AUTOMATIC TRANSAXLE UNIT REASSEMBLY


  1. BEARING POSITION


    1. Check the position and installation direction of the bearing.

      A01IS99E01
      A01IUJUE01
      Bearing Position
      Mark

      Front Race Diameter

      Inside/Outside

      Thrust Bearing Diameter

      Inside/Outside

      Rear Race Diameter

      Inside/Outside
      A - 57.7 mm (2.27 in.)/75.2 mm (2.96 in.) -
      B - 29.1 mm (1.15 in.)/48.6 mm (1.91 in.) 30.7 mm (1.21 in.)/48.3 mm (1.90 in.)
      C 65.9 mm (2.59 in.)/80.3 mm (3.16 in.) 62.6 mm (2.47 in.)/82.4 mm (3.24 in.) -
      D 59.4 mm (2.34 in.)/77 mm (3.03 in.) 53.1 mm (2.09 in.)/79 mm (3.11 in.) -
      E - 56.1 mm (2.21 in.)/80.9 mm (3.19 in.) -
      F - 61.2 mm (2.41 in.)/79 mm (3.11 in.) -
      G - 28 mm (1.10 in.)/47.1 mm (1.85 in.) 26.1 mm (1.03 in.)/44 mm (1.73 in.)
      H 52.2 mm (2.06 in.)/70.4 mm (2.77 in.) 48.9 mm (1.93 in.)/72.0 mm (2.84 in.) -

  2. INSTALL COUNTER DRIVEN GEAR BEARING OUTER RACE (REAR)

    A01IU8NE02

    1. Using SST and a hammer, tap in a new counter driven gear 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 bearing outer race so that there is no clearance between the bearing outer race and the transaxle case. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  3. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE

    A01IR5OE02

    1. Using SST and a hammer, tap in a new front differential case rear tapered roller bearing outer race to the transaxle case.

      SST
      09950-60020   ( 09951-00790 )
      09950-70010   ( 09951-07150 )

      Note

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

  4. INSTALL COUNTER DRIVEN GEAR BEARING OUTER RACE (FRONT)

    A01INTSE02

    1. Install the shim to the transaxle housing.

    2. Using SST, install a new counter driven gear 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 bearing outer race so that there is no clearance between the bearing outer race and the transaxle housing. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

  5. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE

    A01IS9WE02

    1. Install the shim to the transaxle housing.

    2. Using SST and a hammer, tap in a new differential case bearing outer race to the transaxle housing.

      SST
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07150 )

      Note

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

  6. ADJUST FRONT DIFFERENTIAL CASE BEARING PRELOAD

    A01IUFV

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

    2. Clean the contact surfaces of the transaxle case and transaxle housing.

    3. A01IT77E01

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

      Torque:
      for bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      for bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

    4. Using SST, turn the front differential case right and left 2 or 3 times to settle the bearing.

      SST
      09564-33010
    5. A01IUKAE02

      Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm.

      SST
      09564-33010
      Standard turning torque
      1.05 to 1.93 N*m (10.7 to 19.7 kgf*cm, 9.29 to 17.1 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim of a different thickness so that the turning torque is within the specified range, and replace the installed shim with the selected shim.

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

    6. Remove the 20 bolts and transaxle housing from the transaxle case.

    7. Remove the front differential case from the transaxle case.

  7. INSTALL COUNTER DRIVEN GEAR BEARING (FRONT)

    A01IOQWE02

    1. Using SST and a press, install a new counter driven gear bearing to the counter driven gear.

      SST
      09950-60010   ( 09951-00530 )

      Note

      Be sure to install the counter driven gear 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.

  8. INSTALL COUNTER DRIVEN GEAR BEARING (REAR)

    A01IPQJE02

    1. Using SST and a press, install a new counter driven gear bearing to the counter driven gear.

      SST
      09950-60010   ( 09951-00420 )

      Note

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

  9. ADJUST COUNTER DRIVEN GEAR BEARING PRELOAD

    A01IO8K

    1. Install the counter driven gear and front differential case to the transaxle case.

    2. A01IT77E01

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

      Torque:
      for bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      for bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
    3. A01IUKAE02

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

      SST
      09564-33010
      Standard turning torque
      Front differential case bearing preload + 3.29 to 6.07 N*m (33.5 to 61.9 kgf*cm, 29.1 to 53.7 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim of a different thickness so that the turning torque is within the specified range, and replace the installed shim with the selected shim.

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

    4. Remove the 20 bolts and transaxle housing from the transaxle case.

    5. Remove the front differential case and counter driven gear from the transaxle case.

  10. INSTALL TRANSAXLE CASE OIL SEAL LH

    A01IR17E02

    1. Using SST and a hammer, tap in a new transaxle case oil seal.

      SST
      09316-10010
      09950-70010   ( 09951-07100 )
      Standard 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.

    2. Coat the lip of the transaxle case oil seal with MP grease.

  11. INSTALL TRANSAXLE CASE OIL SEAL RH

    A01IO5OE02

    1. Using SST and a hammer, tap in a new front transaxle case oil seal.

      SST
      09316-60011   ( 09316-00011 )
      Standard 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.

    2. Coat the lip of the front transaxle case oil seal with MP grease.

  12. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    A01IROCE02

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

    2. Using SST and a hammer, tap in 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.)

  13. INSTALL MANUAL VALVE LEVER SHAFT


    1. Install a new spacer to the parking lock lever.

    2. Install the parking lock lever to the manual valve lever shaft.

    3. Install a new spacer to the manual valve lever.

    4. Install the manual valve lever to the manual valve lever shaft.

    5. A01IS3G

      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. A01ITOG

      Using a 3 mm pin punch and hammer, install a new slotted spring pin to the parking lock lever.

    7. A01ISZ0

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

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

    9. Check that the spacer does not turn.

    10. A01IQST

      Using a 3 mm pin punch and hammer, install a new slotted spring pin to the manual valve lever.

    11. A01IRL8

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

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

    13. Check that the spacer does not turn.

    14. A01IS8CE01

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

  14. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A01IOTH

    1. Align the protrusions on the parking lock rod with the notches in the parking lock lever and install the parking lock rod.

  15. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

    A01IPDWE01

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

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

      Note

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

  16. INSTALL COUNTER DRIVE GEAR BEARING

    Note

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


    1. A01IR1RE02

      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 )

  17. INSTALL NO. 3 BRAKE PISTON


    1. A01IPGA

      Coat the contact surface of the transaxle case with ATF.

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

    3. A01IMXS

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

    4. A01IRZJ

      Press the No. 3 brake piston into the transaxle case to install it.

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

      Tech Tips

      Use the installation surface of the return spring to press the piston into the transaxle case.

    5. Install the return spring to the transaxle case.

    6. A01IN4NE01

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

    7. A01ISB8E02

      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 as shown in the illustration.

      Note


      • Make sure that the snap ring is seated properly in the groove of the transaxle case.

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

  18. INSTALL COUNTER DRIVE GEAR

    A01IRY4E02

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

      SST
      09387-00020
    2. A01ISL4E02

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

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

      Note

      Make sure that there is no clearance between the bearing inner race (front side) and counter drive gear.

  19. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01IS80E03

      Using SST and a press, press in the planetary gear to the transaxle case.

      SST
      09223-15030
      09527-17011
      09951-01100

  20. INSTALL NO. 2 BRAKE PISTON

    A01IQ42E04

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

      Text in Illustration
      *1 O-Ring

      Note

      Ensure that the 2 O-rings are not twisted.

    2. A01IT35

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

      Note

      Be careful not to damage the O-rings.

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


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

    2. A01IS3EE02

      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 as shown in the illustration.

      Note


      • Make sure that the snap ring is seated properly in the groove of the transaxle case.

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

  22. INSTALL NO. 2 BRAKE DISC

    A01ISP0E03

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

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

      Note


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

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. A01INYN

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

      Note


      • Make sure that the snap ring is seated properly in the groove of the transaxle case.

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

  23. INSPECT PISTON STROKE OF NO. 2 BRAKE

    A01ITM7

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

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

      Tech Tips

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

      If the stroke is not as specified, replace the No. 2 brake flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 5 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      40 4.0 mm (0.157 in.)
      41 4.1 mm (0.161 in.)
      42 4.2 mm (0.165 in.)
      43 4.3 mm (0.169 in.)
      44 4.4 mm (0.173 in.)

  24. INSTALL PLANETARY RING GEAR FLANGE

    A01IQK1

    1. 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

      Make sure that the snap ring is seated properly in the groove of the planetary ring gear.

  25. INSTALL PLANETARY RING GEAR

    A01ISDK

    1. Install the planetary ring gear to the one-way clutch.

      Note

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

  26. INSTALL ONE-WAY CLUTCH ASSEMBLY

    A01ITRS

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

      Bearing Diameter
      Item Inside Outside
      Bearing 56.1 mm (2.21 in.) 80.9 mm (3.19 in.)

      Note

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

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

      Note

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

    3. A01IOHM

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

      Note


      • Make sure that the snap ring is seated properly in the groove of the transaxle case.

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

  27. INSTALL PARKING LOCK PAWL

    A01INZJE04

    1. 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. A01IMY0

      Install the spring to the parking lock pawl.

      Note

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

  28. INSTALL PARKING LOCK SLEEVE

    A01IUJS

    1. Install the parking lock sleeve to the transaxle case.

  29. INSTALL PAWL STOPPER PLATE

    A01ITVQ

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

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

  30. INSTALL PAWL SHAFT CLAMP

    A01IPJC

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

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

  31. INSTALL COUNTER DRIVEN GEAR

    A01IMYA

    1. Install the counter driven gear to the transaxle case.

  32. INSTALL COUNTER DRIVE GEAR NUT

    A01ISP9E01

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

    2. A01IOQYE02

      Using SST, install a new counter drive gear nut.

      SST
      09387-00130
      Torque:
      120 N*m  { 1223 kgf*cm, 88 ft.*lbf }
    3. A01IU8RE01

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

    4. A01IMZNE02

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

      SST
      09387-00130
      Standard turning torque
      0.1 to 0.22 N*m (1.02 to 2.24 kgf*cm, 0.885 to 1.95 in.*lbf)

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

      Maximum torque
      180 N*m (1835 kgf*cm, 132 ft.*lbf)
    5. A01ISRIE03

      Using SST and a hammer, stake the planetary gear.

      SST
      09930-00010

  33. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH

    A01IU5FE01

    1. 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.)

      If the backlash is not within the specified range, replace both side gear thrust washers with side gear thrust washers of a different thickness.

      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.) -

  34. INSTALL FRONT DIFFERENTIAL CASE

    A01IO6F

    1. Install the differential case to the transaxle case.

  35. INSTALL NO. 1 BRAKE PISTON


    1. A01IU5OE06
      Text in Illustration
      *1 O-Ring

      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. A01IPE3

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

      Note

      Be careful not to damage the O-rings.

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

    A01IRNQ

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

      Note

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

  37. INSTALL NO. 1 BRAKE DISC

    A01INYFE03

    1. Install the 4 brake plates, 4 brake discs and brake flange to the oil pump.

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

      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.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. 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. A01IOQ0E03

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

      Note


      • Make sure that the snap ring is seated properly 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 as shown in the illustration to install the snap ring.

    4. A01IRC0

      Install the brake snap ring stopper to the oil pump.

      Note

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

    5. A01IOBLE02

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

      Note


      • Make sure that the snap ring is seated properly 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 and gear body as shown in the illustration to install the snap ring.

    6. A01INQUE02
      Text in Illustration
      *1 Snap Ring
      *2 Brake Snap Ring Stopper

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

      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.

  38. INSPECT PISTON STROKE OF NO. 1 BRAKE


    1. A01ISWN

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

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

      Tech Tips

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

      If the stroke is not as specified, replace the No. 1 brake flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      30 3.0 mm (0.118 in.)
      31 3.1 mm (0.122 in.)
      32 3.2 mm (0.126 in.)
      33 3.3 mm (0.130 in.)
      34 3.4 mm (0.134 in.)
      35 3.5 mm (0.138 in.)

  39. INSTALL UNDERDRIVE PLANETARY SUN GEAR

    A01IQKW

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

      Bearing Diameter
      Item Inside Outside
      Bearing 57.7 mm (2.27 in.) 75.2 mm (2.96 in.)

      Note

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

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

  40. INSTALL INPUT SHAFT SUB-ASSEMBLY

    A01IRIYE03

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

      Note

      Do not expand the gaps of the oil seal rings too much.

    2. Coat the thrust needle roller bearing and thrust needle roller bearing race with ATF, and install them to the oil pump.

      Bearing Diameter
      Item Inside Outside
      Bearing 29.1 mm (1.15 in.) 48.6 mm (1.91 in.)
      Race 30.7 mm (1.21 in.) 48.3 mm (1.90 in.)
      Text in Illustration
      *1 Thrust Needle Roller Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring

      Note

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

    3. A01IN69

      Install the input shaft to the oil pump.

  41. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY

    A01INKA

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

  42. INSTALL UNDERDRIVE PLANETARY RING GEAR

    A01IUKS

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

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

      Note

      Make sure that the snap ring is seated properly in the groove of the underdrive planetary ring gear.

  43. INSTALL NO. 3 BRAKE HUB

    A01IR7M

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

      Bearing Diameter
      Item Inside Outside
      Bearing 62.6 mm (2.46 in.) 82.9 mm (3.26 in.)

      Note

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

    2. A01IS95

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

      Bearing Diameter
      Item Inside Outside
      Race 65.9 mm (2.59 in.) 80.3 mm (3.16 in.)
    3. A01IS1M

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

  44. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

    A01IPEB

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

  45. INSTALL NO. 3 BRAKE DISC

    A01INW0E03

    1. Install the 2 brake flanges, 3 brake discs and 2 brake plates to the oil pump.

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

      Note


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

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. A01IRPME02

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

      Note


      • Make sure the snap ring is seated properly in the groove of the oil pump.

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

  46. INSPECT CLEARANCE OF NO. 3 BRAKE

    A01ITP7E01
    Text in Illustration
    *1 Front Oil Pump Assembly
    *2 No. 3 Brake Piston

    1. Using a vernier caliper and 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 straightedge, measure the distance from the contact surface of the front oil pump to the end of the No. 3 brake piston 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, replace the No. 3 brake flange with one of a different thickness so that the clearance is within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      38 3.80 mm (0.150 in.)
      39 3.90 mm (0.154 in.)
      40 4.00 mm (0.157 in.)
      41 4.10 mm (0.161 in.)
      42 4.20 mm (0.165 in.)
      43 4.30 mm (0.169 in.)

  47. INSTALL FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY

    A01ITUBE04

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

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

      Bearing and Race Diameter
      Item Inside Outside
      Bearing 53.1 mm (2.09 in.) 79 mm (3.11 in.)
      Race 59.4 mm (2.34 in.) 77 mm (3.03 in.)
      Text in Illustration
      *1 Thrust Needle Roller Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 O-ring

      Note

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

    3. A01IRFJE03

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

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

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

  48. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

    A01IRBOE01

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

      Note

      Insert the differential gear lube apply tube into the transaxle case 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  { 231 kgf*cm, 17 ft.*lbf }

      Note

      Make sure there is clearance between the differential lube apply tube and clamp.

  49. INSTALL TRANSAXLE HOUSING


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

      Note

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

    2. A01INSAE03
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the transaxle case.

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

      Note

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

    3. A01IT77E01

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

      Torque:
      for bolt A
      31 N*m  { 312 kgf*cm, 23 ft.*lbf }
      for bolt B
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }

  50. INSTALL NO. 1 CLUTCH DISC

    A01IQ03E05

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

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

      Note


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

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

    2. A01IT3T

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

      Note

      Make sure that the snap rings are seated properly in the groove of the direct multiple disc clutch.

  51. INSPECT PISTON STROKE OF NO. 1 CLUTCH DISC

    A01IT7Y

    1. Install the direct multiple disc clutch to the rear transaxle cover.

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

      Tech Tips

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

      Standard stroke
      0.806 to 0.974 mm (0.0317 to 0.0383 in.)

      If the stroke is not as specified, replace the No. 1 clutch flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      30 3.0 mm (0.118 in.)
      31 3.1 mm (0.122 in.)
      32 3.2 mm (0.126 in.)
      33 3.3 mm (0.130 in.)
      34 3.4 mm (0.134 in.)
      35 3.5 mm (0.138 in.)

  52. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

    A01IT9JE03

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

      Bearing and Race Diameter
      Item Inside Outside
      Bearing 28 mm (1.10 in.) 47.1 mm (1.85 in.)
      Race 26.1 mm (1.03 in.) 44 mm (1.73 in.)
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Bearing Race

      Note

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

    2. A01IULX

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

    3. A01IN70

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

  53. INSTALL NO. 2 CLUTCH DISC

    A01IQ0GE04
    Text in Illustration
    *1 Clutch Flange
    *2 Clutch Disc
    *3 Clutch Plate

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

      Note


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

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  54. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING

    A01IPQBE04

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

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

      Text in Illustration
      *1 Intermediate Shaft Oil Seal
      *2 O-Ring
    3. A01IOM5

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

      Note

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

    4. A01IQDRE01

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

      Note


      • Position the opening of the snap ring as shown in the illustration.

      • Make sure the snap ring is seated properly in the groove of the direct multiple disc clutch.

  55. INSPECT PISTON STROKE OF NO. 2 CLUTCH

    A01IOLK

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

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

      Tech Tips

      Measure the stroke 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 stroke
      0.544 to 0.744 mm (0.0214 to 0.0293 in.)

      If the stroke is not as specified, replace the No. 2 clutch flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      30 3.0 mm (0.118 in.)
      31 3.1 mm (0.122 in.)
      32 3.2 mm (0.126 in.)
      33 3.3 mm (0.130 in.)
      34 3.4 mm (0.134 in.)
      35 3.5 mm (0.138 in.)

  56. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

    A01ISFSE02

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

      Bearing Diameter
      Item Inside Outside
      Bearing 61.2 mm (2.41 in.) 79 mm (3.11 in.)

    2. Install the direct multiple disc clutch to the transaxle case.

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

    3. Clean the contact surfaces of the transaxle case and rear transaxle cover.

    4. A01IQFSE01

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

    5. A01IRH5E01

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

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

      End play = Dimension B - Dimension A

      Standard end play
      0.007 to 1.113 mm (0.000275 to 0.0438 in.)

  57. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY

    A01IPYNE01

    1. Using SST and a hammer, install the needle roller bearing to the rear transaxle cover.

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )
      Installation depth
      21.5 to 21.9 mm (0.846 to 0862 in.)

    2. Apply adhesive to the 2 screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A01IQWEE01

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A01IT9WE03
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Needle Roller Bearing Race

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

      Bearing Diameter
      Item Inside Outside
      Bearing 48.9 mm (1.93 in.) 72.0 mm (2.84 in.)
      Race 52.2 mm (2.06 in.) 70.4 mm (2.77 in.)

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

    6. A01IQ4VE01

      Coat the 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 old seal packing material from the contact surfaces between the rear transaxle cover and transaxle case.

    8. A01IUO9E02

      Apply seal packing to the transaxle case.

      Note

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

      Seal packing
      Toyota Genuine Seal Packing 1281,
      Three Bond 1281 or equivalent
    9. A01IPWCE01

      Install the rear transaxle cover to the transaxle case with the 14 bolts.

      Torque:
      Bolt A
      23 N*m  { 231 kgf*cm, 17 ft.*lbf }
      Bolt B
      17 N*m  { 172 kgf*cm, 12 ft.*lbf }
    10. A01IPVI

      Install a new gasket to the refill plug.

    11. Install the refill plug to the rear transaxle cover.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    12. A01ISGR

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

    13. Install the 3 No. 1 automatic transaxle case plugs to the rear transaxle cover.

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

  58. INSPECT INPUT SHAFT END PLAY

    A01IQMZ

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

      Standard end play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  59. INSTALL TRANSAXLE CASE GASKET

    A01ISK2E01

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

  60. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    A01INQDE02

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

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

      Note


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

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

      • Temporarily install the bolts marked by *1 in the illustration first because they are positioning bolts.

      Tech Tips

      Each bolt length is indicated below.

      for bolt A: 25 mm (0.984 in.)

      for bolt B: 30 mm (1.18 in.)

      for bolt C: 35 mm (1.38 in.)

      for bolt D: 45 mm (1.77 in.)

      for bolt E: 55 mm (2.17 in.)

  61. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    A01IQS1

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

      Note

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

    2. A01IT74

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

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

  62. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

    A01IP69E05

    1. Install the 2 magnets in the automatic transaxle oil pan.

      Text in Illustration
      *1 Magnet

    2. Install a new gasket to the oil pan.

    3. A01IQ7UE01

      Apply seal packing to the bolt labeled A in the illustration.

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

    4. Install the oil pan to the automatic transaxle with the 18 bolts.

      Torque:
      for bolt labeled A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for other bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note


      • In order to ensure proper sealing of the transmission oil pan bolt, apply seal packing to the bolt and install it within 10 minutes of seal packing application.

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

    5. A01IT8S

      Using a 6 mm hexagon wrench, install the No. 1 transmission oil filler tube to the automatic transaxle.

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

    6. Using a 6 mm hexagon wrench, install the a new gasket and the overflow plug to the oil pan.

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

  63. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. Install 3 new gaskets to the 3 transaxle case plugs.

    2. Apply adhesive to the 3 transaxle case plugs.

      Adhesive
      Toyota Genuine Seal Packing 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper sealing of the transaxle case plugs, apply adhesive to the plugs and install them within 10 minutes of adhesive application.

    3. A01IPIQ

      Using a 6 mm hexagon wrench, install the 3 gaskets and 3 transaxle case plug to the transaxle housing.

      Torque:
      17 N*m  { 173 kgf*cm, 12 ft.*lbf }
    4. A01IMY2

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

    5. Install the 3 transaxle case plugs to the transaxle case.

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

  64. INSTALL OIL COOLER TUBE UNION (INLET)

    A01IQ6D

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

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

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

  65. INSTALL OIL COOLER TUBE UNION (OUTLET)

    A01IP92

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

    2. Install the oil cooler tube union (outlet) to the transaxle case as shown in the illustration.

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

  66. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01ISTF

    1. Install the park/neutral position switch to the control shaft.

    2. Temporarily install the 2 bolts.

    3. Temporarily install the control shaft lever.

    4. A01INUIE01

      Turn the lever clockwise until it stops, and then turn it counterclockwise 2 notches.

    5. Remove the control shaft lever.

    6. A01ISDHE08

      Align the protrusions of the park/neutral position switch.

    7. Hold the switch in that position and tighten the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Text in Illustration
      *1 Protrusion
    8. A01IN3E

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

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

  67. INSTALL BREATHER PLUG HOSE

    A01IP9V

    1. Coat a new O-ring with ATF and install it to the breather plug.

    2. Install the breather plug to the breather plug hose.

    3. A01INOY

      Install the breather plug hose to the transaxle case.