AUTOMATIC TRANSAXLE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Check each bearing position and installation direction.

B005N01N01
B005OZHN01
Mark Front Thrust Bearing Race Diameter Inside / Outside (mm (in.)) Thrust Bearing Diameter Inside / Outside (mm (in.)) Rear Thrust Bearing Race Diameter Inside / Outside (mm (in.))
A 31.1 (1.22) / 51 (2.01) 29.8 (1.17) / 48.8 (1.92) 29.8 (1.17) / 48.8 (1.92)
B 58.8 (2.31) / 72.7 (2.86) 57.3 (2.26) / 71.94 (2.83) -
C - 39.2 (1.54) / 52.6 (2.07) 38.1 (1.50) / 50.2 (1.98)
D - 33.2 (1.31) / 45.6 (1.80) 35.2 (1.39) / 47 (1.85)
E 33.2 (1.31) / 45.6 (1.80) - 25.6 (1.01) / 43.7 (1.72)
F - 24.25 (0.955) / 41.17 (1.62) 24.2 (0.953) / 41.7 (1.64)
G - 50.5 (1.99) / 71.1 (2.80) 52.8 (2.08) / 76.4 (3.01)

PROCEDURE


  1. INSTALL COUNTER DRIVEN GEAR TAPERED ROLLER BEARING (FRONT SIDE OUTER RACE)


    1. B005MDZN01

      Using SST and a hammer, install a new counter driven gear tapered roller bearing (front side outer race) to the transaxle housing.

      SST
      09950-60020   ( 09951-00910 )
      09950-70010   ( 09951-07150 )

      Note

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

  2. INSTALL DIFFERENTIAL CASE TAPERED ROLLER BEARING (FRONT SIDE OUTER RACE)


    1. B005LXNN01

      Using SST and a hammer, install a new differential case tapered roller bearing (front side outer race) to the transaxle housing.

      SST
      09950-60020   ( 09951-00890 )
      09950-70010   ( 09951-07200 )

      Note

      Be sure to install the differential case tapered roller bearing (front side outer race) so that there is no clearance between the differential case tapered roller bearing (front side outer race) and the transaxle housing. If there is any clearance, the turning torque of the differential case assembly cannot be measured correctly.

  3. INSTALL COUNTER DRIVEN GEAR TAPERED ROLLER BEARING (REAR SIDE OUTER RACE)


    1. B005OY0N01

      Using SST and a hammer, install a new counter driven gear tapered roller bearing (rear side outer race) and shim to the automatic transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00680 )
      09950-70010   ( 09951-07200 )

      Note

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

  4. INSTALL DIFFERENTIAL CASE TAPERED ROLLER BEARING (REAR SIDE OUTER RACE)


    1. B005MLFN01

      Using SST and a hammer, install a new differential case tapered roller bearing (rear side outer race) and new shim to the automatic transaxle case sub-assembly.

      SST
      09950-60020   ( 09951-00910 )
      09950-70010   ( 09951-07150 )

      Note

      Be sure to install the differential case tapered roller bearing (rear side outer race) so that there is no clearance between the differential case tapered roller bearing (rear side outer race) and shim, and the automatic transaxle case sub-assembly. If there is any clearance, the turning torque of the differential case assembly cannot be measured correctly.

  5. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

    Click here

  6. INSTALL TIGHT PLUG (COUNTER DRIVEN GEAR SIDE)


    1. B005N9EC01
      *a Depth

      Using SST and a hammer, install a new tight plug (counter driven gear side) to the pinion and counter driven gear sub-assembly.

      SST
      09201-41020
      Standard Depth
      12.8 to 13.65 mm (0.504 to 0.537 in.)

  7. INSTALL TIGHT PLUG (DIFFERENTIAL DRIVE PINION SIDE)


    1. B005P36C01
      *a Depth

      Using SST and a hammer, install a new tight plug (differential drive pinion side) to the pinion and counter driven gear sub-assembly.

      SST
      09950-60010   ( 09951-00260 )
      09950-70010   ( 09951-07150 )
      Standard Depth
      25.3 to 26.15 mm (0.996 to 1.03 in.)

  8. INSTALL COUNTER DRIVEN GEAR TAPERED ROLLER BEARING (REAR SIDE INNER RACE)


    1. B005PP9N01

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

      SST
      09316-60011   ( 09316-00071 )
      09950-60010   ( 09951-00560 )
      09950-70010   ( 09951-07150 )

      Note

      Be sure to install the counter driven gear tapered roller bearing (rear side inner race) so that there is no clearance between the counter driven gear tapered roller bearing (rear side inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  9. INSTALL COUNTER DRIVEN GEAR TAPERED ROLLER BEARING (FRONT SIDE INNER RACE)


    1. B005NW6N01

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

      SST
      09636-20010

      Note

      Be sure to install the counter driven gear tapered roller bearing (front side inner race) so that there is no clearance between the counter driven gear tapered roller bearing (front side inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  10. ADJUST PINION AND COUNTER DRIVEN GEAR SUB-ASSEMBLY PRELOAD


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

    2. B005LQD

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

    3. B005MXN

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

    4. B005O9SN01

      Install the transaxle housing to the automatic transaxle case sub-assembly with the 24 bolts.

      Torque:
      Bolt (A), (B), (D)
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Bolt (C)
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips

      Bolt Length

      • Bolt (A): 30 mm (1.18 in.)

      • Bolt (B): 39 mm (1.54 in.)

      • Bolt (C): 43 mm (1.69 in.)

      • Bolt (D): 35 mm (1.38 in.)

    5. B005PA4N01

      Using SST, turn the differential case assembly right and left 2 or 3 times to settle the bearings.

      SST
      09564-33010

    6. Using SST and a torque wrench, measure the turning torque of the pinion and counter driven gear sub-assembly while rotating SST at 100 rpm.

      Turning Torque
      0.9 to 3.5 N*m (9 to 36 kgf*cm, 8 to 31 in.*lbf)

      If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

      Shim Thickness
      Part Number

      Thickness

      (mm (in.))

      		 Mark
      90564-57035 1.19 (0.0469) CA
      90564-57036 1.22 (0.0480) CB
      90564-57037 1.25 (0.0492) CC
      90564-57038 1.28 (0.0504) CD
      90564-57039 1.31 (0.0516) CE
      90564-57040 1.34 (0.0528) CF
      90564-57041 1.37 (0.0539) CG
      90564-57042 1.40 (0.0551) CH
      90564-57043 1.43 (0.0563) CJ
      90564-57044 1.46 (0.0575) CK
      90564-57045 1.49 (0.0587) CL
      90564-57046 1.52 (0.0598) CM
      90564-57047 1.55 (0.0610) CN
      90564-57048 1.58 (0.0622) CP
      90564-57049 1.61 (0.0634) CR
      90564-57050 1.64 (0.0646) CS
      90564-57051 1.67 (0.0657) CT
      90564-57052 1.70 (0.0669) CU
      90564-57053 1.73 (0.0681) CV
      90564-57054 1.76 (0.0693) CW
      90564-57055 1.79 (0.0705) CX
      90564-57056 1.82 (0.0717) CY
      90564-57057 1.85 (0.0728) CZ
      90564-57058 1.88 (0.0740) DA
      90564-57059 1.91 (0.0752) DB
      90564-57060 1.94 (0.0764) DC
      90564-57061 1.97 (0.0776) DD
      90564-57062 2.00 (0.0787) DE
      90564-57063 2.03 (0.0799) DF
      90564-57064 2.06 (0.0811) DG
      90564-57065 2.09 (0.0823) DH
      90564-57066 2.12 (0.0835) DJ
      90564-57067 2.15 (0.0846) DK
      90564-57068 2.18 (0.0858) DL
      90564-57069 2.21 (0.0870) DM
    7. B005O9SN01

      Remove the 24 bolts and transaxle housing from the automatic transaxle case sub-assembly.

      Tech Tips

      Bolt Length

      • Bolt (A): 30 mm (1.18 in.)

      • Bolt (B): 39 mm (1.54 in.)

      • Bolt (C): 43 mm (1.69 in.)

      • Bolt (D): 35 mm (1.38 in.)

    8. Remove the pinion and counter driven gear sub-assembly from the transaxle case sub-assembly.

    9. Remove the differential case assembly from the automatic transaxle case sub-assembly.

  11. INSTALL NO. 2 TRANSAXLE CASE PLUG


    1. B005MBO

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

      Note

      Ensure that the 2 O-rings are not twisted.

    2. Using a T55 "TORX" socket wrench, install the 2 No. 2 transaxle case plugs to the automatic transaxle case sub-assembly.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
    3. B005NMZ

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

      Note

      Ensure that the 2 O-rings are not twisted.

    4. Using a T55 "TORX" socket wrench, install the 2 No. 2 transaxle case plugs to the transaxle housing.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  12. INSTALL NO. 1 TRANSAXLE CASE PLUG


    1. B005OKE

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

      Note

      Ensure that the 3 O-rings are not twisted.

    2. Install the 3 No. 1 transaxle case plugs to the transaxle housing.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    3. B005Q22

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

      Note

      Ensure that the 4 O-rings are not twisted.

    4. Install the 4 No. 1 transaxle case plugs to the automatic transaxle case sub-assembly.

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

  13. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


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

    2. B005POMC01
      *a Depth

      Using SST and a hammer, install the manual valve lever shaft oil seal to the automatic transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07150 )
      Standard Depth
      -0.3 to 0.4 mm (-0.0118 to 0.0157 in.)

  14. INSTALL BREATHER PLUG


    1. B005PNG

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

      Note

      Ensure that the O-ring is not twisted.

    2. B005O0DC01
      *a Push in

      Engage each claw to install the breather plug to the automatic transaxle case sub-assembly.

      Note

      Securely push in the automatic transaxle case sub-assembly until the breather plug is engaged.

  15. INSTALL DIRECT CLUTCH DRUM OIL SEAL RING


    1. B005N0C

      Coat 2 new direct clutch drum oil seal rings with ATF and install them to the automatic transaxle case sub-assembly.

  16. INSTALL NO. 1 THRUST BEARING RACE


    1. B005LVJ

      Coat the No. 1 thrust bearing race with ATF and install it to the automatic transaxle case sub-assembly.

      No. 1 Thrust Bearing Race Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      No. 1 thrust bearing race 52.8 (2.08) 76.4 (3.01)

  17. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. B005OZA

      Coat 2 new O-rings with ATF and install them to the 1st and reverse brake piston.

      Note

      Ensure that the 2 O-rings are not twisted.

    2. Install the 1st and reverse brake piston to the automatic transaxle case sub-assembly.

      Note

      Be careful not to damage the 2 O-rings.

    3. B005OKQ

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

    4. B005NRCC01
      *a Protective Tape

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

      SST
      09387-00140
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07200 )

      Note


      • Place SST on the 1st and reverse brake return spring sub-assembly as shown in the illustration.

      • Make sure that SST does not interfere with the 1st and reverse brake piston.

      • Stop pressing when the spring seat is 1 to 2 mm (0.0394 to 0.0787 in.) below the snap ring groove to prevent the spring seat from being deformed.

    5. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the automatic transaxle case sub-assembly.

      Note


      • Install the snap ring as shown in the illustration.

      • Be careful not to damage the automatic transaxle case sub-assembly.

  18. INSTALL INTERMEDIATE SHAFT O-RING


    1. B005NFN

      Coat 2 new intermediate shaft O-rings with ATF and install them to the intermediate shaft sub-assembly.

      Note

      Ensure that the 2 intermediate shaft O-rings are not twisted.

  19. INSTALL C-2 CLUTCH PISTON


    1. B005QAZ

      Coat the rubber portion on the edge of the C-2 clutch piston with ATF.

    2. Install the C-2 clutch piston to the intermediate shaft sub-assembly.

  20. INSTALL CLUTCH RETURN WITH RETAINER SPRING SUB-ASSEMBLY


    1. B005P1Z

      Install the clutch return with retainer spring sub-assembly to the intermediate shaft sub-assembly.

  21. INSTALL C-2 CLUTCH BALANCER


    1. B005QGY

      Coat the rubber portion on the edge of the C-2 clutch balancer with ATF.

    2. Install the C-2 clutch balancer to the intermediate shaft sub-assembly.

    3. B005L89N02

      Place SST on the C-2 clutch balancer and compress the clutch return with retainer spring sub-assembly with a press.

      SST
      09387-00020

      Note

      Stop pressing when the spring seat is 1 to 2 mm (0.0394 to 0.0787 in.) below the snap ring groove to prevent the spring seat from being deformed.

    4. Using a snap ring expander, install the snap ring to the intermediate shaft sub-assembly.

      Note

      Do not expand the snap ring excessively.

  22. INSTALL NO. 2 CLUTCH DISC


    1. B005M8IC01
      *1 Direct Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate

      Install the direct clutch flange, 4 No. 2 clutch discs and 4 No. 2 clutch plates to the intermediate shaft sub-assembly.

      Note

      Make sure that the direct clutch flange, 4 No. 2 clutch discs and 4 No. 2 clutch plates are installed in the correct order.

    2. B005NOLC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the intermediate shaft sub-assembly.

      Note

      Be careful not to damage the intermediate shaft sub-assembly.

  23. INSTALL C-2 CLUTCH ASSEMBLY


    1. B005NX6C01
      *1 C-2 Clutch Assembly
      *2 Thrust Needle Roller Bearing

      Coat the thrust needle roller bearing with ATF and install it to the C-2 clutch assembly.

      Thrust Needle Roller Bearing Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      Thrust needle roller bearing 50.5 (1.99) 71.1 (2.80)

    2. Install the C-2 clutch assembly to the automatic transaxle case sub-assembly.

    3. B005M0NC01
      *1 Thrust Needle Roller Bearing
      *2 No. 2 Thrust Bearing Race

      Coat the thrust needle roller bearing and No. 2 thrust bearing race with ATF and install them to the C-2 clutch assembly.

      Thrust Needle Roller Bearing and No. 2 Thrust Bearing Race Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      Thrust needle roller bearing 24.25 (0.955) 41.17 (1.62)
      No. 2 thrust bearing race 24.2 (0.953) 41.7 (1.64)

  24. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC


    1. B005M8CC01
      *1 1st and Reverse Brake Flange
      *2 1st and Reverse Brake Clutch Disc
      *3 1st and Reverse Brake Clutch Plate

      Install the 2 1st and reverse brake flanges, 5 1st and reverse brake clutch discs and 4 1st and reverse brake clutch plates to the automatic transaxle case sub-assembly.

      Note


      • Make sure that the 2 1st and reverse brake flanges, 5 1st and reverse brake clutch discs and 4 1st and reverse brake clutch plates are installed in the correct order.

      • Be sure to install the 1st and reverse brake flanges in the correct direction as shown in the illustration.

    2. B005PM9C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the automatic transaxle case sub-assembly.

      Note


      • Install the snap ring as shown in the illustration.

      • Be careful not to damage the automatic transaxle case sub-assembly.

  25. INSPECT CLEARANCE OF NO. 2 BRAKE

    Click here

  26. INSPECT CLEARANCE OF C-2 CLUTCH

    Click here

  27. INSTALL REAR PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B005MTPC01
      *1 No. 4 Thrust Bearing Race
      *2 Rear Planetary Sun Gear Sub-assembly
      *3 No. 3 Thrust Bearing Race

      Coat the No. 4 thrust bearing race and No. 3 thrust bearing race with ATF and install them to the rear planetary sun gear sub-assembly.

      No. 4 Thrust Bearing Race and No. 3 Thrust Bearing Race Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      No. 4 thrust bearing race 33.2 (1.31) 45.6 (1.80)
      No. 3 thrust bearing race 25.6 (1.01) 43.7 (1.72)

    2. Install the rear planetary sun gear sub-assembly to the C-2 clutch assembly.

  28. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. B005QBY

      Coat the No. 4 planetary carrier thrust washer with ATF and install it to the rear planetary gear assembly.

    2. B005QE0

      Install the one-way clutch assembly to the rear planetary gear assembly.

    3. B005NAM

      Install the one-way clutch assembly with rear planetary gear assembly to the C-2 clutch assembly.

    4. B005P78C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the automatic transaxle case sub-assembly.

      Note


      • Install the snap ring as shown in the illustration.

      • Be careful not to damage the automatic transaxle case sub-assembly.

    5. B005N8W

      Coat the No. 3 planetary carrier thrust washer with ATF and install it to the rear planetary gear assembly.

  29. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B005M1J

      Install the thrust needle roller bearing to the rear planetary gear assembly.

    2. B005O6D

      Install the planetary sun gear sub-assembly to the rear planetary gear assembly.

  30. INSTALL FRONT PLANETARY GEAR SUB-ASSEMBLY


    1. B005Q60C01
      *1 Transmission Revolution Sensor (NC)
      *2 Spacer

      Install the transmission revolution sensor (NC) and spacer to the front planetary gear sub-assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    2. B005O8K

      Install the front planetary gear sub-assembly to the automatic transaxle case sub-assembly.

      Note

      Be careful not to damage the wire harness.

    3. B005OPJ

      Using a T55 "TORX" socket wrench, install the 6 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }
    4. B005LC3

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

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    5. Engage the wire harness clamp.

      Note


      • Make sure that the wire harness will not get caught on other components.

      • Remove any slack in the wire harness.

  31. INSTALL B-1 BRAKE PISTON


    1. B005NLF

      Coat a new O-ring with ATF and install it to the B-1 brake piston.

      Note

      Ensure that the O-ring is not twisted.

    2. B005NIE

      Coat 3 new O-rings with ATF and install them to the brake piston cover.

      Note

      Ensure that the 3 O-rings are not twisted.

    3. B005LB2C01
      *1 B-1 Brake Piston Compression Spring
      *2 B-1 Brake Piston
      *3 Brake Piston Cover

      Install the B-1 brake piston compression spring, B-1 brake piston and brake piston cover to the automatic transaxle case sub-assembly.

    4. B005MT3

      Using snap ring pliers, install the snap ring to the automatic transaxle case sub-assembly.

  32. INSTALL TRANSMISSION LUBE APPLY TUBE


    1. B005NN6

      Install the transmission lube apply tube to the automatic transaxle case sub-assembly.

    2. B005OGS

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

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  33. INSTALL FRONT DRIVE SHAFT OIL SEAL LH


    1. Coat the lip of a new front drive shaft oil seal LH with MP grease.

    2. B005P9RC01
      *a Depth

      Using SST and a hammer, install the front drive shaft oil seal LH to the automatic transaxle case sub-assembly.

      SST
      09316-10010
      09950-70010   ( 09951-07150 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  34. INSTALL FRONT DRIVE SHAFT OIL SEAL RH


    1. Coat the lip of a new front drive shaft oil seal RH with MP grease.

    2. B005O1EC01
      *a Depth

      Using SST and a hammer, install the front drive shaft oil seal RH to the transaxle housing.

      SST
      09316-60011   ( 09316-00011 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

  35. INSTALL DIFFERENTIAL CASE ASSEMBLY


    1. B005LQD

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

  36. INSTALL PINION AND COUNTER DRIVEN GEAR SUB-ASSEMBLY


    1. B005MXN

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

  37. INSTALL INPUT SUN GEAR DRUM


    1. B005PR6

      Install the input sun gear drum to the rear planetary gear assembly.

    2. B005MA6C01
      *1 Thrust Needle Roller Bearing
      *2 No. 5 Thrust Bearing Race

      Coat the thrust needle roller bearing and No. 5 thrust bearing race with ATF and install them to the input sun gear drum.

      Thrust Needle Roller Bearing and No. 5 Thrust Bearing Race Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      Thrust needle roller bearing 33.2 (1.31) 45.6 (1.80)
      No. 5 thrust bearing race 35.2 (1.39) 47 (1.85)

  38. INSTALL C-1 DRUM O-RING


    1. B005OD6

      Coat 2 new C-1 drum O-rings with ATF and install them to the clutch drum sub-assembly.

      Note

      Ensure that the 2 C-1 drum O-rings are not twisted.

  39. INSTALL FORWARD CLUTCH PISTON


    1. B005P68

      Coat a new O-ring with ATF and install it to the forward clutch piston.

      Note

      Ensure that the O-ring is not twisted.

    2. B005OIJ

      Install the forward clutch piston to the clutch drum sub-assembly.

      Note

      Be careful not to damage the O-ring.

  40. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. B005N3X

      Install the forward clutch return spring sub-assembly to the clutch drum sub-assembly.

  41. INSTALL NO. 1 CLUTCH BALANCER


    1. B005LYE

      Install the No. 1 clutch balancer to the clutch drum sub-assembly.

    2. B005ND9N01

      Place SST on the No. 1 clutch balancer and compress the forward clutch return spring sub-assembly with a press.

      SST
      09387-00020

      Note

      Stop pressing when the spring seat is 1 to 2 mm (0.0394 to 0.0787 in.) below the snap ring groove to prevent the spring seat from being deformed.

    3. Using a snap ring expander, install the snap ring to the clutch drum sub-assembly.

      Note

      Do not expand the snap ring excessively.

  42. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC


    1. B005MU1C01
      *1 Forward Clutch Flange
      *2 Forward Multiple Disc Clutch Disc
      *3 Forward Multiple Disc Clutch Plate

      Install the forward clutch flange, 5 forward multiple disc clutch discs and 5 forward multiple disc clutch plates to the clutch drum sub-assembly.

      Note

      Make sure that the forward clutch flange, 5 forward multiple disc clutch discs and 5 forward multiple disc clutch plates are installed in the correct order.

    2. B005PD1C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the clutch drum sub-assembly.

      Note

      Be careful not to damage the clutch drum sub-assembly.

  43. INSPECT CLEARANCE OF C-1 CLUTCH

    Click here

  44. INSTALL C-1 CLUTCH ASSEMBLY


    1. B005NNA

      Install the C-1 clutch assembly to the rear planetary sun gear sub-assembly.

    2. B005LVCC01
      *1 Thrust Needle Roller Bearing
      *2 No. 6 Thrust Bearing Race

      Coat the thrust needle roller bearing and No. 6 thrust bearing race with ATF and install them to the C-1 clutch assembly.

      Thrust Needle Roller Bearing and No. 6 Thrust Bearing Race Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      Thrust needle roller bearing 39.2 (1.54) 52.6 (2.07)
      No. 6 thrust bearing race 38.1 (1.50) 50.2 (1.98)

  45. INSTALL FRONT PLANETARY RING GEAR


    1. B005N7X

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

    2. B005OVEC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front planetary ring gear.

      Note

      Be careful not to damage the front planetary ring gear.

    3. B005MRQ

      Install the front planetary ring gear with front planetary ring gear flange to the C-1 clutch assembly.

    4. B005OT3

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

      Thrust Needle Roller Bearing Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      Thrust needle roller bearing 57.3 (2.26) 71.94 (2.83)

  46. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B005QGB

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

    2. B005ODQ

      Coat 4 new input shaft oil seal rings with ATF and install them to the front planetary gear assembly.

    3. B005OZQ

      Coat 2 new rear input shaft oil seal rings with ATF and install them to the front planetary gear assembly.

    4. B005NPQC01
      *1 No. 9 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 No. 8 Thrust Bearing Race

      Coat the No. 9 thrust bearing race, thrust needle roller bearing and No. 8 thrust bearing race with ATF and install them to the front planetary gear assembly.

      No. 9 Thrust Bearing Race, Thrust Needle Roller Bearing and No. 8 Thrust Bearing Race Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      No. 9 thrust bearing race 31.1 (1.22) 51 (2.01)
      Thrust needle roller bearing 29.8 (1.17) 48.8 (1.92)
      No. 8 thrust bearing race 29.8 (1.17) 48.8 (1.92)
    5. B005OTV

      Install the planetary sun gear to the front planetary gear assembly.

    6. B005NO4C01
      *1 No. 2 Planetary Carrier Thrust Washer
      *2 No. 7 Thrust Bearing Race

      Coat the No. 2 planetary carrier thrust washer and No. 7 thrust bearing race with ATF and install them to the front planetary gear assembly.

      No. 7 Thrust Bearing Race Diameter
      - Inside (mm (in.)) Outside (mm (in.))
      No. 7 thrust bearing race 58.8 (2.31) 72.7 (2.86)

  47. INSTALL C-4 CLUTCH BALANCER O-RING


    1. B005LPO

      Coat a new C-4 clutch balancer O-ring with ATF and install it to the C-3 and C-4 clutch sub-assembly.

      Note

      Ensure that the C-4 clutch balancer O-ring is not twisted.

  48. INSTALL C-4 CLUTCH PISTON


    1. B005OUT

      Coat the rubber portion on the edges of the C-4 clutch piston with ATF.

    2. Install the C-4 clutch piston to the C-3 and C-4 clutch sub-assembly.

  49. INSTALL UNDER DRIVE RETURN WITH RETAINER SPRING SUB-ASSEMBLY


    1. B005NQB

      Install the under drive return with retainer spring sub-assembly to the C-3 and C-4 clutch sub-assembly.

  50. INSTALL C-4 CLUTCH BALANCER


    1. B005N66

      Coat the rubber portion on the edge of the C-4 clutch balancer with ATF.

    2. Install the C-4 clutch balancer to the C-3 and C-4 clutch sub-assembly.

    3. B005P7VN01

      Place SST on the C-4 clutch balancer and compress the under drive return with retainer spring sub-assembly with a press.

      SST
      09387-00020

      Note

      Stop pressing when the spring seat is 1 to 2 mm (0.0394 to 0.0787 in.) below the snap ring groove to prevent the spring seat from being deformed.

    4. Using a snap ring expander, install the snap ring to the C-3 and C-4 clutch sub-assembly.

      Note

      Do not expand the snap ring excessively.

  51. INSTALL NO. 4 CLUTCH DISC


    1. B005P6OC01
      *1 No. 1 Underdrive Clutch Flange
      *2 No. 4 Clutch Disc
      *3 No. 4 Clutch Plate

      Install the No. 1 underdrive clutch flange, 4 No. 4 clutch discs and 4 No. 4 clutch plates to the C-3 and C-4 clutch sub-assembly.

      Note

      Make sure that the No. 1 underdrive clutch flange, 4 No. 4 clutch discs and 4 No. 4 clutch plates are installed in the correct order.

    2. B005NNWC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the C-3 and C-4 clutch sub-assembly.

      Note

      Be careful not to damage the C-3 and C-4 clutch sub-assembly.

  52. INSTALL NO. 3 CLUTCH DISC


    1. B005OQGC01
      *1 Reverse Clutch Flange
      *2 No. 3 Clutch Disc
      *3 No. 3 Clutch Plate

      Install the reverse clutch flange, 3 No. 3 clutch discs and 3 No. 3 clutch plates to the C-3 and C-4 clutch sub-assembly.

      Note


      • Make sure that the 3 No. 3 clutch discs, 3 No. 3 clutch plates and reverse clutch flange are installed in the correct order.

      • Be sure to install the reverse clutch flange in the correct direction as shown in the illustration.

    2. B005O5QC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the C-3 and C-4 clutch sub-assembly.

      Note


      • Be careful not to damage the C-3 and C-4 clutch sub-assembly.

      • Make sure that the openings of the No. 4 clutch disc snap ring and No. 3 clutch disc snap ring are positioned 180° apart.

  53. INSPECT CLEARANCE OF C-4 CLUTCH

    Click here

  54. INSPECT CLEARANCE OF C-3 CLUTCH

    Click here

  55. INSTALL C-3 AND C-4 CLUTCH ASSEMBLY


    1. B005MVZ

      Install the C-3 and C-4 clutch assembly to the front planetary gear assembly.

    2. B005LV1

      Install the C-3 and C-4 clutch assembly with front planetary gear assembly to the automatic transaxle case sub-assembly.

    3. B005LMR

      Install the B-1 brake band assembly to the C-3 and C-4 clutch drum.

    4. B005PRH

      Install the bolt to the automatic transaxle case sub-assembly.

      Torque:
      167 N*m  { 1703 kgf*cm, 123 ft.*lbf }

  56. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B005N6U

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

      Note

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

  57. INSTALL PARKING LOCK PIN SUB-ASSEMBLY

    B005MOB

    1. Coat the parking lock pin sub-assembly with ATF and install it to the automatic transaxle case sub-assembly.

  58. INSTALL PARKING LOCK PAWL


    1. B005L6N

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

    2. B005OB3C01
      *1 Parking Lock Pawl Shaft
      *2 Torsion Spring

      Install the parking lock pawl shaft and torsion spring to the automatic transaxle case sub-assembly.

  59. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. B005OSHC01
      *1 Parking Lock Pawl
      *2 Parking Lock Rod Sub-assembly
      *3 Parking Lock Pin Sub-assembly

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

    2. B005PMO

      Install the parking lock pawl bracket to the automatic transaxle case sub-assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    3. B005O74

      Install the spring guide sleeve and torsion spring to the automatic transaxle case sub-assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  60. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B005L82C01
      *1 Manual Detent Spring Cover
      *2 Manual Detent Spring Sub-assembly

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

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  61. INSTALL NO. 1 GOVERNOR APPLY GASKET


    1. B005MIG

      Coat a new No. 1 governor apply gasket with ATF and install it to the automatic transaxle case sub-assembly.

  62. INSTALL FRONT OIL PUMP ASSEMBLY


    1. B005NVW

      Coat the planetary carrier thrust washer with ATF and install it to the front oil pump assembly.

    2. B005OION01

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

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Bolt Length

      • Bolt (A): 35 mm (1.38 in.)

      • Bolt (B): 25 mm (0.984 in.)

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

      Note

      Ensure that the front oil pump body O-ring is not twisted.

    4. B005Q8Y

      Coat 3 new transaxle case gaskets with ATF and install them to the front oil pump assembly.

  63. INSPECT B-1 BRAKE PISTON ROD STROKE

    Click here

  64. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. B005MGE

      Install the 3 transmission oil cleaner magnets to the transaxle housing oil separator.

    2. B005Q2Z

      Install the transaxle housing oil separator to the transaxle housing with the 2 bolts.

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

      Note

      If the transaxle housing oil separator is deformed or damaged, replace it with a new one.

  65. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. B005P53

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

    2. B005L5R

      Install the clamp to the transaxle housing with the bolt.

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

  66. INSTALL TRANSAXLE HOUSING


    1. Remove any remaining seal packing from the sealing surfaces of the transaxle housing and automatic transaxle case sub-assembly.

      Note

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

    2. B005OTOC01
      *a FIPG

      Apply FIPG to the automatic transaxle case sub-assembly.

      FIPG
      Toyota Genuine Seal Packing 1281 Three Bond 1281 or equivalent

      Note


      • Apply FIPG in a continuous line (width 1.4 mm (0.0551 in.)) along the sealing surface.

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

    3. B005O9SN01

      Install the transaxle housing to the automatic transaxle case sub-assembly with the 24 bolts.

      Torque:
      Bolt (A), (B), (D)
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Bolt (C)
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips

      Bolt Length

      • Bolt (A): 30 mm (1.18 in.)

      • Bolt (B): 39 mm (1.54 in.)

      • Bolt (C): 43 mm (1.69 in.)

      • Bolt (D): 35 mm (1.38 in.)

  67. INSPECT INPUT SHAFT END PLAY

    Click here

  68. INSTALL TRANSMISSION REVOLUTION SENSOR (NT)

    Click here

  69. INSTALL TRANSMISSION REVOLUTION SENSOR (NC3)

    Click here

  70. INSTALL TRANSMISSION WIRE

    Click here

  71. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    Click here

  72. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. B005L2QC01
      *1 Transmission Oil Cleaner Magnet

      Install the 2 transmission oil cleaner magnets to the transaxle side cover sub-assembly.

  73. INSTALL TRANSAXLE SIDE COVER SUB-ASSEMBLY


    1. Remove any remaining seal packing from the sealing surface of the automatic transaxle case sub-assembly.

      Note

      Make sure that there is no ATF on the sealing surface.

    2. Clean the 13 bolts and bolt holes in the automatic transaxle case sub-assembly.

    3. B005P9S

      Temporarily install 2 stud bolts to the automatic transaxle case sub-assembly by hand, to the positions shown in the illustration.

      Item Part No.
      Stud Bolt 92122-80825
    4. B005NYIC01
      *a FIPG

      Apply FIPG to a new transaxle side cover sub-assembly.

      FIPG
      Toyota Genuine Seal Packing 1281 Three Bond 1281 or equivalent

      Note


      • Apply FIPG in a continuous line (width 2.5 mm (0.0984 in.)) along the sealing surface.

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

    5. B005QFCC74
      *a Adhesive

      Apply adhesive to 2 or 3 threads on the ends of the 13 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Make sure to install the bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

    6. B005NBVC01
      *a Stud Bolt

      Using a T40 "TORX" socket wrench, install the transaxle side cover sub-assembly to the automatic transaxle case sub-assembly with the 11 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    7. Remove the 2 stud bolts.

    8. B005PZW

      Using a T40 "TORX" socket wrench, install the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  74. INSTALL TRANSMISSION CASE PLUG ASSEMBLY


    1. B005M59

      Install a new transmission case plug assembly to the transaxle housing.

  75. INSTALL REFILL PLUG


    1. B005LMI

      Install the refill plug and a new gasket to the automatic transaxle case sub-assembly.

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

  76. INSTALL INLET NO. 1 OIL COOLER TUBE SUB-ASSEMBLY


    1. B007ZOY

      Coat a new O-ring with ATF and install it to the inlet No. 1 oil cooler tube sub-assembly.

      Note

      Ensure that the O-ring is not twisted.

    2. B005OUY

      Install the inlet No. 1 oil cooler tube sub-assembly to the transaxle housing.

      Note

      The installation bolts will be installed after installing the outlet No. 1 oil cooler tube sub-assembly.

  77. INSTALL OUTLET NO. 1 OIL COOLER TUBE SUB-ASSEMBLY


    1. B007ZSI

      Coat a new O-ring with ATF and install it to the outlet No. 1 oil cooler tube sub-assembly.

      Note

      Ensure that the O-ring is not twisted.

    2. B005N9J

      Install the outlet No. 1 oil cooler tube sub-assembly to the transaxle housing.

    3. B005LR2N01

      Temporarily install the 4 bolts in the order shown in the illustration.

    4. Fully tighten the 4 bolts in the order shown in the illustration.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  78. INSTALL OVERFLOW PLUG


    1. B005PB2

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

      Note

      Ensure that the O-ring is not twisted.

    2. B005PCM

      Using a 17 mm straight hexagon wrench, install the overflow plug to the transaxle housing.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  79. INSTALL DRAIN PLUG


    1. B005P1J

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

      Note

      Ensure that the O-ring is not twisted.

    2. Using a T40 "TORX" socket wrench, install the drain plug to the overflow plug.

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

  80. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B005N14C01
      *a Neutral Alignment Mark Line
      *b Groove

      Align the groove and the neutral alignment mark line.

    2. Install the park/neutral position switch assembly to the manual valve lever sub-assembly.

      Note


      • Before installing the park/neutral position switch assembly, remove any dirt or foreign matter on the installation portion of the manual valve lever sub-assembly. Be sure to install the park/neutral position switch assembly straight along the manual valve lever sub-assembly while being careful not to deform the plate spring that supports the manual valve lever 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, check that the neutral alignment mark line and groove on the park/neutral position switch assembly are aligned.

    3. Temporarily install the 2 bolts.

    4. Install the lock nut and a new lock plate to the manual valve lever sub-assembly.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

    5. Temporarily install the transmission control shaft lever to the manual valve lever sub-assembly.

    6. B005MJ2C01
      *a P Position
      *b N Position

      Turn the transmission control shaft lever clockwise until it stops, and then turn it counterclockwise 2 notches to set it to the N position.

    7. Remove the transmission control shaft lever from the manual valve lever sub-assembly.

    8. Align the neutral alignment mark line with the park/neutral position switch assembly groove and tighten the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    9. B005PS5

      Using a screwdriver, bend the tabs of the lock plate.

  81. INSTALL TRANSMISSION CONTROL SHAFT LEVER


    1. B005LZ3

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

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  82. INSTALL BREATHER PLUG HOSE


    1. B005O6SC01
      *1 No. 1 Breather Plug (ATM)
      *2 Breather Hose Clamp
      *3 Transmission Breather Clamp
      *4 Breather Plug Hose

      Install the breather hose clamp and transmission breather clamp to the breather plug hose.

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

    3. B005Q4S

      Install the breather plug hose to the breather plug.