AUTOMATIC TRANSAXLE UNIT REASSEMBLY

Tech Tips

Check bearing position and installation direction.

A011TO2E01
A011SYQE01
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. Using SST and a press, install a new counter drive gear bearing and snap ring to the transaxle case sub-assembly.

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

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

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

      A011T9KE01

    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 oil seal is installed in the correct direction.

  3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

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

      A011THJ

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

      A011RPB

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

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

      A011RYP

  5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

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

      A011S4P
      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. Coat 2 new O-rings with ATF and install them to the No. 3 brake piston.

      A011RYS

      Note

      Ensure that the 2 O-rings are not twisted.

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

      A011UU5E02
      Text in Illustration
      *1 No. 3 Brake Piston

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

      A011TZRE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

      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 return spring to press the piston into the transaxle case sub-assembly.

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

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

      A011RCWE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Brake Piston Return Spring

      Note

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

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

      A011TDLE02
      Text in Illustration
      *1 Snap Ring
      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. Using SST and a press, install a new counter drive gear bearing inner race (front side) to the counter drive gear.

      A011S65E02
      SST
      09387-00020

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

      A011RHWE01
      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. Using SST and a press, press in a new front planetary gear assembly to the transaxle case sub-assembly.

      A011UBYE01
      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.

      A011URJ

      Note

      Ensure that the 2 O-rings are not twisted.

    2. Install the No. 2 brake piston to the transaxle case sub-assembly.

      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 sub-assembly.

      A011T5RE01

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

      A011SOCE01
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 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 sub-assembly.

      A011RA2

      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

    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).

      A011UKP
      Standard clearance
      0.707 to 0.974 mm (0.0278 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. 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. 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 ONE-WAY CLUTCH ASSEMBLY

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

      A011RSHE02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

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

      A011RXHE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      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. Using a screwdriver, install the snap ring to the transaxle case sub-assembly.

      A011RZD

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

      A011RK6E01
      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. Install the parking lock pawl to the transaxle case sub-assembly with the parking lock pawl shaft.

      A011UKSE02
      Text in Illustration
      *1 Parking Lock Pawl Pin
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 Parking Lock Pawl

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

    3. Install the torsion spring to the parking lock pawl.

      A011R9C

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

      A011UJY

  18. INSTALL PAWL STOPPER PLATE

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

      A011S9V
      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

  19. INSTALL NO. 1 TRANSMISSION CASE PLATE

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

      A011TAKE01

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

      A011UBH
      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

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

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

      A011TYHE01
      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. Using SST and a press, install a new differential drive pinion tapered roller bearing LH (inner race) to the counter driven gear sub-assembly.

      A011UHWE01
      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. Install the counter driven gear to the transaxle case sub-assembly.

      A011SMZ

  24. INSTALL COUNTER DRIVE GEAR NUT

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

      A011R93E01

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

      A011R4EE01
      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 88 ft.*lbf }

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

      A011U7ME01

    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 0.8 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, 132 ft.*lbf)

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

      A011QYPE01
      SST
      09930-00010

  25. INSTALL FRONT DIFFERENTIAL CASE

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

      A011U8J

  26. INSTALL NO. 1 BRAKE PISTON

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

      A011QSAE04

      Note

      Ensure that the 2 O-rings are not twisted.

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

      A011TDF

      Note

      Be careful not to damage the O-rings.

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

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

      A011TJC

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

      A011UR2E03
      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 with a press.

      A011UU1E01
      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 front oil pump assembly as shown in the illustration.

      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 and gear body assembly shown in the illustration to install the snap ring.

    4. Install the brake snap ring stopper to the front 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 front oil pump assembly as shown in the illustration.

      A011S61E01

      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.

      A011U6YE03
      Text in Illustration
      *1 Brake Snap Ring Stopper
      *2 Snap Ring
      *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.

  29. 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
      0.601 to 0.819 mm (0.0237 to 0.0322 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.

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

      A011UTNE02
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing
      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. Coat 3 new oil seal rings with ATF and install them to the input shaft sub-assembly.

      A011SV1E02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft
      *4 Oil Seal Ring

      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 on 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. Install the input shaft to the front oil pump assembly.

      A011T4L

  32. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY

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

      A011USHE02
      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.

  33. INSTALL NO. 3 BRAKE HUB

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

      A011RH4E02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      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. Install the No. 3 brake hub to the underdrive planetary gear assembly.

      A011UQC

  34. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

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

      A011QQC

  35. 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 front 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 front 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).

  36. 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.

      A011SWWE01
      Text in Illustration
      *1 Front Oil Pump Assembly
      *2 No. 3 Brake
      *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 - 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 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. Coat a new O-ring with ATF and install it to the transaxle case sub-assembly.

      A011U5AE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 O-ring

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

      A011QWX

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

      A011UZFE02
      Text in Illustration
      *1 O-ring
      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. Clean and degrease the 3 bolts and the installation holes in the transaxle housing.

      A011SCZ

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

      A011QU4

      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 apply tube 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 lube apply tube and apply tube clamp.

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

    1. Install the shim to the transaxle housing.

      A011T96E01

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

      A011T8ME01

    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. 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 + 2.68 to 5.85 N*m (27.33 to 59.65 kgf*cm, 23.73 to 51.77 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. Remove the 20 bolts and the transaxle housing.

      A011T8M

  42. INSTALL TRANSAXLE HOUSING

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

      A011SP9

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

      A011R20
      Torque:
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }

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

      A011T5E

    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.

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

  43. INSPECT CLEARANCE OF NO. 1 CLUTCH

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

      A011SHQ

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

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

      A011TLPE02
      Text in Illustration
      *1 Feeler Gauge

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

      A011RI7E02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race
      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 rear planetary sun gear 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.

      A011UHBE02
      Text in Illustration
      *1 Rear Planetary Sun Gear

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

      A011UD7

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

      A011URLE01
      Text in Illustration
      *1 O-ring
      *2 Oil Seal Ring

      Note

      Ensure that the O-ring is not twisted.

    5. Coat a new oil seal ring with ATF and install it to the intermediate shaft.

  45. INSPECT CLEARANCE OF NO. 2 CLUTCH

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

      A011S2X

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

      A011UAUE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Multiple Disc Clutch Assembly
      Bearing Diameter
      - Inside [mm (in.)] Outside [mm (in.)]
      Bearing 61.2 (2.41) 79 (3.11)

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

  47. INSPECT INTERMEDIATE SHAFT END PLAY

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

      A011RYCE02

    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).

      Text in Illustration
      *a Dimension A

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

      A011R49E03
      Text in Illustration
      *a 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. Using SST and a hammer, install a new needle roller bearing into the rear transaxle cover sub-assembly.

      A011SBTE01
      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Installation depth
      21.5 to 21.9 mm (0.846 to 0.862 in.)

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

      A011TWB

    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. Coat the thrust needle roller bearing and thrust bearing race with ATF and install them on the rear transaxle cover sub-assembly.

      A011RYHE02
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race
      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. Coat 3 new O-rings with ATF and install them to the transaxle case sub-assembly.

      A011V4SE01

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

      A011SKN

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

      A011RUYE03
      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

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

      A011RUYE04

    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.

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

  49. INSTALL REAR TRANSAXLE COVER PLUG

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

      A011TT2

      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. Install a new gasket to the refill plug.

      A011R9J

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

      A011QZS
      Standard end play
      0.020 to 1.242 mm (0.000788 to 0.0488 in.)

  52. INSTALL NO. 1 GOVERNOR APPLY GASKET

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

      A011V2H

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

  53. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

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

      A011T7EE03

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

      Text in Illustration
      *a Positioning Bolt
      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. Coat a new O-ring with ATF.

      A011UD0

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

      Note

      Ensure that the O-ring is not twisted.

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

      A011QMB
      Torque:
      9.6 N*m  { 98 kgf*cm, 85 in.*lbf }

  55. INSTALL TRANSMISSION OIL CLEANER MAGNET

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

      A011TKLE04
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

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

      A011SGZ
      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 oil pan sub-assembly with the gasket before installation.

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

      A011U0W

    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 2 bolts.

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

  58. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE

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

      A011TGU
      Torque:
      0.8 N*m  { 8 kgf*cm, 7 in.*lbf }

  59. INSTALL OVERFLOW PLUG

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

      A011U4C
      Torque:
      40 N*m  { 408 kgf*cm, 29 ft.*lbf }

  60. INSTALL NO. 2 TRANSAXLE CASE PLUG

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

      A011S8L

    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, 12 ft.*lbf }

  61. INSTALL NO. 1 TRANSAXLE CASE PLUG

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

      A011UV3

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

      A011VAB

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

      A011TVQ

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

      A011TTN

      Note

      Before installing the park/neutral position switch assembly, remove any dirt or rust on the manual valve lever shaft sub-assembly. Be sure to install the 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. Align the protrusions of the park/neutral position switch assembly as shown in the illustration.

      A011V9DE06
      Text in Illustration
      *1 Protrusion

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

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

  66. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

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

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

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

      A011U0IE01
      Text in Illustration
      *1 No. 2 Breather Plug
      *a Boss

      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.