AUTOMATIC TRANSAXLE UNIT REASSEMBLY

Tech Tips

Check bearing position and installation direction.

A01G9PLE01
A01G4AUE01
Mark

Front Race Diameter

Inside / Outside [mm (in.)]

Thrust Bearing Diameter

Inside / Outside [mm (in.)]

Rear Race Diameter

Inside / Outside [mm (in.)]
A - 57.7 (2.27) / 75.2 (2.96) -
B - 29.1 (1.15) / 48.6 (1.91) 30.7 (1.21) / 48.3 (1.90)
C - 62.6 (2.46) / 82.4 (3.24) 65.9 (2.59) / 82.3 (3.24)
D 59.4 (2.34) / 76 (2.99) 53.46 (2.10) / 79 (3.11) -
E - 56.1 (2.21) / 81.1 (3.19) -
F - 61.2 (2.41) / 79 (3.11) -
G - 28 (1.10) / 47.1 (1.85) 26.1 (1.03) / 44 (1.73)
H 52.2 (2.06) / 70.4 (2.77) 48.9 (1.93) / 72.0 (2.83) -

  1. INSTALL COUNTER DRIVE GEAR BEARING

    Tech Tips

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


    1. A01G9H0E01

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

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

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01G6MQE01

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

    2. Using SST and a hammer, tap in the manual valve lever shaft oil seal.

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

      Note

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

  3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01G5EE

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

      Note

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

    2. A01G58M

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

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01G5S4

      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. A01G7I3

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

  6. INSTALL NO. 3 BRAKE PISTON


    1. A01G6MW

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A01G7WIE02
      Text in Illustration
      *1 No. 3 Brake Piston

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

    3. A01G6SAE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

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

      Note

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

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

      Note

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

      Tech Tips

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

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

    6. A01G80YE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Brake Piston Return Spring

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

      Note

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

    7. A01G8XGE02
      Text in Illustration
      *1 Snap Ring

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

      SST
      09387-00070

      Note

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

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

      Note


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

      • Be sure to align the opening of the snap ring with one of the protrusions on the brake piston return spring as shown in the illustration.

  7. INSTALL COUNTER DRIVE GEAR


    1. A01G4BRE02

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

      SST
      09387-00020
    2. A01G98IE01

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

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

      Note

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

  8. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01G5E9E01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  9. INSTALL NO. 2 BRAKE PISTON


    1. A01G59H

      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 sub-assembly.

      Note

      Be careful not to damage the O-rings.

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


    1. A01G9TBE01

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

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

      SST
      09387-00060

      Note

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

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

      Note


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

      • Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case sub-assembly as shown in the illustration.

  11. INSTALL NO. 2 BRAKE DISC


    1. A01G84LE01
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

      Install the 4 No. 2 brake discs, 4 No. 2 brake plates, and No. 2 brake flange to the transaxle case sub-assembly.

      Note

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

    2. A01G4LT

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

      Note


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

      • Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case sub-assembly as shown in the illustration.

  12. INSPECT CLEARANCE OF NO. 2 BRAKE PISTON


    1. A01G6YN

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

      Standard clearance
      0.707 to 0.974 mm (0.0278 to 0.0383 in.)

      Tech Tips

      Measure the clearance at 3 points where the No. 2 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.

      No. 2 Brake Flange Thickness
      Mark Thickness [mm (in.)]
      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 ONE-WAY CLUTCH ASSEMBLY


    1. A01G8LFE02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

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

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

      Note

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

    3. A01G5YVE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing

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

      Bearing Diameter
      - Inside [mm (in.)] Outside [mm (in.)]
      Bearing 56.1 (2.21) 81.1 (3.19)

      Note

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

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

      Note

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

    5. A01G4TF

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

      Note


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

      • Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case sub-assembly as shown in the illustration.

  15. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)


    1. A01G5KVE01

      Using SST and a hammer, install a new differential drive pinion tapered roller bearing LH (outer race) to the transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00630 )
      09950-70010   ( 09951-07100 )

      Note

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

  16. INSTALL PARKING LOCK PAWL


    1. A01G6GZE02
      Text in Illustration
      *1 Parking Lock Pawl Pin
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 Parking Lock Pawl

      Install the parking lock pawl to the transaxle case sub-assembly with the parking lock pawl shaft.

    2. Install the parking lock pawl pin to the transaxle case sub-assembly.

    3. A01G5H7

      Install the spring to the parking lock pawl.

      Note

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

  17. INSTALL PARKING LOCK SLEEVE


    1. A01G90L

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

  18. INSTALL PAWL STOPPER PLATE


    1. A01G4IF

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

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

  19. INSTALL NO. 1 TRANSMISSION CASE PLATE


    1. A01G7O2E01

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

      Tech Tips

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

  20. INSTALL PAWL SHAFT CLAMP


    1. A01G7CW

      Install the pawl shaft clamp to the transaxle case sub-assembly with the bolt.

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

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


    1. A01G8ITE01

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

      SST
      09950-60010   ( 09951-00490 )

      Note

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

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


    1. A01G87FE01

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

      SST
      09950-60010   ( 09951-00400 )

      Note

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

  23. INSTALL COUNTER DRIVEN GEAR


    1. A01G4HS

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

  24. INSTALL COUNTER DRIVE GEAR NUT


    1. A01G6UJE01

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

    2. A01G7XTE01

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. A01G54AE01

      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 0.8 N*m (1 to 8 kgf*cm, 1 to 7 in.*lbf)

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

      Maximum torque
      180 N*m (1835 kgf*cm, 133 ft.*lbf)
    5. A01G7Y3E01

      Using SST and a hammer, stake the counter drive gear nut.

      SST
      09930-00010

  25. INSTALL FRONT DIFFERENTIAL CASE


    1. A01G745

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

  26. INSTALL NO. 1 BRAKE PISTON


    1. A01G65FE04

      Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A01G9JX

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01G62O

      Install the 3 2nd brake piston return springs to the front oil pump assembly.

      Note

      Make sure that the 3 2nd brake piston return springs are installed onto the protrusions on the front oil pump assembly.

  28. INSTALL NO. 1 BRAKE DISC


    1. A01G6QME03
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

      Install the 3 No. 1 brake discs, 3 No. 1 brake plates, and No. 1 brake flange to the front oil pump assembly.

      Note


      • Make sure that the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are installed in the correct order.

      • Be sure to install the No. 1 brake flange in the correct direction.

    2. A01G8NBE01

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

      SST
      09387-00070
      09495-65040

      Note

      Stop the press when the 2nd brake piston return spring is flush with the snap ring groove. This prevents the 2nd brake piston return spring from being deformed.

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

      Note


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

      • Make sure to align the protruding part of the snap ring with the indented part (#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. A01G687E01

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

      Note


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

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

    6. A01G8JJE03
      Text in Illustration
      *1 Brake Snap Ring Stopper
      *2 Snap Ring
      *a Correctly Installed

      Check that the brake snap ring stopper can be turned by hand.

      Note

      If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or the snap ring may not have been completely located in the groove on the front oil pump assembly. Remove and reinstall the snap ring and the brake snap ring stopper.

  29. INSPECT CLEARANCE OF NO. 1 BRAKE PISTON


    1. A01G59E

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

      Standard clearance
      0.601 to 0.819 mm (0.0237 to 0.0322 in.)

      Tech Tips

      Measure the clearance at 3 points where the No. 1 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.

      No. 1 Brake Flange Thickness
      Mark Thickness [mm (in.)]
      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)

  30. INSTALL UNDERDRIVE PLANETARY SUN GEAR


    1. A01G8ZCE02
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

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

      Bearing Diameter
      - Inside [mm (in.)] Outside [mm (in.)]
      Bearing 57.7 (2.27) 75.2 (2.96)

      Note

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

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

  31. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01G84AE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft
      *4 Oil Seal Ring

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

      Note

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

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

      Bearing and Race Diameter
      - Inside [mm (in.)] Outside [mm (in.)]
      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.

  32. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01G8TTE02
      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.

  33. INSTALL NO. 3 BRAKE HUB


    1. A01G77AE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

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

      Bearing and Race Diameter
      - Inside [mm (in.)] Outside [mm (in.)]
      Bearing 62.6 (2.47) 82.4 (3.24)
      Race 65.9 (2.59) 82.3 (3.24)

      Note

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

    2. Coat the thrust bearing 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.

  34. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01G4H4

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

  35. 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 discs, No. 3 plates, and No. 3 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).

  36. INSPECT CLEARANCE OF NO. 3 BRAKE PISTON


    1. A01G886E01
      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 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 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 - Flange Thickness

      Standard clearance
      0.599 to 0.799 mm (0.0236 to 0.0315 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.

      No. 3 Brake Flange Thickness
      Mark Thickness [mm (in.)]
      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)

  37. INSTALL FRONT OIL PUMP ASSEMBLY


    1. A01G8UVE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 O-ring

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

    2. Coat the thrust needle roller bearing and thrust bearing race with ATF and install them on the counter drive gear nut.

      Bearing and Race Diameter
      - Inside [mm (in.)] Outside [mm (in.)]
      Bearing 53.46 (2.10) 79 (3.11)
      Race 59.4 (2.34) 76 (2.99)

      Note

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

    3. A01G49N

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

    4. A01G6QHE02
      Text in Illustration
      *1 O-ring

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

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

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

  38. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. A01G81K

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

  39. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01G4TE

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

      Note

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

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the 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 apply tube clamp.

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


    1. A01G5KCE01

      Install the shim to the transaxle housing.

    2. Using SST, install a new differential drive pinion tapered roller bearing RH (outer race) to the transaxle housing.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

      Note

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

  41. ADJUST COUNTER DRIVEN GEAR PRELOAD


    1. A01G5AXE01

      Remove packing material from the contact surfaces between the transaxle housing and transaxle case sub-assembly.

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

      Torque:
      Bolt A
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
      except Bolt A
      31 N*m  { 312 kgf*cm, 23 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 + 2.85 to 6.13 N*m (29.07 to 62.50 kgf*cm, 25.23 to 54.25 in.*lbf)

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

      Shim Thickness
      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.275 (0.0896) 2.550 (0.100) 2.825 (0.111)
      2.025 (0.0797) 2.300 (0.0906) 2.575 (0.101) 2.850 (0.112)
      2.050 (0.0807) 2.325 (0.0915) 2.600 (0.102) 2.875 (0.113)
      2.075 (0.0817) 2.350 (0.0925) 2.625 (0.103) 2.900 (0.114)
      2.100 (0.0827) 2.375 (0.0935) 2.650 (0.104) 2.925 (0.115)
      2.125 (0.0837) 2.400 (0.0945) 2.675 (0.105) 2.950 (0.116)
      2.150 (0.0846) 2.425 (0.0955) 2.700 (0.106) 2.975 (0.117)
      2.175 (0.0856) 2.450 (0.0965) 2.725 (0.107) 3.000 (0.118)
      2.200 (0.0866) 2.475 (0.0974) 2.750 (0.108) -
      2.225 (0.0876) 2.500 (0.0984) 2.775 (0.109) -
      2.250 (0.0886) 2.525 (0.0994) 2.800 (0.110) -
    4. A01G5AX

      Remove the 20 bolts and the transaxle housing.

  42. INSTALL TRANSAXLE HOUSING


    1. A01G7NY

      Clean and degrease the contact surfaces between the transaxle housing and transaxle case sub-assembly.

      Note

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

    2. Apply FIPG to the transaxle case sub-assembly.

      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Note


      • Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

      • After applying FIPG, install the transaxle housing to the transaxle case sub-assembly within 3 minutes and tighten the bolts within 20 minutes.

    3. A01G5E0

      Install the transaxle housing to the transaxle case sub-assembly with the 17 bolts.

      Torque:
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
    4. A01G7GQ

      Clean and degrease the 3 bolts and the installation holes in the automatic transaxle assembly.

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the 3 bolts to the transaxle housing.

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

  43. INSPECT CLEARANCE OF NO. 1 CLUTCH


    1. A01G943

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

    2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.

    3. A01G88WE02
      Text in Illustration
      *1 Feeler Gauge

      Using a feeler gauge, measure the No. 1 clutch pack clearance.

      Tech Tips

      Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

      Standard pack clearance
      0.601 to 0.819 mm (0.0237 to 0.0322 in.)

      If the pack clearance is not as specified, replace the rear multiple disc clutch assembly.

  44. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01G8ETE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

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

      Bearing and Race Diameter
      - Inside [mm (in.)] Outside [mm (in.)]
      Bearing 28 (1.10) 47.1 (1.85)
      Race 26.1 (1.03) 44 (1.73)

      Note

      Install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

    2. A01G8LOE02
      Text in Illustration
      *1 Rear Planetary Sun Gear Assembly

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

    3. A01G5EU

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

    4. A01G89RE01
      Text in Illustration
      *1 O-ring
      *2 Oil Seal Ring

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

      Note

      Ensure that the O-ring is not twisted.

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

  45. INSPECT CLEARANCE OF NO. 2 CLUTCH


    1. A01G90V

      Install the rear multiple disc clutch assembly onto 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).

      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.

      Standard pack clearance
      0.394 to 0.605 mm (0.0155 to 0.0238 in.)

      If the pack clearance is not as specified, replace the rear multiple disc clutch assembly.

  46. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01G4RXE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Multiple Disc Clutch Assembly

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

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

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

  47. INSPECT INTERMEDIATE SHAFT END PLAY


    1. A01G69QE02
      Text in Illustration
      *a Dimension A

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

    2. As shown in the illustration, place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case sub-assembly and the straightedge using a vernier caliper (Dimension A).

    3. A01G5OEE03
      Text in Illustration
      *a Dimension B

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

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

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

      Standard end play
      0.022 to 1.099 mm (0.000867 to 0.0432 in.)

  48. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01G843E01

      Using SST and a hammer, install a new needle roller bearing into the rear transaxle cover sub-assembly.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Installation depth
      21.5 to 21.9 mm (0.846 to 0.862 in.)
    2. A01G7VU

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A01G7POE02
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 No. 4 Thrust Bearing Race

      Coat the thrust needle roller bearing and No. 4 thrust bearing race with ATF and install them on the rear transaxle cover sub-assembly.

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

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

    7. A01G5UFE01

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

    8. A01G4LU

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

      Note

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

    9. Apply FIPG to the transaxle case sub-assembly.

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

      Note


      • Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

      • After applying FIPG, install the rear transaxle cover sub-assembly to the transaxle case sub-assembly within 3 minutes and tighten the bolts within 20 minutes.

    10. A01G5WRE03

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

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

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the 2 bolts to the rear transaxle cover sub-assembly.

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

  49. INSTALL REAR TRANSAXLE COVER PLUG


    1. A01G5LM

      Coat 3 new O-rings with ATF and install them to the 3 rear transaxle cover plugs.

      Note

      Ensure that the 3 O-rings are not twisted.

    2. Install the 3 rear transaxle cover plugs to the rear transaxle cover sub-assembly.

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

  50. INSTALL REFILL PLUG


    1. A01G9C4

      Install a new gasket to the refill plug.

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

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

  51. INSPECT INPUT SHAFT END PLAY


    1. A01G6H9

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

      Standard end play
      0.020 to 1.242 mm (0.000788 to 0.0488 in.)

  52. INSTALL NO. 1 GOVERNOR APPLY GASKET


    1. A01G8OZ

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

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

  53. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A01G95HE03
      Text in Illustration
      *a Positioning Bolt

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

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

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

      Note


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

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

  54. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01G8K1

      Coat a new O-ring with ATF.

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

      Note

      Ensure that the O-ring is not twisted.

    3. A01G7CR

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

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

  55. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. A01G9REE04
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

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

  56. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET


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

  57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01G99X

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

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

      Note

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

    2. A01G61W

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the 2 bolts to the automatic transaxle oil pan sub-assembly.

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

  58. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE


    1. A01G4FK

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

      Torque:
      0.8 N*m  { 8 kgf*cm, 7 in.*lbf }

  59. INSTALL OVERFLOW PLUG


    1. A01G7FF

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

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

  60. INSTALL NO. 2 TRANSAXLE CASE PLUG


    1. A01G6IH

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

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

  61. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A01G8X0

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. Install the 3 No. 1 transaxle case plugs to the transaxle case sub-assembly.

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

  62. INSTALL OIL COOLER TUBE UNION (INLET)


    1. A01G4F2

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  63. INSTALL OIL COOLER TUBE UNION (OUTLET)


    1. A01G6UD

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  64. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01G869

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

      Note

      Before installing the park/neutral position switch assembly, remove any foreign matter or rust on the manual valve lever shaft sub-assembly. Be sure to install the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral position switch assembly cannot be reinstalled correctly.

    2. A01G80OE06
      Text in Illustration
      *1 Protrusion

      Align the protrusions of the park/neutral position switch assembly as shown in the illustration.

    3. Tighten the 2 bolts.

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

      Note

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

  65. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. 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 }

  66. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A01G8P0E04
      Text in Illustration
      *1 No. 1 Breather Plug
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug
      *4 O-ring

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

      Note

      Ensure that the O-ring is not twisted.

    2. Install the No. 2 breather plug to the breather plug hose.

    3. Install the No. 1 breather plug to the breather plug hose.

    4. A01G79GE01
      Text in Illustration
      *1 No. 2 Breather Plug
      *a Boss

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

      Note

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