AUTOMATIC TRANSAXLE UNIT REASSEMBLY

Tech Tips

Check bearing position and installation direction.

A01EYNSE01
A01EYD2E01
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. A01EUXIE01

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

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

  2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01EYQXE01

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

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

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

      Note

      Check that the oil seal is installed in the correct direction.

  3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01EUC9

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

      Note

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

    2. A01EVB8

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

  4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01EU4N

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

  5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01EYK8

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

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

      Note

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

  6. INSTALL NO. 3 BRAKE PISTON


    1. A01EZ2E

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A01EZ2PE02
      Text in Illustration
      *1 No. 3 Brake Piston

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

    3. A01EV26E02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Pawl Stopper Plate

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

      Note

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

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

      Note

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

      Tech Tips

      Use the installation surface of the 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. A01EYQZE02
      Text in Illustration
      *1 No. 3 Brake Piston
      *2 Brake Piston Return Spring

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

      Note

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

    7. A01EVC1E02
      Text in Illustration
      *1 Snap Ring

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

      SST
      09387-00070

      Note

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

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

      Note


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

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

  7. INSTALL COUNTER DRIVE GEAR


    1. A01EUWQE02

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

      SST
      09387-00020
    2. A01ETY4E01

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

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

      Note

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

  8. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01EXCLE01

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

      SST
      09223-15030
      09527-17011
      09951-01100

  9. INSTALL NO. 2 BRAKE PISTON


    1. A01EYC3

      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. A01EYNT

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01EW88E01

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

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

      SST
      09387-00060

      Note

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

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

      Note


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

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

  11. INSTALL NO. 2 BRAKE DISC


    1. A01EYR3E01
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

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

      Note

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

    2. A01EWXR

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

      Note


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

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

  12. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01EYKL

      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
      0.707 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. A01EXKZE02
      Text in Illustration
      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 Planetary Ring Gear

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

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

      Note

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

  14. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A01EX7YE02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

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

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

      Note

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

    3. A01EURKE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing

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

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

      Note

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

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

      Note

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

    5. A01EWJC

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

      Note


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

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

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


    1. A01EWUIE01

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

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

      Note

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

  16. INSTALL PARKING LOCK PAWL


    1. A01EY81E02
      Text in Illustration
      *1 Parking Lock Pawl Pin
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 Parking Lock Pawl

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

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

    3. A01EVLZ

      Install the torsion spring to the parking lock pawl.

      Note

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

  17. INSTALL PARKING LOCK SLEEVE


    1. A01EVE7

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

  18. INSTALL PAWL STOPPER PLATE


    1. A01EV45

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

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

  19. INSTALL NO. 1 TRANSMISSION CASE PLATE


    1. A01EY5DE01

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

      Tech Tips

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

  20. INSTALL PAWL SHAFT CLAMP


    1. A01EWML

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

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

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


    1. A01ESZBE01

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

      SST
      09950-60010   ( 09951-00490 )

      Note

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

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


    1. A01ETMBE01

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

      SST
      09950-60010   ( 09951-00400 )

      Note

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

  23. INSTALL COUNTER DRIVEN GEAR


    1. A01EWVJ

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

  24. INSTALL COUNTER DRIVE GEAR NUT


    1. A01EULIE01

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

    2. A01EXAGE01

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1224 kgf*cm, 88 ft.*lbf }
    3. A01EWQGE01

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

    4. A01EXK9E01

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

      SST
      09387-00130
      Turning torque
      0.1 to 0.8 N*m (1 to 8 kgf*cm, 1 to 7 in.*lbf)

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

      Maximum torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)
    5. A01EXH5E01

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

      SST
      09930-00010

  25. INSTALL FRONT DIFFERENTIAL CASE


    1. A01EW6T

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

  26. INSTALL NO. 1 BRAKE PISTON


    1. A01EY29E04

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A01EYTP

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

      Note

      Be careful not to damage the O-rings.

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


    1. A01EYFJ

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

      Note

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

  28. INSTALL NO. 1 BRAKE DISC


    1. A01EUJDE03
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

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

      Note


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

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

    2. A01ETGME01

      Place SST on the flange and compress the flange with 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 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. A01EYLE

      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. A01ESYJE01

      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 (#2) of the front oil pump assembly shown in the illustration to install the snap ring.

    6. A01EVJBE03
      Text in Illustration
      *1 Brake Snap Ring Stopper
      *2 Snap Ring
      *a Correctly Installed

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

      Note

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

  29. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A01ESZI

      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
      0.601 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. A01EX57E02
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

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

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

      Note

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

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

  31. INSTALL INPUT SHAFT SUB-ASSEMBLY


    1. A01EWDME02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft
      *4 Oil Seal Ring

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

      Note

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

    2. Coat the thrust needle roller bearing and thrust bearing race with ATF, and install them 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. A01EW3Y

      Install the input shaft to the front oil pump assembly.

  32. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01EWYGE02
      Text in Illustration
      *1 Planetary Sun Gear Sub-assembly
      *2 Underdrive Planetary Gear Assembly
      *3 Snap Ring

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

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

  33. INSTALL NO. 3 BRAKE HUB


    1. A01EXRME02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

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

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

      Note

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

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

    3. A01EVF4

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

  34. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01ETFA

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

  35. INSTALL NO. 3 BRAKE DISC


    1. A01ETCYE02
      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 discs, plates, and flanges are installed in the correct order.

    2. A01ETM7E02

      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 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. A01EVKAE01
      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

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

      Tech Tips

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

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

      Tech Tips

      Measure dimension B at 3 points where the No. 3 brake 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. A01EWK8E02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 O-ring

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

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

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

      Note

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

    3. A01ESPJ

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

    4. A01EVEDE02
      Text in Illustration
      *1 O-ring

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

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

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

  38. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. A01EU7L

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

  39. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01EYGE

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

      Note

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

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the 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. A01EYJLE01

      Install the shim to the transaxle housing.

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

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

      Note

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

  41. ADJUST COUNTER DRIVEN GEAR PRELOAD


    1. A01EUM3E01

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

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

      Torque:
      Bolt A
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
      except Bolt A
      31 N*m  { 312 kgf*cm, 22 ft.*lbf }
    3. A01EY66E01

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

      SST
      09564-33010
      Turning torque
      Differential side bearing preload + 2.85 to 6.13 N*m (29.07 to 62.50 kgf*cm, 25.23 to 54.25 in.*lbf)

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

      Shim Thickness
      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.275 (0.0896) 2.550 (0.100) 2.825 (0.111)
      2.025 (0.0797) 2.300 (0.0906) 2.575 (0.101) 2.850 (0.112)
      2.050 (0.0807) 2.325 (0.0915) 2.600 (0.102) 2.875 (0.113)
      2.075 (0.0817) 2.350 (0.0925) 2.625 (0.103) 2.900 (0.114)
      2.100 (0.0827) 2.375 (0.0935) 2.650 (0.104) 2.925 (0.115)
      2.125 (0.0837) 2.400 (0.0945) 2.675 (0.105) 2.950 (0.116)
      2.150 (0.0846) 2.425 (0.0955) 2.700 (0.106) 2.975 (0.117)
      2.175 (0.0856) 2.450 (0.0965) 2.725 (0.107) 3.000 (0.118)
      2.200 (0.0866) 2.475 (0.0974) 2.750 (0.108) -
      2.225 (0.0876) 2.500 (0.0984) 2.775 (0.109) -
      2.250 (0.0886) 2.525 (0.0994) 2.800 (0.110) -
    4. A01EUM3

      Remove the 20 bolts and the transaxle housing.

  42. INSTALL TRANSAXLE HOUSING


    1. A01EX6T

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

      Note

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

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

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

      Note


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

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

    3. A01EYRC

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

      Torque:
      31 N*m  { 312 kgf*cm, 22 ft.*lbf }
    4. A01EX1C

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the 3 bolts.

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

  43. INSPECT CLEARANCE OF NO. 1 CLUTCH


    1. A01EV1Y

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

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

    3. A01EY33E02
      Text in Illustration
      *1 Feeler Gauge

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

      Tech Tips

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

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

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

  44. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01ET7HE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

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

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

      Note

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

    2. A01EYAUE02
      Text in Illustration
      *1 Rear Planetary Sun Gear

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

    3. A01EUBM

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

    4. A01ETZ3E01
      Text in Illustration
      *1 O-ring
      *2 Oil Seal Ring

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

      Note

      Ensure that the O-ring is not twisted.

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

  45. INSPECT CLEARANCE OF NO. 2 CLUTCH


    1. A01EU9L

      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.

      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. A01ETDYE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Multiple Disc Clutch Assembly

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

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

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

  47. INSPECT INTERMEDIATE SHAFT END PLAY


    1. A01EYWTE02
      Text in Illustration
      *a Dimension A

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

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

    3. A01ESY2E03
      Text in Illustration
      *a Dimension B

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

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

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

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

  48. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01EUIRE01

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

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Installation depth
      21.5 to 21.9 mm (0.846 to 0.862 in.)
    2. A01EZ2S

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A01EXBSE02
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race

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

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

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

    7. A01EWBCE01

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

    8. A01EXMG

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

      Note

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

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

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

      Note


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

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

    10. A01EXN6E03

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

      Torque:
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    11. A01EXN6E04

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    13. Install the 2 bolts.

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

  49. INSTALL REAR TRANSAXLE COVER PLUG


    1. A01EXEX

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

      Note

      Ensure that the 3 O-rings are not twisted.

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

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

  50. INSTALL REFILL PLUG


    1. A01EYCU

      Install a new gasket to the refill plug.

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

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

  51. INSPECT INPUT SHAFT END PLAY


    1. A01EVLW

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

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

  52. INSTALL NO. 1 GOVERNOR APPLY GASKET


    1. A01ESRH

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

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

  53. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A01EV2JE03
      Text in Illustration
      *a Positioning Bolt

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

    2. Insert the pin of the manual valve lever 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.

      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. A01ETGY

      Coat a new O-ring with ATF.

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

      Note

      Ensure that the O-ring is not twisted.

    3. A01EYCK

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

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

  55. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. A01EXD7E04
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

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

  56. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET


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

  57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01EWX4

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

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

      Note

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

    2. A01EUEB

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

    3. Apply adhesive to 2 or 3 threads on the ends of 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. A01EUVK

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

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

  59. INSTALL OVERFLOW PLUG


    1. A01EY4G

      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, 29 ft.*lbf }

  60. INSTALL NO. 2 TRANSAXLE CASE PLUG


    1. A01EYKC

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

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

  61. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. A01EV8P

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

      Note

      Ensure that the 2 O-rings are not twisted.

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

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

  62. INSTALL OIL COOLER TUBE UNION (INLET)


    1. A01EXZ5

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  63. INSTALL OIL COOLER TUBE UNION (OUTLET)


    1. A01ETSG

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

      Note

      Ensure that the O-ring is not twisted.

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

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

  64. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01ETUU

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

      Note

      Before installing the park/neutral position switch assembly, remove any 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. A01EWJGE06
      Text in Illustration
      *1 Protrusion

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

    3. Tighten the 2 bolts

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

      Note

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

  65. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. A01EVJ1

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

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

  66. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A01EXIGE04
      Text in Illustration
      *1 No. 1 Breather Plug
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug
      *4 O-ring

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

      Note

      Ensure that the O-ring is not twisted.

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

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

    4. A01EWZRE01
      Text in Illustration
      *1 No. 2 Breather Plug
      *a Boss

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

      Note

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