the C-2 clutch assembly, if the thrust needle roller bearing falls off, coat the C-2 clutch assembly installation surface with MP grease and install the parts.

  29. INSTALL C-2 CLUTCH ASSEMBLY


    1. B006PAQ

      Install the C-2 clutch assembly to the automatic transaxle case sub-assembly.

  30. INSPECT CLEARANCE OF C-2 CLUTCH

    Click here

  31. INSTALL NO. 4 PLANETARY CARRIER THRUST WASHER


    1. B006QCF

      Install the No. 4 planetary carrier thrust washer to the rear planetary gear assembly.

      Tech Tips


      • Securely insert each protrusion of the No. 4 planetary carrier thrust washer into each indentation of the rear planetary gear assembly.

      • When installing the rear planetary gear assembly, if the No. 4 planetary carrier thrust washer falls off, coat the rear planetary gear assembly installation surface with MP grease and install the parts.

  32. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. B006NRT

      Install the rear planetary gear assembly to the C-2 clutch assembly.

  33. INSTALL NO. 2 THRUST BEARING RACE


    1. B006O8A

      Coat the No. 2 thrust bearing race with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

      No. 2 Thrust Bearing Race Diameter
      Inside Outside
      24.2 mm (0.953 in.) 43.7 mm (1.72 in.)

  34. INSTALL THRUST NEEDLE ROLLER BEARING


    1. B006QIT

      Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      24.2 mm (0.953 in.) 43.7 mm (1.72 in.)

  35. INSTALL NO. 3 THRUST BEARING RACE


    1. B006MRP

      Coat the No. 3 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

      No. 3 Thrust Bearing Race Diameter
      Inside Outside
      25.58 mm (1.01 in.) 43.7 mm (1.72 in.)

      Tech Tips

      When installing the rear planetary sun gear sub-assembly, if the No. 3 thrust bearing race falls off, coat the rear planetary sun gear sub-assembly installation surface with MP grease and install the parts.

  36. INSTALL REAR PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B006MQ3

      Install the rear planetary sun gear sub-assembly to the C-2 clutch assembly.

  37. INSTALL THRUST BEARING RACE


    1. B006M1C

      Coat the thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

      Thrust Bearing Race Diameter
      Inside Outside
      33.2 mm (1.31 in.) 47.7 mm (1.88 in.)

  38. INSTALL THRUST NEEDLE ROLLER BEARING


    1. B006L08

      Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      33.2 mm (1.31 in.) 47.7 mm (1.88 in.)

  39. INSTALL NO. 4 THRUST BEARING RACE


    1. B006MGN

      Coat the No. 4 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

      No. 4 Thrust Bearing Race Diameter
      Inside Outside
      34.4 mm (1.35 in.) 48.7 mm (1.92 in.)

  40. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B006OAW

      Install the planetary sun gear sub-assembly to the rear planetary gear assembly.

  41. INSTALL NO. 3 PLANETARY CARRIER THRUST WASHER


    1. B006RKL

      Coat the No. 3 planetary carrier thrust washer with Toyota Genuine ATF WS and install it to the rear planetary gear assembly.

      Note

      Securely insert the claw of the No. 3 planetary carrier thrust washer into the hole of the rear planetary gear assembly.

  42. INSTALL NO. 1 BRAKE DISC


    1. B006PRUC01
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate
      *a Snap Ring Side
      *b No. 1 Brake Disc Side

      Install the 4 No. 1 brake plates, 4 No. 1 brake discs and No. 1 brake flange to the counter drive gear sub-assembly.

      Note


      • Be careful during assembly because there are 2 types of No. 1 brake plate with different thicknesses.

      • Assemble the No. 1 brake flange with its tapered surface facing toward the No. 1 brake disc.

    2. B006NDAC01
      *a Snap ring opening within this area.

      Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the counter drive gear sub-assembly.

      Note


      • Be careful not to damage the counter drive gear sub-assembly.

      • Make sure that the snap ring is installed in the groove of the counter drive gear sub-assembly correctly.

      • The opening of the snap ring should be within the area shown in the illustration (spline portion).

  43. INSTALL COUNTER DRIVE GEAR SUB-ASSEMBLY


    1. Clean and degrease the counter drive gear sub-assembly installation bolts and the 8 bolt holes.

      Note

      If the bolts are tightened without cleaning and degreasing the bolts and bolt holes, the tightening torque will be too high and the counter drive gear sub-assembly or automatic transaxle case sub-assembly may be damaged.

    2. B006LM5

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

    3. B006MUQ

      Install the counter drive gear sub-assembly together with the pinion and counter driven gear sub-assembly to the automatic transaxle case sub-assembly.

    4. B006QDUC02
      *a Bolt A
      *b Bolt B

      Temporarily install the 8 bolts (A and B).

      Tech Tips

      Bolt (A) is a hexagon socket head cap bolt.

    5. Fully tighten the 6 bolts (B).

      Torque:
      76 N*m  { 775 kgf*cm, 56 ft.*lbf }

    6. Using a T50 "TORX" socket wrench, fully tighten the 2 bolts (A).

      Torque:
      31.8 N*m  { 324 kgf*cm, 23 ft.*lbf }

  44. INSPECT CLEARANCE OF B-1 BRAKE

    Click here

  45. INSTALL PARKING LOCK SLEEVE


    1. B006OJW

      Coat the parking lock sleeve with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

  46. INSTALL PARKING LOCK PAWL


    1. B006MK1

      Coat the parking lock pawl with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

  47. INSTALL PARKING LOCK PAWL SHAFT


    1. B006L26

      Coat the parking lock pawl shaft with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

  48. INSTALL PARKING LOCK PAWL TORSION SPRING


    1. B006KJ4

      Install the parking lock pawl torsion spring to the automatic transaxle case sub-assembly as shown in the illustration.

      Note

      Securely insert the parking lock pawl torsion spring all the way into the parking lock pawl shaft.

  49. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B006OMQ

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

      Note

      When installing the manual valve lever shaft sub-assembly, be careful not to damage the manual valve lever shaft oil seal.

  50. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. B006L3GC01
      *1 Manual Valve Lever Shaft Sub-assembly
      *2 Parking Lock Rod Sub-assembly

      Parking lock rod sub-assembly as shown in the illustration, and install the parking lock rod sub-assembly.

      Note

      Securely align the cutouts of the parking lock rod sub-assembly and manual valve lever shaft sub-assembly.

  51. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING


    1. B006Q8H

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

  52. INSTALL PAWL STOPPER PLATE


    1. B006M0M

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

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  53. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B006RBD

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

      Note

      The pin portion of the manual valve lever shaft sub-assembly must be inserted into the slot of the manual valve lever sub-assembly.

  54. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B006RL0

      Coat a new O-ring with Toyota Genuine ATF WS and install it to the manual valve lever shaft sub-assembly.

      Note

      Ensure that the O-ring it not twisted.

    2. B006MPH

      Align the cutouts of the manual valve lever sub-assembly and manual valve lever shaft sub-assembly, and install the manual valve lever shaft sub-assembly.

      Tech Tips

      Installing the manual valve lever shaft sub-assembly to the area shown in the illustration will align the cutouts.

    3. B006Q0H

      Secure the manual valve lever shaft sub-assembly to the automatic transaxle case sub-assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  55. INSTALL NO. 5 THRUST BEARING RACE


    1. B006LKE

      Coat the No. 5 thrust bearing race with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.

      No. 5 Thrust Bearing Race Diameter
      Inside Outside
      34.2 mm (1.35 in.) 47.3 mm (1.86 in.)

  56. INSTALL THRUST NEEDLE ROLLER BEARING


    1. B006KYM

      Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      33.3 mm (1.31 in.) 46.3 mm (1.82 in.)

  57. INSTALL SUN GEAR INPUT HUB SUB-ASSEMBLY


    1. B006LEO

      Install the sun gear input hub sub-assembly to the counter drive gear sub-assembly.

  58. INSTALL FORWARD CLUTCH PISTON


    1. B006NSW

      Apply a light coat of Toyota Genuine ATF WS to a new D-ring and install it to the clutch drum sub-assembly.

      Tech Tips


      • Be careful not to damage or twist the D-ring.

      • The rounded surface of the D-ring will be on the outer side of the ring groove.

    2. B006KP3

      Apply a light coat of Toyota Genuine ATF WS to a new O-ring and install it to the clutch drum sub-assembly.

      Note

      Be careful not to damage or twist the O-ring.

    3. B006NBA

      Apply a light coat of Toyota Genuine ATF WS to the forward clutch piston and install it to the clutch drum sub-assembly.

      Note


      • Make sure that the O-ring and the D-ring is not damaged or does not jump out of position during installation.

      • Make sure the lip is not cut or folded.

  59. INSTALL REAR CLUTCH PISTON RETURN COMPRESSION SPRING


    1. B006LYD

      Install the rear clutch piston return compression spring to the forward clutch piston.

      Note

      Make sure to install in the correct direction.

  60. INSTALL NO. 1 CLUTCH BALANCER


    1. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the forward clutch piston.

    2. B006PST

      Install the No. 1 clutch balancer to the forward clutch piston.

      Note

      Be careful not to damage the lip seal of the forward clutch piston.

    3. B006P9MN01

      Place SST on the No. 1 clutch balancer and compress the rear clutch piston return compression spring with a press.

      SST
      09387-00020

      Note

      Stop the press when the rear clutch piston return compression spring is flush with the snap ring groove.

    4. Using SST, install the snap ring to the clutch drum sub-assembly.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Make sure that the snap ring is installed in the groove of the clutch drum sub-assembly correctly.

  61. INSTALL FRONT CLUTCH CLUTCH DISC


    1. B006M6BC01
      *1 Forward Clutch Flange
      *2 Front Clutch Clutch Disc
      *3 Forward Multiple Disc Clutch Clutch Plate
      *a Snap Ring Side
      *b Front Clutch Clutch Disc Side

      Install the 5 forward multiple disc clutch clutch plates, 5 front clutch clutch discs and forward clutch flange to the clutch drum sub-assembly.

      Note


      • Be careful during assembly because there are 2 types of forward multiple disc clutch clutch plate with different thicknesses.

      • Assemble the forward clutch flange with its tapered surface facing toward the front clutch clutch disc.

    2. B006KZM

      Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the clutch drum sub-assembly.

      Note


      • Be careful not to damage the clutch drum sub-assembly.

      • Make sure that the snap ring is installed in the groove of the clutch drum sub-assembly correctly.

  62. INSPECT CLEARANCE OF C-1 CLUTCH

    Click here

  63. INSTALL C-1 CLUTCH ASSEMBLY


    1. B006P2J

      Install the C-1 clutch assembly to the sun gear input hub sub-assembly.

  64. INSTALL NO. 6 THRUST BEARING RACE


    1. B006QI2

      Coat the No. 6 thrust bearing race with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.

      No. 6 Thrust Bearing Race Diameter
      Inside Outside
      38.1 mm (1.50 in.) 50.2 mm (1.98 in.)

  65. INSTALL THRUST NEEDLE ROLLER BEARING


    1. B006PBF

      Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      39.2 mm (1.54 in.) 52.6 mm (2.07 in.)

  66. INSTALL FRONT PLANETARY RING GEAR


    1. B006N0L

      Install the front planetary ring gear flange to the front planetary ring gear.

    2. B006O47

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front planetary ring gear.

      Note

      Be careful not to damage the front planetary ring gear and front planetary ring gear flange.

    3. B006NPP

      Install the front planetary ring gear with front planetary ring gear flange to the C-1 clutch assembly.

  67. INSTALL REAR INPUT SHAFT OIL SEAL RING


    1. B006O6T

      Apply a small amount of MP grease to the entire circumference of the rear input shaft oil seal ring installation groove portion.

      Tech Tips

      By applying MP grease, the wobble within the rear input shaft oil seal ring installation groove will be eliminated, preventing damage to the rear input shaft oil seal ring at the time of front planetary gear assembly installation.

    2. Coat 2 new rear input shaft oil seal rings with Toyota Genuine ATF WS and install them to the front planetary gear assembly.

      Note

      While making the spread of the opening of the rear input shaft oil seal ring as small as possible, install it to the front planetary gear assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  68. INSTALL INPUT SHAFT OIL SEAL RING


    1. B006MTL

      Apply a small amount of MP grease to the entire circumference of the input shaft oil seal ring installation groove portion.

      Tech Tips

      By applying MP grease, the wobble within the input shaft oil seal ring installation groove will be eliminated, preventing damage to the input shaft oil seal ring at the time of front oil pump assembly and torque converter clutch assembly installation.

    2. Coat 5 new input shaft oil seal rings with Toyota Genuine ATF WS and install them to the front planetary gear assembly.

      Note

      While making the spread of the opening of the input shaft oil seal ring as small as possible, install it to the front planetary gear assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  69. INSTALL NO. 7 THRUST BEARING RACE


    1. B006PNI

      Coat the No. 7 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary gear assembly.

      No. 7 Thrust Bearing Race Diameter
      Inside Outside
      59.8 mm (2.35 in.) 77.0 mm (3.03 in.)

      Note

      Securely insert the claw of the No. 7 thrust bearing race into the hole of the front planetary gear assembly.

      Tech Tips

      When installing the front planetary gear assembly, if the No. 7 thrust bearing race falls off, coat the front planetary gear assembly installation surface with MP grease and install the parts.

  70. INSTALL THRUST NEEDLE ROLLER BEARING


    1. B006OYN

      Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary ring gear.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      58.3 mm (2.30 in.) 75.0 mm (2.95 in.)

  71. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B006QFL

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

  72. INSTALL NO. 8 THRUST BEARING RACE


    1. B006LEI

      Coat the No. 8 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary ring gear.

      No. 8 Thrust Bearing Race Diameter
      Inside Outside
      31.7 mm (1.25 in.) 52.3 mm (2.06 in.)

  73. INSTALL THRUST NEEDLE ROLLER BEARING


    1. B006N1V

      Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary ring gear.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      31.7 mm (1.25 in.) 52.3 mm (2.06 in.)

  74. INSTALL NO. 9 THRUST BEARING RACE


    1. B006LEI

      Coat the No. 9 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary ring gear.

      No. 9 Thrust Bearing Race Diameter
      Inside Outside
      32.6 mm (1.28 in.) 54.2 mm (2.13 in.)

  75. INSTALL PLANETARY SUN GEAR


    1. B006OV6

      Install the planetary sun gear to the front planetary gear assembly.

  76. INSTALL NO. 2 PLANETARY CARRIER THRUST WASHER


    1. B006MD1

      Install the No. 2 planetary carrier thrust washer to the front planetary gear assembly.

      Note

      Securely insert each protrusion of the No. 2 planetary carrier thrust washer into each indentation of the front planetary gear assembly.

  77. INSPECT CLEARANCE OF C-4 CLUTCH

    Click here

  78. INSPECT CLEARANCE OF C-3 CLUTCH

    Click here

  79. INSTALL C-3 AND C-4 CLUTCH ASSEMBLY


    1. B006NLX

      Install the C-3 and C-4 clutch assembly to the front planetary gear assembly.

  80. INSTALL PLANETARY CARRIER THRUST WASHER


    1. B006L20

      Install the planetary carrier thrust washer to the C-3 and C-4 clutch assembly.

      Note

      Securely insert the protrusion of the planetary carrier thrust washer into the indentation of the C-3 and C-4 clutch assembly.

  81. INSTALL FRONT OIL PUMP ASSEMBLY


    1. B006KVBN01

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

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }
      Bolt Length
      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 30 mm (1.18 in.)

  82. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B006RKAC01
      *1 Manual Detent Spring Sub-assembly
      *2 Manual Valve Lever Shaft Sub-assembly
      *a Correct
      *b Incorrect

      Install the manual detent spring sub-assembly to the front oil pump assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      Note


      • Securely insert the claw of the manual detent spring sub-assembly into the hole of the front oil pump assembly.

      • Check that the roller portion of the manual detent spring sub-assembly is engaged with the manual valve lever shaft sub-assembly.

  83. INSTALL OIL PUMP SPROCKET REAR THRUST WASHER


    1. B006QQA

      Install the oil pump sprocket rear thrust washer to the front oil pump assembly.

      Note

      Securely insert the protrusion of the oil pump sprocket rear thrust washer into the indentation of the front oil pump assembly.

  84. INSTALL TRANSMISSION DRIVE CHAIN


    1. B006LWLC01
      *1 Front Oil Pump Drive Gear
      *a Correct
      *b Incorrect
      *c Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, align the cutout of the front oil pump drive gear with the position (*a) shown in the illustration.

      Note

      Do not pry with excessive force when aligning the cutout of the front oil pump drive gear.

    2. B006NVJ

      Install the transmission drive chain together with the transmission oil pump drive sprocket and oil pump drive shaft sub-assembly to the front oil pump assembly.

      Note


      • To avoid damaging the bush of the front oil pump assembly, install the transmission drive chain, transmission oil pump drive sprocket and oil pump drive shaft sub-assembly horizontally relative to the front oil pump assembly.

      • Align the cutout of the oil pump drive shaft sub-assembly and the cutout of the front oil pump drive gear, and install the parts.

  85. INSTALL OIL PUMP SPROCKET FRONT THRUST WASHER


    1. B006LK2

      Install the oil pump sprocket front thrust washer to the transmission oil pump drive sprocket.

      Note

      Securely insert the long protrusion of the oil pump sprocket rear thrust washer into the slot of the oil pump sprocket front thrust washer.

  86. INSTALL CLUTCH DRUM OIL SEAL RING


    1. B006QTW

      Apply a small amount of MP grease to the entire circumference of the clutch drum oil seal ring installation groove portion.

      Tech Tips

      By applying MP grease, the wobble within the clutch drum oil seal ring installation groove will be eliminated, preventing damage to the clutch drum oil seal ring at the time of torque converter clutch assembly installation.

    2. Coat a new clutch drum oil seal ring with Toyota Genuine ATF WS and install it to the front oil pump assembly.

      Note

      While making the spread of the opening of the clutch drum oil seal ring as small as possible, install it to the front oil pump assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  87. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. B006MUU

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

  88. INSTALL TRANSMISSION LUBE APPLY TUBE


    1. B006L8IC01
      *a Correct
      *b Incorrect

      Install the transmission lube apply tube to the transaxle housing.

      Note

      Insert the transmission lube apply tube until its spool portion is contacting the transaxle housing.

    2. B006NAQ

      Install the clamp to the transaxle housing with the bolt.

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

  89. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. B006NKDC01
      *a Correct
      *b Incorrect

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

      Note

      Insert the differential gear lube apply tube until its spool portion is contacting the transaxle housing.

  90. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. B006NHC

      Install the 3 transmission oil cleaner magnets to the transaxle housing oil separator.

  91. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. B006PC1

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

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

  92. INSTALL TRANSAXLE HOUSING

    Note

    When installing the transaxle housing check that the transmission drive chain rotates smoothly.

    B006L9Z

    1. Peel off the old seal packing from the transaxle housing and automatic transaxle case sub-assembly installation surface, and clean it.

      Note

      Do not damage the installation surface.

    2. B006L6Z

      Clean the 21 bolts and bolt holes in the automatic transaxle case sub-assembly.

    3. B006MCQC01
      B006REL Area to be cleaned

      Clean the inner chamfer of the automatic transaxle case sub-assembly shown in the illustration.

    4. B006MIR

      Apply seal packing to the automatic transaxle case sub-assembly as shown in the illustration.

      Seal Packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Standard Seal Diameter
      1.8 mm (0.0709 in.)

      Note

      After applying seal packing, install the transaxle housing within 3 minutes and tighten the bolts within 20 minutes of applying the seal packing.

    5. B006RE1C01
      *1 Transaxle Case Gaskets
      *2 O-ring

      Coat 5 new transaxle case gaskets with Toyota Genuine ATF WS and install it to the front oil pump assembly.

    6. Coat a new O-ring with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

    7. B006LD9N01

      Install the transaxle housing to the automatic transaxle case sub-assembly with the 6 bolts (A) and 12 bolts (B).

      Torque:
      Bolt (A) and (B)
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }
      Bolt Length
      Bolt (A) Bolt (B)
      40 mm (1.57 in.) 35 mm (1.38 in.)
    8. B006MJ5C53
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the end of the 3 bolts (C).

      Bolt Length
      40 mm (1.57 in.)
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Make sure to install the bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

      Tech Tips

      The 3 bolts (C) are in the locations shown in the following step.

    9. B006N9BN01

      Install the 3 bolts (C).

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

  93. INSPECT INPUT SHAFT END PLAY

    Click here

  94. INSTALL TRANSMISSION REVOLUTION SENSOR (NC)


    1. B006R77

      Install the transmission revolution sensor (NC) to the counter drive gear sub-assembly with the bolt.

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

  95. INSTALL TRANSMISSION REVOLUTION SENSOR (NT)


    1. B006PF0

      Install the transmission revolution sensor (NT) to the automatic transaxle case sub-assembly with the bolt.

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

  96. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. B006OCIC01
      *1 Transaxle Case Gasket
      *2 No. 1 Front Oil Pump Cover Gasket
      *3 No. 2 Front Oil Pump Cover Gasket

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

    2. Coat a new transaxle case gasket with Toyota Genuine ATF WS and install it to the counter drive gear sub-assembly.

    3. Coat a new transaxle case gasket with Toyota Genuine ATF WS and install it to the front oil pump assembly.

    4. Coat a new No. 1 front oil pump cover gasket with Toyota Genuine ATF WS and install it to the front oil pump assembly.

    5. Coat a new No. 2 front oil pump cover gasket with Toyota Genuine ATF WS and install it to the front oil pump assembly.

    6. B006NICC01
      *1 Manual Valve
      *2 Manual Valve Lever Sub-assembly

      Align the slit portion of the manual valve and the manual valve lever sub-assembly as shown in the illustration, and install the transmission valve body assembly to the automatic transaxle case sub-assembly with the 9 bolts.

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

      Note

      Be careful that the transmission revolution sensor (NC) wire is not pinched.

    7. B006O8XC01
      B006REL Do not let transmission revolution sensor (NC) wire ride up over this area.

      Engage the clamp to connect the transmission revolution sensor (NC) wire connector.

      Note

      To prevent it from being pinched between the transmission valve body assembly and the transmission case cover side, do not let the transmission revolution sensor (NC) wire ride up over the area shown in the illustration.

  97. INSTALL TRANSMISSION WIRE


    1. B006OPY

      Coat the O-ring of the transmission wire with Toyota Genuine ATF WS.

    2. Install the transmission wire to the automatic transaxle case sub-assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    3. B006QSZ

      Connect the transmission revolution sensor (NT) connector and transmission revolution sensor (NC) connector.

    4. B006QV7

      Install the temperature sensor to the transmission valve body assembly with the bolt and temperature sensor clamp.

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

      Note

      To prevent it from being pinched between the transmission valve body assembly and the transmission case side cover, pass the transmission revolution sensor (NC) wire under the transmission wire (temperature sensor wire) as shown in the illustration.

      B006P3EC02
      *a Transmission Wire (Temperature Sensor Wire)
      *b Transmission Revolution Sensor (NC) Wire
    5. B006PXC

      Engage the clamp to connect the transmission wire (oil pump with solenoid assembly) to the solenoid lock plate.

    6. B006NHU

      Connect the transmission wire connector.

    7. B006Q0W

      Engage the wire harness clamp to connect the transmission wire (oil pump with solenoid assembly).

    8. B006MP8

      Connect the 9 solenoid valve connectors as shown in the illustration.

      Note

      B006QPDC01
      B006REL Do not let transmission wire protrude into this area.

      • To prevent it from being pinched between the transmission valve body assembly and the transmission case side cover, do not let the transmission wire ride up over the area shown in the illustration.

      • To prevent it from being pinched between the transmission case side cover and the automatic transaxle case sub-assembly, do not let the transmission wire protrude toward the transmission case side cover installation surface.

    9. B006RJH

      Engage the clamp to connect the transmission wire to the solenoid lock plate.

  98. INSTALL TRANSMISSION CASE SIDE COVER


    1. B006NL7C01
      B006REL Area to be cleaned

      Clean the transmission case side cover installation surface of the automatic transaxle case sub-assembly.

      Note

      Completely remove any oil or grease from the contact surfaces of the automatic transaxle case sub-assembly.

    2. B006NOJ

      Clean the 3 bolt holes shown in the illustration.

    3. B006MJ5C53
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the end of the bolt (A) and 2 bolts (D).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Make sure to install the bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

      Tech Tips

      The bolt (A) and 2 bolts (D) are in the locations shown in the following step.

    4. B006KZIN06

      Temporarily install a new transmission case side cover to the automatic transaxle case sub-assembly with the 2 bolts (A and B).

      Note


      • Bolt (A) is an adhesive-coated bolt.

      • To avoid damaging the gasket, prevent it from contacting the surrounding area during installation procedures.

    5. Temporarily install the 6 bolts (C) and 2 bolts (D).

      Note

      Bolt (D) is an adhesive-coated bolt.

    6. B006KY7N04

      Fully tighten the 10 bolts in the order shown in the illustration.

      Torque:
      Bolt (A) and Bolt (D)
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      Bolt (B) and Bolt (C)
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  99. INSTALL NO. 1 BREATHER PLUG (ATM)


    1. Coat the O-ring portion of the No. 1 breather plug (ATM) with Toyota Genuine ATF WS.

    2. B006O3CC01
      *a Indented Portion
      *b Detent Aligned

      Engage each claw to install a new No. 1 breather plug (ATM) to the automatic transaxle case sub-assembly.

      Note

      Securely push in the automatic transaxle case sub-assembly until the No. 1 breather plug (ATM) is engaged.

      Tech Tips

      Install the No. 1 breather plug (ATM) with its detent aligned with the indented portion of the automatic transaxle case sub-assembly.

  100. INSTALL NO. 1 OIL COOLER OUTLET TUBE SUB-ASSEMBLY


    1. B006LCC

      Coat a new O-ring with Toyota Genuine ATF WS and install it to the No. 1 oil cooler outlet tube sub-assembly.

      Note

      Ensure that the O-ring is not twisted.

    2. B006RJ8C01
      *a Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 19 mm union nut wrench, install the No. 1 oil cooler outlet tube sub-assembly to the automatic transaxle case sub-assembly.

      Torque:
      Specified tightening torque
      31.1 N*m  { 317 kgf*cm, 23 ft.*lbf }

      Tech Tips


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

        Click here

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

        26.7 N*m (272 kgf*cm, 20 ft.*lbf)

  101. INSTALL OIL COOLER UNION SUB-ASSEMBLY


    1. B006N53C01
      *1 Oil Cooler Union Bolt
      *2 Gasket

      Pass the oil cooler union sub-assembly through 2 new gaskets and temporarily install it to the automatic transaxle case sub-assembly.

    2. Temporarily install the oil cooler union sub-assembly bracket portion to the automatic transaxle case sub-assembly with the bolt.

    3. Fully tighten the oil cooler union bolt.

      Torque:
      22.6 N*m  { 230 kgf*cm, 17 ft.*lbf }

    4. Fully tighten the bolt.

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

  102. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE


    1. B006QDL

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

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

  103. INSTALL OVERFLOW PLUG


    1. B006M9O

      Using a 10 mm socket hexagon wrench, install the overflow plug and a new gasket to the transaxle housing.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

      Note

      To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

  104. INSTALL REFILL PLUG


    1. B006RJX

      Install the refill plug and a new gasket to the automatic transaxle case sub-assembly.

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

      Note

      To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

  105. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B006N37

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

    2. B006N8R

      Temporarily install the transmission control shaft lever to the manual valve lever shaft sub-assembly.

    3. B006NJYC01
      *a P Position
      *b N Position

      Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

    4. Remove the transmission control shaft lever from the manual valve lever shaft sub-assembly.

    5. B006PEKC01
      *a Neutral Basic Line
      *b Protrusion

      Align the protrusion with the neutral basic line.

    6. Hold the park/neutral position switch assembly in that position and tighten the 2 bolts.

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

  106. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. B006N8R

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

      Note

      Be careful of the assembly direction of the transmission control shaft lever.

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