AUTOMATIC TRANSAXLE UNIT REASSEMBLY


  1. BEARING POSITION


    1. Check each bearing position and installation direction.

      A01CDB2E01
      A01CBQDE01
      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) / 80.3 (3.16)
      D 59.4 (2.34) / 77 (3.03) 53.1 (2.09) / 79 (3.11) -
      E - 56.1 (2.21) / 80.9 (3.19) -
      F - 61.2 (2.41) / 79 (3.11) -
      G - 28 (1.10) / 47.1 (1.85) 26.1 (1.03) / 44 (1.73)
      H 52.2 (2.06) / 70.4 (2.77) 48.9 (1.93) / 72.0 (2.83) -

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01CAXLE01

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

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

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

  3. INSTALL MANUAL VALVE LEVER SHAFT


    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. A01CB24

      Install the manual valve lever shaft to the transaxle case.

      Note

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

    6. A01CBAJ

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

    7. A01CFEF

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

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

    9. Check that the spacer does not turn.

    10. A01CBYH

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

    11. A01CB74

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

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

    13. Check that the spacer does not turn.

    14. A01CCUS

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

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01CFSA

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

  5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01CCA4

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

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

      Note

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

  6. INSTALL NO. 3 BRAKE PISTON


    1. A01CCPI

      Coat the contact surface of the transaxle case with ATF.

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

    3. A01CFEJ

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

    4. A01CFFXE02
      Text in Illustration
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

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

      Note


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

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

      Tech Tips

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

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

    6. A01CBA5E01

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

    7. A01CGB8E01

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

      SST
      09387-00070

      Note

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

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

      Note


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

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

  7. INSTALL COUNTER DRIVE GEAR

    Note

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


    1. A01CGH7E01

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

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

    2. Install 2 new balls of the counter drive gear bearing to the counter drive gear bearing.

    3. A01CB37E01

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

      SST
      09223-15030
      09527-17011
      09950-60020   ( 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. A01CAUJE01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  9. INSTALL NO. 2 BRAKE PISTON


    1. A01CFUUE02

      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. A01CBG8

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

      Note

      Be careful not to damage the O-rings.

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


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

    2. A01CFY7E01

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

      SST
      09387-00060

      Note

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

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

      Note


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

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

  11. INSTALL NO. 2 BRAKE DISC


    1. A01CAM7E02
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

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

      Note

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

    2. A01CFUS

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

      Note


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

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

  12. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01CEBS

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

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

      Tech Tips

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

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

      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. A01CDRIE01

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

    2. Using a screwdriver, install the snap ring to the planetary ring gear.

      Note

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

  14. INSTALL PLANETARY RING GEAR


    1. A01CCP1E02
      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 planetary ring gear to the one-way clutch assembly.

      Note

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

  15. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A01CGC9E01
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Transaxle Case

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller 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 with the planetary ring gear to the transaxle case.

      Note


      • Make sure that there is no clearance between the outer race retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the outer race retainer should be deformed and replace it with a new one.

      • Ensure that there is no clearance between the one-way clutch assembly and transaxle case.

    3. A01CEUP

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

      Note


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

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

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


    1. A01CB2AE01

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

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

      Note

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

  17. INSTALL PARKING LOCK PAWL


    1. A01CF7GE01

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

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

    3. A01CF8M

      Install the spring to the parking lock pawl.

      Note

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

  18. INSTALL PARKING LOCK SLEEVE


    1. A01CGJ3

      Install the parking lock sleeve to the transaxle case.

  19. INSTALL PAWL STOPPER PLATE


    1. A01CGCM

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

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

  20. INSTALL PAWL SHAFT CLAMP


    1. A01CCGP

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

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

  21. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. A01CG7IE01

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

      SST
      09950-60010   ( 09951-00530 )

      Note

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

  22. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. A01CE3FE01

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

      SST
      09950-60010   ( 09951-00420 )

      Note

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

  23. INSTALL COUNTER DRIVEN GEAR


    1. A01CF2S

      Install the counter driven gear to the transaxle case.

  24. INSTALL COUNTER DRIVE GEAR NUT


    1. A01CE5DE01

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

    2. A01CAOFE01

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    3. A01CCJIE01

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

    4. A01CAJUE01

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

      SST
      09387-00130
      Turning Torque
      0.1 to 0.2 N*m (1 to 2 kgf*cm, 0.9 to 1.7 in.*lbf)

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

      Maximum Torque
      180 N*m (1835 kgf*cm, 133 ft.*lbf)
    5. A01CFGSE01

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

      SST
      09930-00010

  25. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH


    1. A01CF0G

      Hold the differential case in a vise between aluminum plates.

      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 to 0.15 mm (0 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. A01CGEG

      Install the front differential case to the transaxle case.

  27. INSTALL NO. 1 BRAKE PISTON


    1. A01CFFSE02

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

      Note

      Ensure that the O-rings are not twisted.

    2. A01CELW

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01CFGP

      Install the 3 2nd brake piston return spring sub-assemblies to the front oil pump assembly.

      Note

      Make sure that the 3 2nd brake piston return spring sub-assemblies are installed to the protrusions on the front oil pump assembly.

  29. INSTALL NO. 1 BRAKE DISC


    1. A01CARME01
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

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

      Note


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

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

    2. A01CB3XE01

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

      SST
      09387-00070
      09495-65040

      Note

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

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

      Note


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

      • Make sure to align the protruding part of the snap ring with the cutout (#1) of the front oil pump assembly shown in the illustration to install the snap ring.

    4. A01CE3E

      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. A01CBRME01

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

      Note


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

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

    6. A01CC03E04
      Text in Illustration
      *1 Snap Ring
      *2 Brake Snap Ring Stopper
      *a Correctly Installed

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

      Note

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

  30. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A01CFVD

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

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

      Tech Tips

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

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

      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. A01CBP3E01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Underdrive Planetary Sun Gear

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller 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.

  32. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01CAK9E02
      Text in Illustration
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring
      *4 Input Shaft Sub-assembly

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

      Note

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

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

      Thrust Needle Roller Bearing and Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 29.1 (1.15) 48.6 (1.91)
      Thrust needle roller race 30.7 (1.21) 48.3 (1.90)

      Note

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

    3. A01CER0

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

  33. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01CGEWE03

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

    2. Using a snap ring expander, install the planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded.

  34. INSTALL UNDERDRIVE PLANETARY RING GEAR

    Tech Tips

    Perform this procedure only when replacement of the underdrive planetary ring gear or No. 3 brake hub is necessary.


    1. A01CC6Z

      Install the snap ring to the underdrive planetary ring gear.

    2. A01CDUG

      While compressing the snap ring with a screwdriver, install the underdrive planetary ring gear to the No. 3 brake hub.

      Note

      Confirm that the snap ring is correctly located in the groove of the No. 3 brake hub.

  35. INSTALL NO. 3 BRAKE HUB


    1. A01CFQ3E02
      Text in Illustration
      *1 Thrust Needle Roller Bearing

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 62.6 (2.46) 82.9 (3.26)

      Note

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

    2. A01CBTXE02
      Text in Illustration
      *1 Thrust Needle Roller Race

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

      Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller race 65.9 (2.59) 80.3 (3.16)
    3. A01CESZ

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

  36. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01CG3H

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

  37. INSTALL NO. 3 BRAKE DISC


    1. A01CDUUE02
      Text in Illustration
      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc

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

      Note

      Make sure that the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are installed in the correct order.

    2. A01CFIHE02

      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).

  38. INSPECT CLEARANCE OF NO. 3 BRAKE


    1. A01CDO2E01

      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 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 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 BODY O-RING


    1. A01CDV0

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

  40. INSTALL FRONT OIL PUMP ASSEMBLY


    1. A01CD2JE05
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 O-ring

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

    2. Coat the thrust needle roller bearing with ATF.

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 53.1 (2.09) 79 (3.11)

      Note

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

    4. Coat the thrust needle roller race with MP grease.

    5. A01CC53E01
      Text in Illustration
      *1 Thrust Needle Roller Race

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

      Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller race 59.4 (2.34) 77 (3.03)
    6. A01CEKXE02
      Text in Illustration
      *1 Gasket

      Coat a new gasket with ATF and install it to the front oil pump assembly.

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

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

  41. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01CDITE01

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

      Note

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

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

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

      Note

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

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


    1. A01CENVE01

      Install the shim to the transaxle housing.

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

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

      Note

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

  43. ADJUST COUNTER DRIVEN GEAR PRELOAD


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

    2. A01CBCUE02

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

      Torque:
      Bolt (A)
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
      Bolt (B)
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    3. A01CE3BE01

      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 + 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 for the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range.

      Shim Thickness: mm (in.)
      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.275 (0.0896) 2.525 (0.0994) 2.775 (0.109)
      2.025 (0.0797) 2.300 (0.0906) 2.550 (0.100) 2.800 (0.110)
      2.050 (0.0807) 2.325 (0.0915) 2.575 (0.101) 2.825 (0.111)
      2.075 (0.0817) 2.350 (0.0925) 2.600 (0.102) 2.850 (0.112)
      2.100 (0.0827) 2.375 (0.0935) 2.625 (0.103) 2.875 (0.113)
      2.125 (0.0837) 2.400 (0.0945) 2.650 (0.104) 2.900 (0.114)
      2.150 (0.0846) 2.425 (0.0955) 2.675 (0.105) 2.925 (0.115)
      2.175 (0.0856) 2.450 (0.0965) 2.700 (0.106) 2.950 (0.116)
      2.200 (0.0866) 2.475 (0.0974) 2.725 (0.107) 2.975 (0.117)
      2.225 (0.0876) 2.500 (0.0984) 2.750 (0.108) 3.000 (0.118)
      2.250 (0.0886) - - -
    4. A01CC58E01

      Remove the 20 bolts and transaxle housing.

  44. INSTALL TRANSAXLE HOUSING


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

      Note

      Make sure that there is no ATF on the contact surfaces of the transaxle housing and transaxle case.

    2. A01CC7ZE04
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case.

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

      Note

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

    3. A01CC58E05

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

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    4. A01CC58E06

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    6. Install the 3 bolts.

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

  45. INSTALL NO. 1 CLUTCH DISC


    1. A01CBUDE03
      Text in Illustration
      *1 No. 1 Clutch Flange
      *2 No. 1 Clutch Plate
      *3 No. 1 Clutch Disc

      Install the No. 1 clutch flange, 4 No. 1 clutch discs and 4 No. 1 clutch plates to the direct multiple disc clutch assembly.

      Note

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

    2. A01CEA6

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

      Note

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

  46. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC


    1. A01CEF0

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

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

      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
      0.806 to 0.974 mm (0.0317 to 0.0383 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 6 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)

  47. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01CG9OE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

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

      Thrust Needle Roller Bearing and Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 28 (1.10) 47.1 (1.85)
      Thrust needle roller 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. A01CFNW

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

    3. A01CEVV

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

  48. INSTALL NO. 2 CLUTCH DISC


    1. A01CAQ5E03
      Text in Illustration
      *1 No. 2 Clutch Plate
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Flange

      Install the No. 2 clutch flange, 3 No. 2 clutch discs and 3 No. 2 clutch plates to the direct multiple disc clutch assembly.

      Note

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

  49. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING


    1. A01CGGP

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

      Note

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

    2. A01CCC8E01

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

      Note


      • Position the opening of the direct multiple disc clutch snap ring as shown in the illustration.

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

  50. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC


    1. A01CFPE

      Install the direct 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.

      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 6 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)

  51. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01CDIYE01
      Text in Illustration
      *1 Intermediate Shaft Oil Seal
      *2 O-ring

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

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

    3. A01CF1KE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Direct Multiple Disc Clutch Assembly

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

      Thrust Needle Roller Bearing Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 61.2 (2.41) 79 (3.11)

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

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

    6. A01CDE1E01

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

    7. A01CFMNE01

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

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

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

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

  52. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01CG92E01

      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 )
      Standard Depth
      21.5 to 21.9 mm (0.846 to 0.862 in.)

    2. Apply adhesive to the 2 "TORX" screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the 2 "TORX" screws, apply adhesive to the 2 "TORX" screws and install them within 10 minutes of adhesive application.

    3. A01CG12E01

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A01CFAR

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

      Note

      Confirm that the 2 oil seal rings are correctly located in the groove of the rear transaxle cover sub-assembly.

    5. A01CCM3E01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

      Coat the thrust needle roller bearing and thrust needle roller race with MP grease and install them to the rear transaxle cover sub-assembly.

      Thrust Needle Roller Bearing and Thrust Needle Roller Race Diameter: mm (in.)
      - Inside Outside
      Thrust needle roller bearing 48.9 (1.93) 72.0 (2.83)
      Thrust needle roller race 52.2 (2.06) 70.4 (2.77)
    6. A01CFPRE01

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

      Note

      Ensure that the O-rings are not twisted.

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

      Note

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

    8. A01CDT4E05
      Text in Illustration
      *a FIPG

      Apply FIPG to the transaxle case.

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

      Note

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

    9. A01CF50E06

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

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    10. A01CF50E07

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    12. Install the 2 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    13. A01CF5C

      Install a new gasket to the refill plug.

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

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    15. A01CEKA

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

    16. Install the 3 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.

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

  53. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A01CF81

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

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

  54. INSTALL TRANSAXLE CASE GASKET


    1. A01CFOGE01

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

  55. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


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

    2. A01CD1TE01

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

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

      -

      Bolt Length
      Bolt (A) 25 mm (0.984 in.)
      Bolt (B) 30 mm (1.18 in.)
      Bolt (C) 35 mm (1.38 in.)
      Bolt (D) 45 mm (1.77 in.)
      Bolt (E) 55 mm (2.17 in.)

      Note


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

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

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

  56. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01CEF6E02

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

      Note

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

    2. A01CFOD

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

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

  57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01CFCEE03
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

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

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

    3. A01CC6X

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

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

      Note

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

    4. A01CCNN

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

    5. Apply adhesive to the bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    6. Install the bolt.

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

      Note

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

    7. A01CDX8

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

      Torque:
      1.7 N*m  { 17 kgf*cm, 15 in.*lbf }
    8. A01CG9X

      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 }

  58. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. Install 3 new gaskets to the 3 No. 1 transaxle case plugs.

    2. Apply adhesive to the 3 No. 1 transaxle case plugs.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      In order to ensure proper sealing of the 3 No. 1 transaxle case plugs, apply adhesive to the 3 No. 1 transaxle case plugs and install them within 10 minutes of adhesive application.

    3. A01CCQL

      Using a 6 mm hexagon socket wrench, install the 3 No. 1 transaxle case plugs to the transaxle housing.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    4. A01CAWI

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

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

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

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


    1. A01CBPIE01

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

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

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

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


    1. A01CCB7E02

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

    2. Install the oil cooler tube union (inlet oil cooler union) to the transaxle case.

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

  61. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01CD1PE05

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

    2. A01CDLS

      Install the park/neutral position switch assembly to the transaxle case with the 2 bolts.

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

      Note


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

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

    3. A01CBOD

      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 }

  62. INSTALL BREATHER PLUG HOSE


    1. A01CDGUE02

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

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

    3. A01CG82

      Install the breather plug hose to the transaxle case.