AUTOMATIC TRANSAXLE UNIT REASSEMBLY

  1. BEARING POSITION

    1. Check bearing position and installation direction.

      A011UGYE01
      A011SC3E01
      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 (2.47) / 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 (2.84) -

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

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

      A011T9KE01

    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 )
      Oil seal driven in depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  3. INSTALL MANUAL VALVE LEVER SHAFT

    1. Install a new spacer to the parking lock lever sub-assembly.

    2. Install the parking lock lever sub-assembly to the manual valve lever shaft.

    3. Install a new spacer to the manual valve lever sub-assembly.

    4. Install the manual valve lever sub-assembly to the manual valve lever shaft.

    5. Install the manual valve lever shaft to the transaxle case.

      A011UAY

      Note

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

    6. Using a pin punch (3 mm) and hammer, install a new slotted spring pin into the parking lock lever sub-assembly.

      A011VBZ

    7. Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft.

      A011RES

    8. Using a pin punch, stake the spacer through the small hole.

    9. Check that the spacer does not turn.

    10. Using a pin punch (3 mm) and hammer, install a new slotted spring pin into the manual valve lever sub-assembly.

      A011RHK

    11. Turn the spacer and the lever shaft to align the smaller hole of the spacer with the staking position mark on the lever shaft.

      A011SE7

    12. Using a pin punch, stake the spacer through the small hole.

    13. Check that the spacer does not turn.

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

      A011R3XE01

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

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

      A011V7B

  5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

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

      A011SD3E01
      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

      Note

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

  6. INSTALL NO. 3 BRAKE PISTON

    1. Coat the contact surface of the transaxle case with ATF.

      A011UJ6

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

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

      A011RW2

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

      A011TF2E02
      Text in Illustration
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

      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 return spring to press the piston into the transaxle case.

    5. Install the return spring to the transaxle case.

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

      A011SEGE01

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

      A011RB6E01
      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 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

    Note

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

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

      A011TNDE01
      SST
      09950-60020   ( 09951-01030 )
      09950-70010   ( 09951-07100 )

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

      A011UPSE01
      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. Using SST and a press, press the planetary gear assembly onto the transaxle case.

      A011QUIE01
      SST
      09223-15030
      09527-17011
      09951-01100

  9. INSTALL NO. 2 BRAKE PISTON

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

      A011THUE03
      Text in Illustration
      *1 O-ring

      Note

      Ensure that the 2 O-rings are not twisted.

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

      A011RMG

      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 to the transaxle case.

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

      A011TYZE01
      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 as shown in the illustration.

      Note

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

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

  11. INSTALL NO. 2 BRAKE DISC

    1. Install the 5 brake discs, 5 brake plates and brake flange to the transaxle case.

      A011TRCE02
      Text in Illustration
      *1 Brake Flange
      *2 Brake Plate
      *3 Brake Disc

      Note

      Make sure that the discs, plates and flange are installed in the correct order.

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

      A011RTW

      Note

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

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

  12. INSPECT CLEARANCE OF NO. 2 BRAKE

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

      A011VBI
      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.

      Tech Tips

      There are 5 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. Install the planetary ring gear flange to the planetary ring gear.

      A011R7KE02
      Text in Illustration
      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 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. Install the planetary ring gear to the one-way clutch assembly.

      A011QSXE02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Planetary Ring Gear

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

      A011S4XE02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Thrust Needle Roller Bearing
      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 will be visible.

    2. Install the one-way clutch assembly to the transaxle case.

      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.

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

      A011RZD

      Note

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

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

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

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

      A011TKWE01
      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 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. Install the parking lock pawl to the transaxle case with the parking lock pawl shaft.

      A011S2HE02
      Text in Illustration
      *1 Parking Lock Pawl Shaft
      *2 Parking Lock Pawl
      *3 Spring
      *4 Parking Lock Pawl Pin

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

    3. Install the spring to the parking lock pawl.

      A011R9C

      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. Install the parking lock sleeve to the transaxle case.

      A011SWD

  19. INSTALL PAWL STOPPER PLATE

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

      A011RIR
      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  20. INSTALL PAWL SHAFT CLAMP

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

      A011UE4
      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  21. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING

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

      A011S6LE01
      SST
      09950-60010   ( 09951-00420 )

      Note

      Be sure to install the counter driven gear rear tapered roller bearing and the differential drive pinion so that there is no clearance between each of them and the counter driven gear.

  22. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING

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

      A011SDGE01
      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 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. Install the counter driven gear sub-assembly to the transaxle case.

      A011UFL

  24. INSTALL COUNTER DRIVE GEAR NUT

    1. Turn the manual valve lever 2 notches counterclockwise to set it to the P position as shown in the illustration.

      A011UTGE01

    2. Using SST, install a new counter drive gear nut.

      A011S3GE01
      SST
      09387-00130
      Torque:
      120 N*m  { 1223 kgf*cm, 88 ft.*lbf }

    3. Turn the manual valve lever 2 notches clockwise to set it to the N position as shown in the illustration.

      A011UG3E01

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

      A011UCYE01
      SST
      09387-00130
      Turning torque
      0.1 to 0.2 N*m (1 to 2 kgf*cm, 0.9 to 1.9 in.*lbf)

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

      Maximum torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)

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

      A011SCYE01
      SST
      09930-00010

  25. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

    1. Hold the differential case in a vise between aluminum plates.

      A011U4O

      Note

      Do not overtighten the vise.

    2. Place a dial indicator at a right angle to one of the side gear teeth.

    3. Hold the pinion gear in the differential case and measure the backlash of the side gear.

      Standard backlash
      0.05 to 0.15 mm (0.00197 to 0.00591 in.)
      Thrust Washer Thickness
      Thickness Thickness
      1.50 mm (0.0591 in.) 1.75 mm (0.0689 in.)
      1.55 mm (0.0610 in.) 1.80 mm (0.0709 in.)
      1.60 mm (0.0630 in.) 1.85 mm (0.0728 in.)
      1.65 mm (0.0650 in.) 1.90 mm (0.0748 in.)
      1.70 mm (0.0669 in.) -

      If the backlash is not within the standard range, select another side gear thrust washer.

  26. INSTALL FRONT DIFFERENTIAL CASE

    1. Install the front differential case to the transaxle case.

      A011R5J

  27. INSTALL NO. 1 BRAKE PISTON

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

      A011QSAE03
      Text in Illustration
      *1 O-ring

      Note

      Ensure that the O-rings are not twisted.

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

      A011TDF

      Note

      Be careful not to damage the O-rings.

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

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

      A011TJC

      Note

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

  29. INSTALL NO. 1 BRAKE DISC

    1. Install the 4 No. 1 brake discs, 4 No. 1 brake plates and No. 1 brake flange to the oil pump assembly.

      A011REQE02
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

      Note

      • Make sure that the discs, plates, and flange are installed in the correct order.

      • Be sure to install the flange in the correct direction.

    2. Place SST on the flange and compress the flange using a press.

      SST
      09387-00070
      09495-65040

      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.

    3. Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#1).

      A011UU1E01

      Note

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

      • 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. Install the brake snap ring stopper to the oil pump assembly.

      A011S7L

      Note

      Be sure to install the brake snap ring stopper in the correct direction.

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

      A011U20E01

      Note

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

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

      A011U6YE04
      Text in Illustration
      *1 Snap Ring
      *2 Brake Snap Ring Stopper
      *a Correctly installed

      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 oil pump. Remove and reinstall the snap ring and the brake snap ring stopper.

  30. INSPECT CLEARANCE OF NO. 1 BRAKE

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

      A011SJR
      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.

      Tech Tips

      There are 6 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)

  31. INSTALL UNDERDRIVE PLANETARY SUN GEAR

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

      A011QVRE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Underdrive Planetary Sun Gear
      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 properly so that the temper colored side of the race will be visible.

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

  32. INSTALL INPUT SHAFT SUB-ASSEMBLY

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

      A011RKSE02
      Text in Illustration
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring
      *4 Input Shaft

      Note

      Do not expand the gap of the oil seal ring excessively.

    2. Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them on the oil pump 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. Install the input shaft to the oil pump assembly.

      A011T4L

  33. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY

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

      A011RECE02
      Text in Illustration
      *1 Planetary Sun Gear Sub-assembly
      *2 Underdrive Planetary Gear Assembly
      *3 Snap Ring

    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 UNDERDRIVE PLANETARY RING GEAR

    1. Install the underdrive planetary ring gear to the underdrive planetary gear assembly.

      A011SPZE03
      Text in Illustration
      *1 Snap Ring
      *2 Underdrive Planetary Ring Gear

    2. Using needle-nose pliers, install the snap ring to the underdrive planetary ring gear.

      Note

      Confirm that the snap ring is correctly located in the groove of the underdrive planetary ring gear.

  35. INSTALL NO. 3 BRAKE HUB

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

      A011UHJE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      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 properly so that the temper colored side of the race will be visible.

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

      A011TQQE02
      Text in Illustration
      *1 Thrust Needle Roller Race

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

      A011UQC

  36. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

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

      A011QQC

  37. INSTALL NO. 3 BRAKE DISC

    1. Install the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates to the oil pump assembly.

      A011URQE02
      Text in Illustration
      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc

      Note

      Make sure that the discs, plates and flanges are installed in the correct order.

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

      A011QNBE02

      Note

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

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

  38. INSPECT CLEARANCE OF NO. 3 BRAKE

    1. 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.

      A011TWRE04
      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

      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 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 brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 6 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)

  39. INSTALL FRONT OIL PUMP ASSEMBLY

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

      A011VB6E02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race
      *3 O-ring

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

      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 53.1 (2.09) 79 (3.11)
      Race 59.4 (2.34) 77 (3.03)

      Note

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

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

      A011TQPE02
      Text in Illustration
      *1 O-ring

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

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

  40. INSTALL FRONT OIL PUMP BODY O-RING

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

      A011UPA

  41. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

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

      A011UESE01

      Note

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

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

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

      Note

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

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

    1. Install the shim to the transaxle housing.

      A011RUGE01

    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.

  43. INSTALL TRANSAXLE HOUSING

    1. Remove any packing material from the contact surfaces between the transaxle housing and case.

      Note

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

    2. Apply FIPG to the transaxle case.

      A011U0JE04
      Text in Illustration
      *a FIPG
      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.

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

      A011TPIE02
      Torque:
      Bolt A
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt B
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  44. ADJUST COUNTER DRIVEN GEAR PRELOAD

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

      A011SOBE01
      SST
      09564-33010
      Turning torque
      Differential side bearing preload 3.3 to 6.0 N*m (34 to 61 kgf*cm, 29 to 53 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: 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) - - -

  45. INSTALL NO. 1 CLUTCH DISC

    1. Install the clutch flange, 4 clutch discs and 4 clutch plates to the direct multiple disc clutch assembly.

      A011THRE03
      Text in Illustration
      *1 Clutch Flange
      *2 Clutch Plate
      *3 Clutch Disc

      Note

      Make sure that the flange, discs and plates are installed in the correct order.

    2. Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly.

      A011SRN

      Note

      Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.

  46. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    Note

    There are two different types of rear multiple disc clutch assembly. Refer to the illustration and visually inspect the rear multiple disc clutch assembly to determine if it is transaxle serial number 2########## or transaxle serial number 3##########.

    A011U3XE01
    Text in Illustration
    *a Transaxle serial number 2##########
    *b Transaxle serial number 3##########

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

      A011S4H

    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).

      Tech Tips

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

      Pack clearance
      0.606 to 0.774 mm (0.0238 to 0.0305 in.)

      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.

      Tech Tips

      There are 7 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)
      36* 3.6 (0.142)*

      Tech Tips

      *Transaxle serial number 3########## only

  47. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

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

      A011UKGE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race
      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

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

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

      A011TVG

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

      A011SWB

  48. INSTALL NO. 2 CLUTCH DISC

    1. Install the clutch flange, 3 clutch discs and 3 clutch plates to the direct multiple disc clutch assembly.

      A011R5LE03
      Text in Illustration
      *1 Clutch Plate
      *2 Clutch Disc
      *3 Clutch Flange

      Note

      Make sure that the flange, discs and plates are installed in the correct order.

  49. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING

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

      A011UGRE04
      Text in Illustration
      *1 Intermediate Shaft Oil Seal
      *2 O-ring

    2. Coat a new intermediate shaft oil seal with ATF and install it to the direct multiple disc clutch assembly.

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

      A011UZA

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

      A011UH3E01

      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.

  50. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

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

      A011TLJ

    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.

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

      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.

      Tech Tips

      There are 7 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)
      36* 3.6 (0.142)*

      Tech Tips

      *Transaxle serial number 3########## only

  51. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

    1. Coat the thrust needle roller bearing with ATF and install it on the transaxle case.

      A011SKKE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Direct Multiple Disc Clutch Assembly
      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. As shown in the illustration, 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).

      A011R4KE03
      Text in Illustration
      *a Dimension A

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

      A011R49E04
      Text in Illustration
      *a 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 (0.000275 to 0.0438 in.)

  52. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY

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

      A011U5XE01
      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Installation 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. Using a "TORX" socket wrench (T30), install the rear transaxle cover plate to the rear transaxle cover sub-assembly with the 2 "TORX" screws.

      A011TLQE01
      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

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

      A011TPXE02
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Needle Roller Race
      Bearing and Race Diameter: mm (in.)
      - Inside Outside
      Bearing 48.9 (1.93) 72.0 (2.84)
      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. Coat 3 new O-rings with ATF and install them to the transaxle case.

      A011V4SE01

      Note

      Ensure that the O-rings are not twisted.

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

      A011SKN

      Note

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

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

    8. Install the rear transaxle cover sub-assembly to the transaxle case with the 14 bolts.

      A011RPOE01
      Torque:
      Bolt A
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }
      Bolt B
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }

    9. Install a new gasket to the refill plug.

      A011R9J

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

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

    11. Coat 2 new O-rings with ATF and install them to the 2 No. 1 automatic transaxle case plugs.

      A011RSU

    12. Install the 2 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.

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

  53. INSPECT INPUT SHAFT END PLAY

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

      A011QZS
      End play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  54. INSTALL TRANSAXLE CASE GASKET

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

      A011UQ6E01

  55. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    1. Install the valve body assembly to the transaxle case with the 11 bolts.

      A011R84E01
      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 into the groove on the end of the manual valve.

      • First, temporarily tighten the bolts marked by *1 in the illustration because they are positioning bolts.

  56. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

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

      A011UTFE05
      Text in Illustration
      *1 O-ring

      Note

      Ensure that the O-ring is not twisted or pinched.

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

      A011RIZ
      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

    1. Install the 2 magnets in the automatic transaxle oil pan sub-assembly.

      A011U1PE04
      Text in Illustration
      *1 Magnet

    2. Install a new gasket to the oil pan.

    3. Install the oil pan to the automatic transaxle with the 17 bolts.

      A011V4Q
      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    4. Clean and degrease the bolt and the installation hole in the automatic transaxle.

      A011RZI

    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 transmission oil pan bolts, apply adhesive to the bolts and install them within 10 minutes of adhesive application.

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

    7. Using a hexagon socket wrench (6 mm), install the No. 1 oil filler tube to the automatic transaxle assembly.

      A011TZW
      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }

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

      A011S18
      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  58. 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 Seal Packing 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. Using a hexagon socket wrench (6 mm), install the 3 hexagon bolts to the transaxle housing with the gaskets.

      A011S8L
      Torque:
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }

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

      A011UV3

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

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

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

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

      A011SZE

    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 }

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

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

      A011TML

    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 }

  61. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

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

      A011V9DE11
      Text in Illustration
      *a Protrusion

    2. Install the park/neutral position switch to the control shaft with the 2 bolts.

      A011TTN
      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Note

      • Before installing the park/neutral position switch, remove any dirt or rust on the control shaft. 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 cannot be reinstalled correctly.

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

    3. Install the control shaft lever to the control shaft with the washer and nut.

      A011TX7
      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  62. INSTALL BREATHER PLUG HOSE

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

      A011QU9E04
      Text in Illustration
      *1 No. 1 Breather Plug (ATM)
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug (ATM)
      *4 O-ring

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

    3. Install the breather plug hose to the transaxle case.

      A011ROH