AUTOMATIC TRANSAXLE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Tip:

Check bearing position and installation direction.

C319493N01
C238855N01

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

-

62.6 mm (2.46 in.) / 82.4 mm (3.24 in.)

65.9 mm (2.59 in.) / 82.3 mm (3.24 in.)

D

59.4 mm (2.34 in.) / 76 mm (2.99 in.)

53.46 mm (2.10 in.) / 79 mm (3.11 in.)

-

E

-

56.1 mm (2.21 in.) / 81.1 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 (2.83 in.)

-

PROCEDURE

  1. INSTALL COUNTER DRIVE GEAR BEARING

    Tip:

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

    1. C138721N07

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

      09950-60020

      09951-01030

      09950-70010

      09951-07100

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

    1. C137443N03

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

      09950-60010

      09951-00630

      09950-70010

      09951-07100

      Note:

      Be sure to install the counter driven gear rear tapered roller bearing outer race so that there is no clearance between the 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

    1. C138714N04

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

      09950-60020

      09951-00810

      09950-70010

      09951-07150

      Note:

      Ensure that there is no clearance between the bearing and transaxle case.

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

    1. Install the shim to the transaxle housing.

    2. C138261N05

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

      09950-60020

      09951-00710

      09950-70010

      09951-07100

      Note:

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

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

    1. Install the shim to the transaxle housing.

    2. C138715N05

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

      09950-60020

      09951-00790

      09950-70010

      09951-07150

      Note:

      Ensure that there is no clearance between the bearing and transaxle housing.

  6. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING INNER RACE

    1. C333247N01

      Using SST and a press, install a new front differential case rear tapered roller bearing inner race to the front differential case.

      09710-30012

      09710-04081

      09950-60010

      09951-00480

      09950-70010

      09951-07100

      Note:

      • Do not damage the front differential case rear tapered roller bearing inner race cage when installing the front differential case rear tapered roller bearing inner race.

      • Ensure that there is no clearance between the front differential case rear tapered roller bearing inner race and front differential case.

  7. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING INNER RACE

    1. C333245N01

      Using SST and a press, install a new front differential case front tapered roller bearing inner race to the front differential case.

      09523-36010

      09950-60010

      09951-00540

      09950-70010

      09951-07100

      Note:

      • Do not damage the front differential case front tapered roller bearing inner race cage when installing the front differential case front tapered roller bearing inner race.

      • Ensure that there is no clearance between the front differential case front tapered roller bearing inner race and front differential case.

  8. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD

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

    2. C209724

      Install the front differential case to the transaxle case.

    3. C280470N01

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

      for Bolt A

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

      for Bolt B

      30.6 N*m

      312 kgf*cm

      23 ft.*lbf

    4. C314367N01

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

      09564-33010

      Turning torque

      1.23 to 1.65 N*m (12.55 to 16.82 kgf*cm, 10.89 to 14.60 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.

      Table 1. 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.)
    5. C205233

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

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

  9. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING

    1. C138250N05

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

      09950-60010

      09951-00490

      Note:

      Be sure to install the counter driven gear front 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.

  10. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING

    1. C138251N05

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

      09950-60010

      09951-00400

      Note:

      Be sure to install the counter driven gear rear tapered roller bearing so that there is no clearance between each of them and the counter driven gear.

  11. ADJUST COUNTER DRIVEN GEAR PRELOAD

    1. C209725

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

    2. C280470N01

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

      for Bolt A

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

      for Bolt B

      30.6 N*m

      312 kgf*cm

      23 ft.*lbf

    3. C317726N01

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

      09564-33010

      Turning torque

      Differential side bearing preload + 2.96 to 6.54 N*m (30.19 to 66.68 kgf*cm, 26.20 to 57.88 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.

      Table 2. 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. C205233

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

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

  12. INSTALL TRANSAXLE CASE OIL SEAL LH

    1. Coat the lip of a new transaxle case oil seal LH with MP grease.

    2. C205332N05

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

      09316-10010

      09950-70010

      09951-07100

      Standard depth

      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note:

      Make sure that the transaxle oil seal LH is installed in the correct direction.

  13. INSTALL TRANSAXLE CASE OIL SEAL RH (OUTER)

    1. Coat the lip of a new transaxle case oil seal RH (outer) with MP grease.

    2. C205241N01

      Using SST and a hammer, tap in the transaxle case oil seal RH (outer).

      09649-17010

      09950-70010

      09951-07200

      Standard depth

      5.5 to 6.5 mm (0.217 to 0.255 in.)

      Note:

      Make sure that the transaxle case oil seal RH is installed in the correct direction.

  14. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    1. C188148N02

      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.

      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 manual valve lever shaft oil seal is installed in the correct direction.

  15. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

    1. C201357

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

      Note:

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

    2. C201356

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

  16. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    1. C201355

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

  17. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

    1. C201354

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

      22.7 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.

  18. INSTALL NO. 3 BRAKE PISTON

    1. C317138

      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. C317912C01

      *1

      No. 3 Brake Piston

      Temporarily install the No. 3 brake piston to the transaxle.

    3. C317914C01

      *1

      No. 3 Brake Piston

      *2

      Pawl Stopper Plate

      Temporarily install the pawl stopper plate to the transaxle case 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.

      Note:

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

      Tip:

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

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

    6. C317915C01

      *1

      No. 3 Brake Piston

      *2

      Brake Piston Return Spring

      Install the brake piston return spring to the transaxle case.

      Note:

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

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

      C317916C01

      *1

      Snap Ring

      -

      -

      *a

      Protective Tape

      -

      -

      09387-00070

      Note:

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

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

      Note:

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

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

      • Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  19. INSTALL COUNTER DRIVE GEAR

    1. C137423N01

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

      09387-00020

    2. C274849N02

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

      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.

  20. INSTALL FRONT PLANETARY GEAR ASSEMBLY

    1. C274850N02

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

      09223-15030

      09527-17011

      09951-01100

  21. INSTALL NO. 2 BRAKE PISTON

    1. C201346

      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. C138726

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

      Note:

      Be careful not to damage the O-rings.

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

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

      C281638C01

      *a

      Protective Tape

      -

      -

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

      09387-00060

      Note:

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

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

      Note:

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

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

      • Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  23. INSTALL NO. 2 BRAKE DISC

    1. C238853C01

      *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.

      Note:

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

    2. C281626C01

      *a

      Protective Tape

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

      Note:

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

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

      • Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  24. INSPECT CLEARANCE OF NO. 2 BRAKE

    Click hereClick here

  25. INSTALL PLANETARY RING GEAR FLANGE

    1. C136480C01

      *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.

      • Be careful not to damage the planetary ring gear.

      Tip:

      Tape the screwdriver tip before use.

  26. INSTALL ONE-WAY CLUTCH ASSEMBLY

    1. C201345C01

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

      C274852C02

      *1

      Thrust Needle Roller Bearing

      -

      -
      Table 3. Bearing Diameter

      -

      Inside

      Outside

      Bearing

      56.1 mm (2.21 in.)

      81.1 mm (3.19 in.)
      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.

      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. C281622C01

      *a

      Protective Tape

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

      Note:

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

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

      • Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

  27. INSTALL PARKING LOCK PAWL

    1. C201343C01

      *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 with the parking lock pawl shaft.

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

    3. C137444

      Install the spring to the parking lock pawl.

      Note:

      Make sure that one end of the spring is secured 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

    1. C201342

      Install the parking lock sleeve to the transaxle case.

  29. INSTALL PAWL STOPPER PLATE

    1. C201341

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

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

  30. INSTALL NO. 1 TRANSMISSION CASE PLATE

    1. C203287N02

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

    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 with the bolt.

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

      Tip:

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

  31. INSTALL PAWL SHAFT CLAMP

    1. C201339

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

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

  32. INSTALL COUNTER DRIVEN GEAR

    1. C201336

      Install the counter driven gear to the transaxle case.

  33. INSTALL COUNTER DRIVE GEAR NUT

    1. C201334N01

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

    2. C201527N02

      Using SST, install a new counter drive gear nut.

      09387-00130

      120 N*m

      1224 kgf*cm

      89 ft.*lbf

    3. C201335N01

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

    4. C138252N01

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

      09387-00130

      Turning torque

      0.1 to 0.8 N*m (1 to 8 kgf*cm, 0.9 to 7.1 in.*lbf)

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

      Maximum torque

      180 N*m (1835 kgf*cm, 133 ft.*lbf)

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

  34. INSTALL FRONT DIFFERENTIAL CASE

    1. C205240

      Install the front differential case to the transaxle case.

  35. INSTALL NO. 1 BRAKE PISTON

    1. C274846

      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. C138253

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

      Note:

      Be careful not to damage the O-rings.

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

    1. C136464

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

      Note:

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

  37. INSTALL NO. 1 BRAKE DISC

    1. C201529C01

      *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 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. C281624C01

      *a

      Protective Tape

      Place SST on the flange and compress the flange with a press.

      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 oil pump assembly as shown in the illustration.

      Note:

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

      • 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.

      • Be careful not to damage the oil pump assembly.

      Tip:

      Tape the screwdriver tip before use.

    4. C176220

      Install the brake snap ring stopper to the oil pump assembly.

      Note:

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

    5. C201519N01

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

      Note:

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

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

      • Be careful not to damage the oil pump assembly.

      Tip:

      Tape the screwdriver tip before use.

    6. C293925C02

      *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 assembly. Remove and reinstall the snap ring and the brake snap ring stopper.

  38. INSPECT CLEARANCE OF NO. 1 BRAKE DISC

    Click hereClick here

  39. INSTALL UNDERDRIVE PLANETARY SUN GEAR

    1. C202904C01

      *1

      Underdrive Planetary Sun Gear

      *2

      Thrust Needle Roller Bearing

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

      Table 4. Bearing Diameter

      -

      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 will be visible.

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

  40. INSTALL INPUT SHAFT SUB-ASSEMBLY

    1. C202905C01

      *1

      Thrust Needle Roller Race

      *2

      Thrust Needle Roller Bearing

      *3

      Input Shaft Sub-assembly

      *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 needle roller race with ATF, and install them on the input shaft sub-assembly.

      Table 5. Bearing and Race Diameter

      -

      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.)
      Note:

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

    3. C136459

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

  41. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY

    1. C201331C01

      *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.

  42. INSTALL UNDERDRIVE PLANETARY RING GEAR

    Tip:

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

    1. C290583

      Install the snap ring to the underdrive planetary ring gear.

    2. C317256C02

      *a

      Protective Tape

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

      Note:

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

      Tip:

      Tape the screwdriver tip before use.

  43. INSTALL NO. 3 BRAKE HUB

    1. C202906C01

      *1

      Thrust Needle Roller Race

      *2

      Thrust Needle Roller Bearing

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

      Table 6. Bearing and Race Diameter

      -

      Inside

      Outside

      Bearing

      62.6 mm (2.47 in.)

      82.4 mm (3.24 in.)

      Race

      65.9 mm (2.59 in.)

      82.3 mm (3.24 in.)
      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 needle roller race with MP grease and install it to the No. 3 brake hub.

    3. C136454

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

  44. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

    1. C136458

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

  45. INSTALL NO. 3 BRAKE DISC

    1. C136452C01

      *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 oil pump assembly.

      Note:

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

    2. C274824N02

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

      Note:

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

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

      • Be careful not to damage the oil pump assembly.

      Tip:

      Tape the screwdriver tip before use.

  46. INSPECT CLEARANCE OF NO. 3 BRAKE DISC

    Click hereClick here

  47. INSTALL OIL PUMP ASSEMBLY

    1. C293927C06

      *1

      Thrust Needle Roller Bearing

      *2

      O-ring

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

    2. Coat the thrust needle roller bearing with ATF.

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

      Table 7. Thrust Needle Roller Bearing Diameter

      -

      Inside

      Outside

      Thrust needle roller bearing

      53.46 mm (2.10 in.)

      79 mm (3.11 in.)
      Note:

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

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

    5. C293929C03

      *1

      Thrust Needle Roller Race

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

      Table 8. Thrust Needle Roller Race Diameter

      -

      Inside

      Outside

      Thrust needle roller race

      59.4 mm (2.34 in.)

      76 mm (2.99 in.)
    6. C201329

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

    7. C201328C01

      *1

      O-ring

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

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

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

  48. INSTALL TRANSAXLE HOUSING OIL SEPARATOR

    1. C201327

      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.

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

  49. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

    1. C201326

      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.

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

      Note:

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

  50. INSTALL TRANSAXLE HOUSING

    1. C201495

      Clean and degrease the contact surfaces between the transaxle housing and transaxle case.

      Note:

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

    2. 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.

      • After applying seal packing, install the transaxle housing to the transaxle case within 3 minutes and tighten the bolts within 10 minutes.

    3. C205494

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

      30.6 N*m

      312 kgf*cm

      23 ft.*lbf

    4. C205495

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

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

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the 3 bolts.

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

  51. INSPECT CLEARANCE OF NO. 1 CLUTCH

    Click hereClick here

  52. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

    1. C201526C01

      *1

      Thrust Needle Roller Bearing

      *2

      Thrust Needle Roller Race

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

      Table 9. Bearing and Race Diameter

      -

      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.)
      Note:

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

    2. C201321C01

      *1

      Rear Planetary Sun Gear

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

    3. C202900

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

    4. C224456C01

      *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 direct multiple disc clutch assembly.

  53. INSPECT CLEARANCE OF NO. 2 CLUTCH

    Click hereClick here

  54. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

    1. C202901C01

      *1

      Thrust Needle Roller Bearing

      *2

      Direct Multiple Disc Clutch Assembly

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

      Table 10. Bearing Diameter

      -

      Inside

      Outside

      Bearing

      61.2 mm (2.41 in.)

      79 mm (3.11 in.)

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

  55. INSPECT INTERMEDIATE SHAFT END PLAY

    Click hereClick here

  56. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY

    1. C205308N05

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

      09950-60010

      09951-00220

      09950-70010

      09951-07100

      Installation depth

      21.5 to 21.9 mm (0.847 to 0.862 in.)

    2. C201318

      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.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    5. C202908C01

      *1

      Oil Seal Ring

      *2

      Thrust Needle Roller Bearing

      *3

      Thrust Needle Roller Race

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

      Table 11. Bearing and Race Diameter

      -

      Inside

      Outside

      Bearing

      48.9 mm (1.93 in.)

      72.0 mm (2.83 in.)

      Race

      52.2 mm (2.06 in.)

      70.4 mm (2.77 in.)

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

    7. C274807

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

    8. C138271

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

      Note:

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

    9. 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.

      • After applying seal packing, install the rear transaxle cover sub-assembly to the transaxle case within 3 minutes and tighten the bolts within 10 minutes.

    10. C280471

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

      22.7 N*m

      231 kgf*cm

      17 ft.*lbf

    11. C280472

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

    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.

      16.9 N*m

      172 kgf*cm

      12 ft.*lbf

    14. C162439

      Install a new gasket to the refill plug.

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

      49 N*m

      500 kgf*cm

      36 ft.*lbf

  57. INSPECT INPUT SHAFT END PLAY

    Click hereClick here

  58. INSTALL TRANSAXLE CASE GASKET

    1. C201316

      Coat 2 new transaxle case gaskets with ATF.

    2. Install the 2 transaxle case gaskets onto the transaxle case.

  59. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    1. C280473C01

      *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 transaxle case with the 11 bolts.

      Table 12. Bolt Length

      Bolt

      Length

      A

      25 mm (0.984 in.)

      B

      30 mm (1.18 in.)

      C and D

      35 mm (1.38 in.)

      Bolt A, B, C

      10.8 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 transaxle case to interfere with each other.

      • First, temporarily tighten the bolts marked (*a) in the illustration because they are positioning bolts.

  60. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    1. C201703

      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. C230619

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

      9.6 N*m

      98 kgf*cm

      85 in.*lbf

  61. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

    1. C304554C01

      *1

      Transmission Oil Cleaner Magnet

      Install the 4 transmission oil cleaner magnets onto the automatic transaxle oil pan sub-assembly as shown in the illustration.

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

    3. C202902

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

      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 and automatic transaxle oil pan sub-assembly with the automatic transaxle oil pan gasket before installation.

    4. C202903

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

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

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Install the 2 bolts.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

    7. C201310

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

      0.8 N*m

      8 kgf*cm

      7 in.*lbf

    8. C201309

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

      40 N*m

      408 kgf*cm

      30 ft.*lbf

  62. INSTALL TRANSAXLE CASE PLUG

    1. C134959

      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 transaxle case plugs.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

    4. Using a 6 mm hexagon socket wrench, install the 3 transaxle case plugs to the transaxle housing with the gaskets.

      17 N*m

      173 kgf*cm

      13 ft.*lbf

    5. C279453

      Coat 6 new O-rings with ATF and install them to the 6 transaxle case plugs.

    6. Install the 6 transaxle case plugs to the transaxle case and rear transaxle cover sub-assembly.

      7.4 N*m

      75 kgf*cm

      65 in.*lbf

  63. INSTALL OIL COOLER TUBE UNION

    1. C279449

      Coat 2 new O-rings with ATF and install them to the 2 oil cooler tube unions.

    2. Using a 19 mm union nut wrench, install the 2 oil cooler tube unions as shown in the illustration.

      27 N*m

      275 kgf*cm

      20 ft.*lbf

      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click hereClick hereClick hereClick here).

  64. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    1. C136686

      Temporarily install the park/neutral position switch assembly to the transaxle case 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. C135733C14

      *a

      Protrusion

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

    3. Tighten the 2 bolts

      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 park/neutral position switch assembly are aligned.

    4. C136685

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

      12.7 N*m

      130 kgf*cm

      9 ft.*lbf

  65. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

    1. C134952C01

      *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. C238851C05

      *1

      No. 2 Breather Plug

      *a

      Boss

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

      Note:

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