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Transaxle Reassembly

NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cutouts of drum. Check thrust bearings and races for wear or damage. Use petroleum jelly to secure parts in place. Clutch discs should be soaked in ATF for at least 15 minutes before installation.
NOTE: Refer to illustration for thrust bearing and race locations. See Fig 24. For component dimensions, see THRUST BEARING & RACE SPECIFICATIONS  table.
  1. Install lube apply tube and clamp with bolt to transaxle housing. See Figure. Install bolt and tighten to 87 INCH lbs. (9.8 N.m). Ensure pipe is installed to stopper.
  2. Install NEW "O" rings to transaxle case No. 1 plugs. See Figure. Install plugs into transaxle rear cover.
  3. Coat NEW oil seal ring with ATF and install into transaxle housing. See Figure. Using appropriate adapter and press, install underdrive cylindrical roller bearing into transaxle housing. DO NOT apply excessive pressure to bearing.
  4. Using vernier calipers, measure underdrive brake piston return spring free length with spring mounted to spring seat. Free length should be .553" (14.04 mm). Replace springs as necessary. Install 2 oil seal rings to transaxle case. See Figure.
  5. For needle roller bearing installation, wrap vinyl tape around bearing installer at a position .157" (4.00 mm) above bottom end of installer, until thickness of tape is about .197" (5.00 mm). Using bearing installer and press, install needle roller bearing to transaxle case until wound vinyl tape contacts transaxle case.
    6. NOTE: In the following step, stop press when piston return spring seat is lowered .039-.079" (1.00-2.00 mm) from snap ring groove. This prevents spring seat from becoming deformed. DO NOT expand snap ring excessively.
  6. Coat 2 NEW "O" rings with ATF and install on underdrive brake piston. See Figure. Using hand pressure, install piston into transaxle case. Using appropriate adapter and press, compress underdrive brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force. See Fig 1.
  7. Using appropriate bearing race adapter and press, install counter drive gear bearing outer race into transaxle case. See Fig 2. Press outer race in until race contacts transaxle case. Install snap ring with White marked side facing up. Using appropriate adapter and press, install tapered roller bearing to counter drive gear until bearing contacts gear. DO NOT apply excessive force.
    Fig 1: Installing Underdrive Clutch Snap Ring
    G00182296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Installing Counter Gear Bearing Outer Race
    G00182297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Using appropriate adapter and press, install counter drive gear and bearing into transaxle case. DO NOT apply excessive pressure. See Fig 3. Using vernier calipers, measure 1st and reverse brake piston return spring free length with spring mounted to spring seat. Free length should be .611" (15.53 mm). Replace springs as necessary.
    Fig 3: Installing Counter Drive Gear & Bearing Into Transaxle Case
    G00182298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. NOTE: In the following step, stop press when piston return spring seat is lowered .039-.079" (1.00-2.00 mm) from snap ring groove. This prevents spring seat from becoming deformed. DO NOT expand snap ring excessively.
  9. Coat 2 NEW "O" rings with ATF and install on 1st and reverse brake piston. Using hand pressure, install piston into transaxle case. See Figure. Using appropriate adapter and press, compress 1st and reverse brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
  10. Install front planetary ring gear and snap ring to brake hub. Install front planetary gear to brake hub. Using appropriate adapter and press, install brake hub with front planetary gear into transaxle case. See Fig 4. Install washer on counter drive gear in correct direction. See Fig 5.
  11. Using holding tool, socket and torque wrench with a fulcrum length of 6.30" (160.0 mm), install nut and tighten to 198 ft. lbs. (268 N.m). See Figure. Using socket, adapter and INCH-lb. torque wrench, measure counter drive gear tapered roller bearing starting torque. Starting torque for NEW bearings should be 4.40-8.70 INCH lbs. (.51-1.02 N.m), or 2.30-4.50 INCH lbs. (.26-.51 N.m) for used bearings. See Fig 6. If starting torque is not within specification, gradually tighten nut until starting torque is within specification. Using a hammer and chisel, stake washer to nut.
  12. Install 2 thrust bearings ("F" and "G" in Fig 24), bearing race and input sun gear to front planetary gear. Coat bearing race with ATF and install race to rear planetary gear. Install rear planetary gear into transaxle case. Install snap ring.
    Fig 4: Installing Front Planetary Gear With Brake Hub Into Transaxle Case
    G00011294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 5: Installing Counter Drive Gear Washer
    G00011295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Measuring Counter Drive Gear Bearing Starting Torque
    G00011296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. Install 1st and reverse brake. Install 6 plates and 6 discs, starting with a plate and alternating with a disc. DO NOT install flange. Measure 1st and reverse brake piston stroke. Using vernier calipers, measure distance between disc surface and contact surface of 2nd brake assembly at transaxle case. See Fig 7.
  14. Piston stroke should be .046-.053" (1.16-1.35 mm). Select appropriate flange to ensure piston stroke is within specification. Flanges are marked in numeric order and are available in thicknesses from .071" (1.80 mm), marked with the number "1", to .098" (2.50 mm), marked with the number "8", in increments of .004" (.10 mm). Recheck piston stroke after flange is installed.
    Fig 7: Measuring 1st & Reverse Brake Piston Stroke
    G00011297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Install 2nd brake assembly into transaxle case. Install snap ring and measure inside diameter. Snap ring inside diameter should be more than 6.57" (167.0 mm). Snap ring has a specific tapered installation direction. If inside diameter is not within specification, ensure snap ring is installed in correct direction. If snap ring is installed correctly, replace snap ring.
  16. Install one-way clutch outer sleeve to 2nd brake assembly. Ensure sleeve is positioned correctly. See Fig 8. Install one-way clutch inner race to one-way clutch. Ensure inner race is installed correctly. Check one-way clutch operating direction. One-way clutch should rotate in counterclockwise direction and lock in clockwise direction. See Fig 9.
    Fig 8: Installing Outer Sleeve Into 2nd Brake
    G00182299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 9: Checking One-Way Clutch Rotation
    G00011310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Install one-way clutch and thrust bearing ("H" in Fig 24) into outer sleeve. See Fig 10. Ensure no colored race on thrust bearing is visible upon installation. Coat planetary carrier thrust washer No. 1 with petroleum jelly and install on rear planetary gear. Coat planetary carrier thrust washer No. 2 with petroleum jelly and install on rear planetary sun gear. Coat thrust bearing and race ("I" in Fig 24) with petroleum jelly and install on rear planetary sun gear. Install rear planetary sun gear onto rear planetary gear.
    Fig 10: Installing One-Way Clutch & Thrust Bearing
    G00182300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Install 2nd brake. Install 4 discs and 4 plates, starting with a plate and alternating with a disc. DO NOT install flange at this time. Temporarily install snap ring. Using vernier calipers, measure 2nd brake piston stroke between disc surface and snap ring surface. See Fig 11. Piston stroke should be .024-.036" (.62-.91 mm).
    Fig 11: Measuring 2nd Brake Piston Stroke
    G00011298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Select appropriate flange to ensure piston stroke is within specification. Use the following formula to determine flange thickness: measured distance, minus flange thickness, minus snap ring thickness of .063" (1.60 mm). Flanges are available in thicknesses from .118" (3.00 mm) to .142" (3.60 mm) in increments of .004" (.10 mm), and are marked in numeric order from "1" to "7". Remove snap ring, install appropriate flange and reinstall snap ring. Ensure snap ring end gap is visible through groove in transaxle case.
  20. Install overdrive direct clutch hub to planetary gear. Install bearing race and thrust bearing ("J" in Fig 24) to overdrive direct clutch hub. Install direct clutch and thrust bearing ("K" in Fig 24) onto rear planetary sun gear. See Figure. Ensure discs in direct clutch completely mate with rear planetary sun gear to ensure rear cover can be installed correctly.
  21. Ensure transaxle case and rear cover mating surfaces are clean. Place a straightedge onto direct clutch drum. Using vernier calipers, measure distance between bottom of straightedge and transaxle case (dimension "B"). See Fig 12.
    Fig 12: Measuring Direct Clutch End Play (Dimension "B")
    G00011299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. Using vernier calipers and straightedge, measure dimension "D" of rear cover. See Fig 13. Calculate direct clutch end play by subtracting dimension "B" in Fig 12 from dimension "D". End play should be .010-.036" (.26-.92 mm).
  23. Select a thrust bearing to ensure end play is within specification. Thrust bearings are available in 2 thicknesses of .134" (3.40 mm) with an outside diameter of 2.99" (76.0 mm), and .146" (3.70 mm) with an outside diameter of 3.02" (76.60 mm). Inside diameter of both thrust bearings is 2.20" (55.9 mm). During installation, ensure no colored race side of thrust bearing is facing direct clutch assembly.
    Fig 13: Measuring Direct Clutch End Play (Dimension "D")
    G00182301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Install clamp to brake apply tube prior to installing tube to transaxle case. This will prevent apply tubes from being deformed or damaged. Install clutch apply tube. Install brake apply tube and bolt to transaxle case. Tighten bolt to 48 INCH lbs. (5.4 N.m). Ensure pipes are securely inserted into transaxle case until they reach the pipe stopper on pipe. See Figure. Install 3 governor apply gaskets to transaxle case. See Figure.
  25. Install needle roller bearing onto transaxle rear cover with inscribed mark side of bearing race facing up. Using appropriate adapter and press, install needle roller bearing to transaxle rear cover. Press bearing in to a depth of .809-.837" (20.55-21.25 mm). Coat needle roller bearing with ATF.
  26. Coat 3 oil seal rings with ATF and install on transaxle rear cover. See Figure. Install NEW "O" rings on transaxle case plugs and install plugs into transaxle rear cover. See Figure.
  27. Ensure transaxle case and rear cover surfaces are clean. DO NOT allow oil to contact surfaces. Apply Three Bond (1281) or equivalent gasket sealant to rear cover around inside edges of bolt holes. Install rear cover onto transaxle case. Install 11 bolts to rear cover. Apply thread sealant to 3 bolts at bottom of rear cover and tighten these bolts to 13 ft. lbs. (18 N.m). Tighten all other bolts to 18 ft. lbs. (24 N.m).
  28. Install underdrive brake. Install 4 discs and 4 plates, starting with a plate and alternating with a disc. DO NOT install flange at this time. Temporarily install snap ring. Using a dial indicator, measure underdrive brake piston stroke by applying and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle case. See Figure and Fig 14 .
  29. Piston stroke should be .071-.087" (1.81-2.20 mm). Select appropriate flange to ensure piston stroke is within specification. Flanges are available in 3 thicknesses of .118" (3.00 mm), .126" (3.20 mm) and .134" (3.40 mm), and are marked in numeric order from "1" to "3". Remove snap ring, install appropriate flange and reinstall snap ring.
    Fig 14: Measuring Underdrive Brake Piston Stroke
    G00011301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. Install outer race retainer to one-way clutch, ensuring long finger of retainer is facing up. See Figure. Install underdrive clutch to one-way clutch. Rotate underdrive clutch to ensure correct installation. Underdrive clutch should rotate in a counterclockwise direction, and lock in a clockwise direction. See Fig 15.
    Fig 15: Checking Underdrive Clutch Assembly Rotation
    G00011302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. Install one-way clutch into transaxle case. Note position of index marks on one-way clutch. Ensure marks are facing up. See Fig 16. Install snap ring into transaxle case. Coat thrust bearing and bearing race ("B" in Fig 24) with petroleum jelly and install onto underdrive clutch. Install underdrive clutch into transaxle case.
    Fig 16: Installing One-Way Clutch & Retainer
    G00011303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. Install pawl pin and torsion spring to parking lock pawl. Temporarily install parking lock pawl, shaft and spring to transaxle case. See Figure. Install underdrive planetary gear assembly into transaxle case. Engage all clutch discs and hub splines of planetary gear assembly firmly and securely. Install parking lock pawl shaft. Install pawl shaft clamp and bolt. Tighten bolt to 87 INCH lbs. (9.8 N.m).
  33. Using vernier calipers and a straightedge, measure gap between top of differential drive pinion in underdrive planetary gear, and contact surface of transaxle case. See Fig 17. Record measurement as dimension "D".
  34. Measure dimension No. 1 and dimension No. 2 of transaxle housing in 2 places. See Fig 18. Subtract dimension No. 2 from dimension No. 1. Record measurement as dimension "E". Install bearing race ("E" in Fig 24) onto counter drive gear in correct direction. See Figure.
    Fig 17: Measuring Gap Between Top Of Differential Drive Pinion & Transaxle Case (Dimension "D")
    G00011304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 18: Measuring Distance Between Transaxle Housing Surfaces (Dimensions No. 1 & 2)
    G00011305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. Coat thrust bearing ("E" in Fig 24) with petroleum jelly and install onto multiple disc clutch hub (shaft side). Coat thrust bearing ("D" in Fig 24) with petroleum jelly and install onto multiple disc clutch hub (forward clutch side). Install multiple disc clutch hub into transaxle case.
  36. Install thrust bearing ("C" in Fig 24) onto forward clutch. Ensure no colored race or Blue ink jet race side of thrust bearing is visible. Install forward clutch onto multiple disc clutch hub. See Figure. Align splines of all discs of forward clutch with multiple disc clutch hub.
  37. Install 2 NEW overdrive brake gaskets to transaxle case. See Figure. Install differential assembly. Install thrust bearing underdrive race No. 2 to underdrive planetary gear. See Figure.
  38. Calculate transaxle housing-to-underdrive planetary gear assembly end play using the following formula: subtract dimension "D" from dimension "E", performed in steps  33 and  34 , minus thrust bearing thickness of .098" (2.50 mm), minus thrust bearing underdrive race No. 2 thickness. End play should be .020-.039" (.50-.99 mm).
  39. Select a bearing race to ensure end play is within specification. If dimension "E" minus dimension "D" is less than .301" (7.64 mm), bearing race thickness should be .138" (3.50 mm). If dimension "E" minus dimension "D" is .301" (7.64 mm) or more, bearing race thickness should be .150" (3.80 mm).
  40. Install appropriate bearing race onto underdrive planetary gear assembly to ensure end play is within specification. Bearing race outside diameter is 3.268" (83.00 mm). Bearing race inside diameter is 2.220" (56.40 mm). Install appropriate thrust bearing onto bearing race. Thrust bearing outside diameter is 3.345" (84.96 mm). Thrust bearing inside diameter is 2.252" (57.20 mm). See thrust bearing and race "C" in Fig 24.
  41. Coat oil pump "O" ring with ATF. Install oil pump and 7 bolts. Tighten bolts to 16 ft. lbs. (22 N.m). Ensure transaxle case and transaxle housing surfaces are clean. DO NOT allow oil to contact surfaces. Apply Three Bond (1281) or equivalent gasket sealant about .047" (1.20 mm) wide, to transaxle case around inside edges of bolt holes. Install transaxle housing to transaxle case.
  42. Install 16 transaxle housing bolts. Apply thread sealant to 5 lower bolts ("A" and "D") inside transaxle housing and tighten these bolts within 10 minutes of installation. Tighten bolts "A" and "D" to 16 ft. lbs. (22 N.m). Tighten bolts "B" and "C" to 21 ft. lbs. (29 N.m). Ensure bolts are in correct locations. See TRANSAXLE HOUSING BOLT IDENTIFICATION  table under DIFFERENTIAL ASSEMBLY. See Fig 19.
    Fig 19: Installing Transaxle Housing Bolts
    G00182265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. If preload is not within specification, remove differential assembly from transaxle case and replace shim or plate washer behind transaxle case bearing outer race. See Figure.
  44. Using a dial indicator, measure input shaft end play and ensure measurement is within specification. See Figure. End play should be .010-.049" (.26-1.24 mm).
  45. Place transaxle on 2 blocks of wood, with oil pan surface facing outward. Coat NEW manual valve lever shaft oil seal with ATF. Install oil seal into transaxle case. Install parking lock rod to manual valve lever. Install NEW spacer and manual valve lever shaft into transaxle case. See Figure.
  46. Using a pin punch and hammer, drive in NEW slotted spring pin. Turn spacer and lever shaft to align small hole for locating staking position in spacer with position mark on lever shaft. Using a pin punch and hammer, stake spacer through small hole. Ensure spacer does not turn. See Fig 20.
    Fig 20: Staking Spacer To Manual Valve Lever Shaft
    G00045615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. Using needle nose pliers, install retainer spring. Install parking lock pawl bracket. Install bolts and tighten to 15 ft. lbs. (20 N.m). Install cover, manual detent spring and 2 bolts. Ensure cover and detent spring are installed correctly. See Figure.
  48. Tighten 1.063" (27.00 mm) bottom bolt to 15 ft. lbs. (20 N.m). Tighten .630" (16.00 mm) top bolt to 104 INCH lbs. (11.8 N.m). Coat NEW "O" rings with ATF and install them onto accumulator pistons. Coat 4 springs and 3 accumulator pistons with ATF, and install components into transaxle case holes. See ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS  table for spring specifications and identification.
    ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS

    Application (Color) Free Length - In. (mm) Outer Diameter - In. (mm)
    Reverse Clutch (Yellow) 2.400 (60.96) .555 (14.10)
    Underdrive Brake
    Inner (Purple) 2.441 (62.00) .610 (15.50)
    Outer (Purple) 2.922 (74.23) .854 (21.70)
    Underdrive Clutch (No Color) 2.843 (72.20) .748 (19.00)
  49. Install check ball body and spring. See Figure. Install brake drum gasket to transaxle case. See Figure. Install 2nd brake gasket and governor apply gasket No. 1 to transaxle case. See Figure.
  50. Coat NEW "O" ring with ATF and install on transaxle solenoid connector. Install connector into transaxle case, above park/neutral position switch, and tighten bolt to 48 INCH lbs. (5.4 N.m). Coat ATF temperature sensor "O" ring with ATF. Install sensor, lock plate and bolt. Tighten bolt to 58 INCH lbs. (6.6 N.m). Connect 7 shift solenoid valve connectors. See Figure.
  51. Install valve body assembly. Push valve body assembly against accumulator piston springs and check ball body to assist in installation. See Fig 21. Ensure 17 bolts are installed in correct locations. Install and tighten 2 positioning bolts first. Then install other valve body bolts. For valve body bolt identification, see VALVE BODY BOLT IDENTIFICATION  table.
    VALVE BODY BOLT IDENTIFICATION

    Bolt Application (1) In. (mm)
    A .984 (25.00)
    B 2.244 (57.00)
    C 1.614 (41.00)
    (1) For bolt locations, see Fig 21.
  52. Coat NEW oil strainer gasket with AFT and install on oil strainer. Install oil strainer and 3 bolts to valve body. Tighten bolts to 96 INCH lbs. (10.8 N.m). Install 3 magnets into oil pan in original locations. See Figure. Apply Three Bond (2430) or equivalent to 18 oil pan bolt threads. Install NEW oil pan gasket, oil pan and bolts. Tighten bolts to 69 INCH lbs. (7.8 N.m) within 10 minutes of installation.
    Fig 21: Installing Valve Body Assembly
    G00182302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. Coat NEW "O" rings with ATF and install on case plugs. Install 4 case plugs. Tighten plugs to 65 INCH lbs. (7.4 N.m). Coat NEW "O" rings with ATF and install on speed sensors. Install turbine and counter gear speed sensors into top of transaxle case. Tighten bolts to 100 INCH lbs. (11.3 N.m). Install NEW "O" rings on oil line union and elbow. Install oil line union and elbow into transaxle case. Tighten to 20 ft. lbs. (27 N.m). See Figure.
  54. Install park/neutral position switch onto manual valve lever shaft and temporarily install 2 adjusting bolts. See Figure.
  55. Install NEW nut stopper and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Temporarily install control shaft lever. Turn lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove control shaft lever. Align groove in park/neutral position switch to neutral basic line. Tighten 2 adjusting bolts to 48 INCH lbs. (5.4 N.m). Stake nut stopper onto nut. Install control shaft lever, washer and nut. Tighten nut to 112 INCH lbs. (12.7 N.m).
  56. Install torque converter into transaxle housing while rotating. Ensure converter is properly installed by measuring the following dimensions. Using vernier calipers, measure dimension "A" between transaxle fitting part and converter fitting part of drive plate. See Fig 22. Using vernier calipers and a straightedge, measure dimension "B" as shown in Fig 23. Ensure dimension "B" is greater than dimension "A". Do not add thickness of straightedge. Standard measurement is dimension "A" plus .039" (1.00 mm) or more.
    Fig 22: Measuring Dimension "A" Between Transaxle & Drive Plate
    G00182303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 23: Measuring Dimension "B" Between Torque Converter & Transaxle Housing
    G00182304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 24: Identifying Thrust Bearing & Race Locations
    G00182305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THRUST BEARING & RACE SPECIFICATIONS (1)

    Application Inner Diameter - In. (mm) Outer Diameter - In. (mm)
    A
    Bearing 2.252 (57.20) 3.345 (84.96)
    Rear Race 2.220 (56.40) 3.268 (83.00)
    B
    Bearing 1.485 (37.73) 2.283 (58.00)
    Rear Race 1.177 (29.90) 2.185 (55.50)
    C
    Bearing 1.333 (33.85) 2.055 (52.20)
    D
    Bearing .925 (23.50) 1.732 (44.00)
    E
    Bearing 1.429 (36.30) 2.055 (52.20)
    Rear Race 1.358 (34.50) 1.909 (48.50)
    F
    Front Race 1.587 (40.30) 2.283 (58.00)
    Bearing 1.520 (38.60) 2.362 (60.00)
    G
    Bearing 1.358 (34.50) 2.055 (52.20)
    H
    Bearing 2.110 (53.60) 2.740 (69.60)
    I
    Front Race 1.303 (33.10) 1.787 (45.40)
    Bearing 1.254 (31.85) 1.780 (45.20)
    J
    Bearing .984 (25.00) 1.555 (39.50)
    Rear Race .929 (23.60) 1.441 (36.60)
    K
    Bearing 2.201 (55.90) 2.992 (76.00) Or 3.016 (76.60)
    (1) Refer to illustration for component locations. See Fig 24.
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