AUTOMATIC TRANSAXLE UNIT REASSEMBLY


  1. BEARING POSITION


    1. Check each bearing position and installation direction.

      A01G5RLE01
      A01G8EUE04
      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 65.9 (2.59) / 80.3 (3.16) 62.6 (2.46) / 82.4 (3.24) -
      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 (2.83) -

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01G6MQE01

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

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

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

  3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01G89T

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

      Note

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

    2. A01G4HZE01

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

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01G4MD

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

  5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01G7IEE01

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

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

      Note

      Make sure to install the manual detent spring sub-assembly first and then the cover.

  6. INSTALL NO. 3 BRAKE PISTON


    1. A01G9PA

      Coat the contact surface of the transaxle case with ATF.

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

    3. A01G6JF

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

    4. A01G8JOE02
      Text in Illustration
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

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

      Note


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

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

      Tech Tips

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

    5. Install the brake piston return spring to the transaxle case.

    6. A01G8G9E01

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

    7. A01G994E01

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

      SST
      09387-00070

      Note

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

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

      Note


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

      • Be sure to 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.

  7. INSTALL COUNTER DRIVE GEAR

    Note

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


    1. A01G9H0E01

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

      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07100 )
    2. A01G69HE01

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

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

      Note

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

  8. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01G8Y8E01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  9. INSTALL NO. 2 BRAKE PISTON


    1. A01G7SOE03
      Text in Illustration
      *1 O-ring

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A01G835

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

      Note

      Be careful not to damage the O-rings.

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


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

    2. A01G4MRE01

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

      SST
      09387-00060

      Note

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

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

      Note


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

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

  11. INSTALL NO. 2 BRAKE DISC


    1. A01G8R0E02
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

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

      Note

      Make sure that the No. 2 brake discs, No. 2 brake plates and No. 2 brake flange are installed in the correct order.

    2. A01G5PE

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

      Note


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

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

  12. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01G9CFE01
      Text in Illustration
      *1 No. 2 Brake Piston
      *a Clearance

      Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 2 brake piston.

    2. Set a dial indicator as shown in the illustration.

    3. Using a dial indicator, measure the clearance of the No. 2 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Standard Clearance
      0.884 to 1.196 mm (0.0348 to 0.0471 in.)

      Tech Tips


      • Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

        If the clearance is not as specified, select an appropriate No. 2 brake flange so that the clearance will be within the specified range.

      • There are 5 No. 2 brake flanges of different thicknesses.

      No. 2 Brake Flange Thickness: mm (in.)
      Mark Thickness
      40 4.0 (0.157)
      41 4.1 (0.161)
      42 4.2 (0.165)
      43 4.3 (0.169)
      44 4.4 (0.173)

  13. INSTALL PLANETARY RING GEAR FLANGE


    1. A01G4BTE02
      Text in Illustration
      *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.

  14. INSTALL PLANETARY RING GEAR


    1. A01G8KXE02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Planetary Ring Gear

      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.

  15. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A01G5YVE06
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Thrust Needle Roller Bearing

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

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

      Note

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

    2. Install the one-way clutch assembly with front planetary gear assembly to the transaxle case.

      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 will be deformed.

    3. A01G4TF

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

      Note


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

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

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


    1. A01G54RE01

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

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

      Note

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

  17. INSTALL PARKING LOCK PAWL


    1. A01G469E02
      Text in Illustration
      *1 Parking Lock Pawl Shaft
      *2 Parking Lock Pawl
      *3 Spring
      *4 Parking Lock Pawl Pin

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

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

    3. A01G5H7

      Install the spring to the parking lock pawl.

      Note

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

  18. INSTALL PARKING LOCK SLEEVE


    1. A01G8O4

      Install the parking lock sleeve to the transaxle case.

  19. INSTALL PAWL STOPPER PLATE


    1. A01G6AW

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

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

  20. INSTALL PAWL SHAFT CLAMP


    1. A01G7HN

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

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

  21. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. A01G9QEE01

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

      SST
      09950-60010   ( 09951-00420 )

      Note

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

  22. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. A01G9OIE01

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

      SST
      09950-60010   ( 09951-00530 )

      Note

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

  23. INSTALL COUNTER DRIVEN GEAR


    1. A01G5Z0

      Install the counter driven gear to the transaxle case.

  24. INSTALL COUNTER DRIVE GEAR NUT


    1. A01G54TE01

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

    2. A01G7T6E01

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. A01G7VFE01

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

    4. A01G6I1E01

      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 1.8 in.*lbf)

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

      Maximum Torque
      180 N*m (1835 kgf*cm, 133 ft.*lbf)
    5. A01G68DE01

      Using SST and a hammer, stake the front planetary gear assembly.

      SST
      09930-00010

  25. INSPECT FRONT DIFFERENTIAL PINION BACKLASH


    1. Install SST as shown in the illustration and tighten it.

      A01G4G3E01
      Text in Illustration
      *a Turn *b Hold
      SST
      09528-52010   ( 09528-05010, 09953-05010 )
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Secure the front differential case in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. A01G6WSE01
      Text in Illustration
      *1 Front No. 1 Differential Pinion Shaft

      Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

    4. Using a dial indicator, measure the front differential pinion backlash.

      Standard Backlash
      0.15 mm (0.00591 in.) or less

      Tech Tips

      Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

      If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select front No. 1 differential side gear thrust washers which will ensure that the backlash is within the specification.

      Front No. 1 Differential Side Gear Thrust Washer Thickness:
      Part No. Thickness (mm (in.))
      41361-33020 1.50 (0.0591)
      41361-33030 1.55 (0.0610)
      41361-33040 1.60 (0.0630)
      41361-33050 1.65 (0.0650)
      41361-33060 1.70 (0.0669)
      41361-33070 1.75 (0.0689)
      41361-33080 1.80 (0.0709)
      41361-33090 1.85 (0.0728)
      41361-33100 1.90 (0.0748)

  26. INSTALL FRONT DIFFERENTIAL CASE


    1. A01G72E

      Install the front differential case to the transaxle case.

  27. INSTALL NO. 1 BRAKE PISTON


    1. A01G65FE03
      Text in Illustration
      *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. A01G9JX

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01G62O

      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.

  29. INSTALL NO. 1 BRAKE DISC


    1. A01G519E02
      Text in Illustration
      *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. 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 are flush with the snap ring groove. This prevents the 2nd brake piston return spring sub-assemblies from being deformed.

    3. A01G8NBE01

      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. A01G65T

      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. A01G5AHE01

      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. A01G8JJE04
      Text in Illustration
      *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 rings and brake snap rings stopper.

  30. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A01G777E02
      Text in Illustration
      *1 No. 1 Brake Piston
      *a Clearance

      Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 1 brake piston.

    2. Set a dial indicator as shown in the illustration.

    3. Using a dial indicator, measure the clearance of the No. 1 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Standard Clearance
      0.807 to 0.974 mm (0.0318 to 0.0383 in.)

      Tech Tips


      • Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

        If the clearance is not as specified, select an appropriate No. 1 brake flange so that the clearance will be within the specified range.

      • There are 7 No. 1 brake flanges of different thicknesses.

      No. 1 Brake Flange Thickness: mm (in.)
      Mark Thickness
      30 3.0 (0.118)
      31 3.1 (0.122)
      32 3.2 (0.126)
      33 3.3 (0.130)
      34 3.4 (0.134)
      35 3.5 (0.138)
      36 3.6 (0.142)

  31. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. A01G49ME01
      Text in Illustration
      *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.

      Bearing Diameter: mm (in.)
      - Inside Outside
      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.

  32. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01G5HOE02
      Text in Illustration
      *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.

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

      Note

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

    3. A01G7CO

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

  33. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01G8DHE02
      Text in Illustration
      *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.

  34. INSTALL NO. 3 BRAKE HUB


    1. A01G6LOE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing

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

      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 62.6 (2.46) 82.9 (3.26)
      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. A01G66UE02
      Text in Illustration
      *1 Thrust Needle Roller Race

      Coat the thrust needle roller race with MP grease and install it to the No. 3 brake hub.

    3. A01G9JH

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

  35. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01G4H4

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

  36. INSTALL NO. 3 BRAKE DISC


    1. A01G9CJE02
      Text in Illustration
      *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. A01G5FLE02

      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).

  37. INSPECT CLEARANCE OF NO. 3 BRAKE


    1. A01G7MBE04
      Text in Illustration
      *1 Front Oil Pump Assembly
      *2 No. 3 Brake Piston
      *a Dimension (A)
      *b Dimension (B)
      *c Contact surface of front oil pump assembly

      Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (A)) while a load of 500 N (51 kgf, 112.4 lbf) is being applied to the flange.

      Tech Tips

      Measure the dimension (A) at 3 points where the flange diameter is approximately 166 mm (6.54 in.) and calculate the average.

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

      Tech Tips

      Measure the dimension (B) at 3 points where the No. 3 brake piston diameter is approximately 166 mm (6.54 in.) and calculate the average.

    3. Calculate the clearance value using the following formula:

      Clearance = Dimension (B) - Dimension (A)

      Standard Clearance
      0.599 to 0.761 mm (0.0236 to 0.0300 in.)

      If the clearance is not as specified, select an appropriate No. 3 brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 8 No. 3 brake flanges of different thicknesses.

      No. 3 Brake Flange Thickness: mm (in.)
      Mark Thickness
      38 3.80 (0.150)
      39 3.90 (0.154)
      40 4.00 (0.157)
      41 4.10 (0.161)
      42 4.20 (0.165)
      43 4.30 (0.169)
      44 4.40 (0.173)
      45 4.50 (0.177)

  38. INSTALL FRONT OIL PUMP BODY O-RING


    1. A01G8DZ

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

  39. INSTALL FRONT OIL PUMP ASSEMBLY


    1. A01G7ICE06
      Text in Illustration
      *1 Thrust Needle Roller Race
      *2 O-ring

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

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

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

      Bearing Diameter: mm (in.)
      - Inside Outside
      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. A01G64CE05
      Text in Illustration
      *1 Thrust Needle Roller Race

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

      Race Diameter: mm (in.)
      - Inside Outside
      Race 59.4 (2.34) 77 (3.03)
    5. A01G7HKE02
      Text in Illustration
      *1 O-ring

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

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  40. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01G88RE01

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

      Note

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

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

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

      Note

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

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


    1. A01G6HGE01

      Install the shim to the transaxle housing.

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

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

      Note

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

  42. ADJUST COUNTER DRIVEN GEAR PRELOAD


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

    2. A01G8VNE02

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

      Torque:
      Bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      Bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    3. A01G81QE01

      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 + 2.2 to 4.1 N*m (22 to 42 kgf*cm, 19 to 36 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) - - -

    4. Remove the 20 bolts and transaxle housing.

  43. INSTALL TRANSAXLE HOUSING


    1. A01G8VNE11

      Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.

      Note

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

    2. A01G8WZE07
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case.

      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.

    3. A01G5RP

      Temporarily install the transaxle housing to the transaxle case with the 17 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    4. A01G7X0

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    6. Install the 3 bolts.

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  44. INSTALL NO. 1 CLUTCH DISC


    1. A01G5YYE03
      Text in Illustration
      *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. A01G6DW

      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.

  45. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC


    1. A01G8YQ

      Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.

    2. Using a dial indicator, measure the No. 1 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Pack Clearance
      0.806 to 0.974 mm (0.0317 to 0.0383 in.)

      Tech Tips


      • Measure the clearance at 3 points where the No. 1 clutch flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

        If the pack clearance is not as specified, select an appropriate No. 1 clutch flange so that the pack clearance will be within the specified range.

      • There are 6 No. 1 clutch flanges of different thicknesses.

      No. 1 Clutch Flange Thickness: mm (in.)
      Mark Thickness
      30 3.0 (0.118)
      31 3.1 (0.122)
      32 3.2 (0.126)
      33 3.3 (0.130)
      34 3.4 (0.134)
      35 3.5 (0.138)

  46. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01G7KBE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

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

      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 28 (1.10) 47.1 (1.85)
      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. A01G5VK

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

    3. A01G48Y

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

  47. INSTALL NO. 2 CLUTCH DISC


    1. A01G9LBE03
      Text in Illustration
      *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.

  48. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING


    1. A01G52TE04
      Text in Illustration
      *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. A01G66G

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

      Note

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

    4. A01G8CME01

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

      Note


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

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

  49. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC


    1. A01G5QO

      Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.

    2. Using a dial indicator, measure the No. 2 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Pack Clearance
      0.544 to 0.744 mm (0.0214 to 0.0293 in.)

      Tech Tips


      • Measure the clearance at 3 points where the diameter of the No. 2 direct multiple clutch piston is approximately 152 mm (5.98 in.) and calculate the average.

        If the pack clearance is not as specified, select an appropriate No. 2 clutch flange so that the pack clearance will be within the specified range.

      • There are 6 No. 2 clutch flanges of different thicknesses.

      No. 2 Clutch Flange Thickness: mm (in.)
      Mark Thickness
      30 3.0 (0.118)
      31 3.1 (0.122)
      32 3.2 (0.126)
      33 3.3 (0.130)
      34 3.4 (0.134)
      35 3.5 (0.138)

  50. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01G6G7E01
      Text in Illustration
      *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.

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

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

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

    4. A01G6LLE03
      Text in Illustration
      *a Dimension A

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

    5. A01G5OEE04
      Text in Illustration
      *a Dimension B

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

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

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

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

  51. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01G843E05

      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
    3. A01G733E01

      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. A01G9COE05
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Needle Roller Race

      Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them to the transaxle case.

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

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

    6. A01G5UFE01

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

      Note

      Ensure that the O-rings are not twisted.

    7. A01G4LUE04

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

    8. Apply seal packing to the transaxle case.

      Text in Illustration
      *a FIPG

      Note

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

      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    9. A01G5WRE16

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

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    10. A01G5WRE04

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

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

    12. Install the 2 bolts.

      Torque:
      17 N*m  { 172 kgf*cm, 12 ft.*lbf }
    13. A01G9C4

      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. A01G5VJ

      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 }

  52. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY


    1. A01G6H9

      Using a dial indicator, measure the input shaft sub-assembly end play.

      End Play
      0.012 to 1.250 mm (0.000472 to 0.0492 in.)

  53. INSTALL TRANSAXLE CASE GASKET


    1. A01G7TPE01

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

  54. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A01G8VRE05
      Text in Illustration
      *a Positioning Bolt

      Confirm that the manual valve lever sub-assembly is positioned as shown in the illustration and install the transmission valve body assembly to the transaxle case with the 11 bolts.

      Torque:
      11 N*m  { 112 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 to interfere with each other.

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

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

  55. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01G489E05
      Text in Illustration
      *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. A01G7VH

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

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

  56. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01G6ERE04
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

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

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

    3. A01G84M

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A01G4AH

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

    5. Apply adhesive to the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Install the bolt.

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

      Note


      • In order to ensure proper sealing of the automatic transaxle oil pan sub-assembly bolts, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

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

    7. A01G4T1

      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. A01G8K2

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

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  57. INSTALL NO. 1 TRANSAXLE CASE PLUG


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

    2. Apply adhesive to the 3 hexagon bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

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

    3. A01G6IH

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

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    4. A01G7AN

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

    5. Install the 3 No. 1 transaxle case plugs to the transaxle case.

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

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


    1. A01G5PK

      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.

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

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


    1. A01G6W3

      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.

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

  60. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01G80OE11
      Text in Illustration
      *a Protrusion

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

    2. A01G869

      Install the park/neutral position switch assembly to the manual valve lever shaft 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 foreign matter 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. A01G92X

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

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

  61. INSTALL BREATHER PLUG HOSE


    1. A01G8P0E04
      Text in Illustration
      *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. A01G6MZ

      Install the breather plug hose to the transaxle case.