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Automatic Transaxle Unit: Reassembly

  1. BEARING POSITION 
    Fig 1: Identifying Bearing Position
    G04088743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THRUST BEARING DIAMETER

    Mark Front Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Race Diameter Inside / Outside mm (in.)
    A - 57.2 (2.252) / 84.96 (3.3449) 56.4 (2.220) / 83.0 (3.268)
    B - 37.73 (1.4854) / 58.0 (2.283) -
    C - 33.85 (1.3327) / 52.2 (2.055) -
    D 24.94 (0.982) 23.5 (0.925) / 44.0(1.732) -
    E - 36.3 (1.429) / 51.93 (2.044) 34.5 (1.358) / 48.35 (1.904)
    F 34.35 (1.352) / 56.57 (2.227) 32.45 (1.278) / 56.48 (2.223) -
    G 40.15 (1.581) / 59.25 (2.333) 38.65 (1.522) / 59.79 (2.354) 38.65 (1.522) / 59.25 (2.332)
    H - 53.6 (2.110) / 69.6 (2.740) -
    I 33.02 (1.3) / 45.8 (1.803) 31.85 (1.254) / 57.3 (2.256) -
    J - 24.79 (0.976) / 39.5 (1.555) 23.6 (0.929) / 37.95 (1.494)
    K - 56.3 (2.216) / 75.96 (2.991) -
  2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Install the differential gear lube apply tube and transaxle apply tube clamp with the bolt to the transaxle housing.

    Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    NOTE: Make sure to insert the pipe to the stopper.
    Fig 2: Installing Differential Gear Lube Apply Tube
    G04088744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSAXLE CASE NO. 1 PLUG 
    1. Install 2 new O-rings to the 2 transaxle case No. 1 plugs.
    2. Install the 2 transaxle case No. 1 plugs to the transaxle rear cover.

    Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

    Fig 3: Installing Transaxle Case No. 1 Plug
    G04088745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Coat a new oil seal ring with ATF and install it to the transaxle housing.
    Fig 4: Installing Underdrive Output Shaft Oil Seal Ring
    G04088746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Coat the underdrive cylindrical roller bearing with ATF.
    2. Using SST and a press, install the underdrive cylindrical roller bearing.

    SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) 

    Fig 5: Installing Underdrive Cylindrical Roller Bearing
    G04088747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not apply excessive pressure to the bearing.
  6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
    NOTE:
    • Do not expand the end gap of the oil seal ring too much.
    • Fix the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.
    Fig 6: Installing Underdrive Clutch Drum Oil Seal Ring
    G04088748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NEEDLE ROLLER BEARING 
    1. Wrap vinyl tape around the SST 4.0 mm (0.157 in.) from the bottom of the SST until the thickness of the tape is about 5.0 mm (0.197 in.).

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: Clean SST to remove deposited oil, before wrapping vinyl tape.
      Fig 7: Wrapping Vinyl Tape Around SST From Bottom Of SST
      G04088749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the needle roller bearing with ATF.
    3. Using SST and a press, install the needle-roller bearing to the transaxle case.

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

    NOTE: When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.
    Fig 8: Installing Needle-Roller Bearing To Transaxle Case
    G04088750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL UNDERDRIVE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
      Fig 9: Coating O-Rings With ATF
      G04088751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
      • Apply sufficient ATF to the O-ring before installing.
    2. Coat the underdrive brake piston with ATF.
    3. Install the underdrive brake piston to the transaxle case.
    NOTE: Be careful not to damage the O-ring.
    Fig 10: Installing Underdrive Brake Piston To Transaxle Case
    G04088752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, install the snap ring to the transaxle case.
    Fig 11: Installing Snap Ring To Transaxle Case
    G04088753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.
    • Do not expand the snap ring excessively.
    • Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.
    • The snap ring should be fully engaged in the groove of the transaxle case.
  10. INSTALL BREATHER PLUG NO. 2 (ATM) 
  11. INSTALL COUNTER DRIVE GEAR BEARING 
    1. Coat the counter drive gear bearing with ATF.
    2. Using SST and a press, install the bearing outer race.

      SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010 

      Fig 12: Installing Bearing Outer Race
      G04088754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive pressure to the bearing.
      • Press-fit the bearing outer race until it contacts the transaxle case.
    3. Using a snap ring expander, install the snap ring.
      NOTE: The white mark side of the snap ring should face upward.
      Fig 13: Installing Snap Ring
      G04088755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COUNTER DRIVE GEAR 
    1. Coat the couter drive gear with ATF.
    2. Using SST and a press, install the tapered roller bearing to the counter drive gear.

      SST 09950-70010 (09951-07150), 09649-17010 

      NOTE: Do not apply excessive pressure to the bearing.
      Fig 14: Installing Tapered Roller Bearing To Counter Drive Gear
      G04088756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the counter drive gear and bearing to the transaxle case.

    SST 09950-70010 (09951-07150), 09223-15030, 09527-17011, 09950-60020 (09951-00750) 

    NOTE: Do not apply excessive pressure to the counter drive gear.
    Fig 15: Installing Counter Drive Gear And Bearing To Transaxle Case
    G04088757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF.
    2. Install the 2 O-rings to the 1st and reverse brake piston.
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
        Fig 16: Coating O-Rings With ATF
        G04088758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Apply sufficient ATF to the O-ring prior to assembling.
    3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.
    NOTE: Be careful not to damage the O-ring.
    Fig 17: Installing O-Rings To 1ST And Reverse Brake Piston
    G04088759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.

      SST 09387-00070 

    2. Using a snap ring expander, install the snap ring to the transaxle case.
    Fig 18: Compressing Return Spring With Press
    G04088760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring seat from being deformed.
    • Do not expand the snap ring excessively.
    • Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.
    • The snap ring should be fully engaged in the groove of the cylinder.
    • Fix the snap ring to the inside of the claw of the spring seat firmly.
  15. INSTALL FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
    NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.
    Fig 19: Installing Front Planetary Ring Gear
    G04088761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the front planetary gear assembly to the brake hub.
      Fig 20: Installing Front Planetary Gear Assembly To Brake Hub
      G04088762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press-fit the front planetary gear assembly.

      SST 09950-60010 (09951-00500), 09950-70010 (09951-07100) 

      NOTE:
      • Do not apply excessive pressure to the planetary gear assembly.
      • Press the inner race of LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no preload should be applied to one pair of tapered roller bearings (left and right).
      Fig 21: Pressing-Fit Front Planetary Gear Assembly
      G04088763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new washer as shown in the illustration.
      Fig 22: Installing Washer
      G04088764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, install the nut.

      SST 09387-00030, 09387-00080 

      Torque: 280 N*m (3,355 kgf*cm, 207 ft.*lbf) 

      NOTE: Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.
      Fig 23: Installing Nut
      G04088765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not as specified, gradually tighten the nut until it reaches the specified value.
      Fig 24: Measuring Turning Torque Of Bearing
      G04088766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09387-00080 

      Standard: 

      Turning torque at 60 rpm 

      Bearing: 

      New Bearing: 

      0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) 

      Used Bearing: 

      0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

    6. Tighten the nut gradually until the specified turning torque of tapered roller bearing is measured.

      Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf) 

    7. Using a chisel and hammer, stake the front lock washer.
    Fig 25: Staking Front Lock Washer
    G04088767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL INPUT SUN GEAR 
    1. Coat the 2 thrust bearings with ATF.
    2. Install the 2 thrust bearings, the bearing race and the input sun gear to the front planetary gear assembly.
    Fig 26: Installing Input Sun Gear
    G04088768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Install the bearing race on the side of the front planetary carrier. Be careful about the direction of the race.
    • Installing thrust bearing and front sun gears, be careful about the direction of the parts.
    • Install the bearing race on the side of the front sun gear. Be careful about the direction of the race.
    • Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.

    Thrust bearing and bearing race diameter: mm (in.) 

    THRUST BEARING AND BEARING RACE DIAMETER

      Inside Outside
    Thrust Bearing, A 32.5 (1.28) 56.5 (2.224)
    Bearing Race, B 40.2 (1.583) 59.3 (2.335)
    Thrust Bearing, C 38.6 (1.520) 59.7 (2.35)
    Bearing Race, D 38.6 (1.520) 59.3 (2.335)
  18. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Install the rear planetary gear assembly to the rear planetary ring gear.
      Fig 27: Installing Rear Planetary Gear Assembly To Rear Planetary Ring Gear
      G04088769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
    NOTE: Confirm that the snap ring is fixed in the groove of the 1st and reverse brake hub correctly.
    Fig 28: Installing Snap Ring
    G04088770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Coat the 6 discs with ATF.
    2. Install the 7 plates and 6 discs.
    NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
    Fig 29: Installing Plates And Discs
    G04088771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE 
    1. Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
    2. Select an appropriate flange so that the pack clearance will meet the specified value.
      Fig 30: Measuring Distance Between Disc Surface And Contact Surface Of 2ND Brake
      G04088772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Pack clearance: 

      1.16 to 1.35 mm (0.0457 to 0.0531 in.) 

      HINT:

      Piston stroke = Dimension A - Flange thickness

      Flange thickness: mm (in.) 

      FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 1.8 (0.071) 5 2.2 (0.087)
      2 1.9 (0.075) 6 2.3 (0.091)
      3 2.0 (0.079) 7 2.4 (0.094)
      4 2.1 (0.083) 8 2.5 (0.098)
    3. Install the flange.
    Fig 31: Installing Flange
    G04088773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL SECOND BRAKE PISTON ASSEMBLY 
    1. Install the second brake piston assembly to the transaxle case.
      Fig 32: Installing Second Brake Piston Assembly To Transaxle Case
      G04088774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the snap ring and measure the inside diameter.

    Inside diameter: 

    Greater than 167 mm (6.57 in.) 

    Fig 33: Installing Snap Ring And Measure Inside Diameter
    G04088775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Make sure that the taper snap ring is installed in the correct direction.
    • When the diameter does not meet the specified value, replace the snap ring with a new one.
    • After installing, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.
  22. INSTALL 1-WAY CLUTCH SLEEVE OUTER 
    1. Install the 1-way clutch sleeve outer to the 2nd brake cylinder assembly.
      NOTE: Make sure that the outer sleeve is installed in the correct direction.
    Fig 34: Installing 1-Way Clutch Sleeve Outer
    G04088776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL 1-WAY CLUTCH ASSEMBLY 
    1. Install the 1-way clutch inner race to the 1-way clutch.
      NOTE:
      • Make sure that the inner race is installed in the correct direction.
      • Confirm that the discrimination mark is visible.
      Fig 35: Installing 1-Way Clutch Inner Race To 1-Way Clutch
      G04088777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the rotating direction of 1-way clutch for the lock or free operation as shown in the illustration.
      Fig 36: Checking Rotating Direction Of 1-Way Clutch For Lock Or Free Operation
      G04088778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER

        Inside Outside
      Bearing 53.6 (2.110) 69.4 (2.732)
      NOTE: Install the thrust bearing properly so that no colored race will be visible.
      Fig 37: Installing Thrust Bearing
      G04088779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL PLANETARY CARRIER THRUST WASHER NO. 1 
    1. Coat the planetary carrier thrust washer No. 1 with yellow petrolatum, and install the washer onto the planetary sun gear assembly.
      NOTE: After installing, confirm that the projection should be fixed firmly in the hole of the planetary sun gear assembly.
      Fig 38: Installing Planetary Carrier Thrust Washer No. 1
      G04088780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Coat the planetary carrier thrust washer No.2 with yellow petrolatum, and install the washer onto the rear planetary sun gear.
      Fig 39: Installing Washer Onto Rear Planetary Sun Gear
      G04088781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER

        Inside Outside
      Race, A 33.0 (1.299) 45.4 (1.787)
      Bearing, B 31.85 (1.254) 45.2 (1.78)
      Fig 40: Installing Bearing Onto Rear Planetary Sun Gear
      G04088782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rear planetary sun gear assembly to the rear planetary gear.
      NOTE: Installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.
      Fig 41: Installing Rear Planetary Sun Gear Assembly To Rear Planetary Gear
      G04088783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL 2ND BRAKE CLUTCH DISC 
    1. Coat the 4 discs with ATF.
    2. Install the 4 discs and 5 plates to the transaxle case.
    3. Temporarily install the snap ring.
    Fig 42: Installing 2Nd Brake Clutch Disc
    G04088784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSPECT PACK CLEARANCE OF 2ND BRAKE 
    1. Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
    2. Select an appropriate flange so that the pack clearance will meet the specified value.
      Fig 43: Inspecting Pack Clearance Of 2Nd Brake
      G04088785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Clearance: 

      0.62 to 0.91 mm (0.0244 to 0.0358 in.) 

      HINT:

      Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

      Flange thickness: mm (in.) 

      FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 3.0 (0.118) 5 3.4 (0.134)
      2 3.1 (0.122) 6 3.5 (0.138)
      3 3.2 (0.126) 7 3.6 (0.142)
      4 3.3 (0.130) 8 -
    3. Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
    NOTE: Secure the snap ring so that the ends visible through the groove of the transaxle case.
    Fig 44: Removing Snap Ring
    G04088786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY 
    1. Install the direct clutch hub to the planetary gear assembly.
      NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation.
    2. Coat the thrust bearing with ATF.
      Fig 45: Installing Overdrive Direct Clutch Hub Subassembly
      G04088787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bearing race and the thrust bearing to the direct clutch hub.
    NOTE: Be careful not to drop the bearing when it is installed.

    Bearing and race diameter: mm (in.) 

    BEARING AND RACE DIAMETER

      Inside Outside
    Bearing, A 24.7 (0.972) 39.5 (1.555)
    Race, B 23.6 (0.929) 38.0 (1.496)
  29. INSTALL DIRECT CLUTCH ASSEMBLY 
    1. Coat the thrust bearing with ATF.
    2. Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.
      NOTE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
      Fig 46: Installing Direct Clutch Assembly And Thrust Bearing To Rear Planetary Sun Gear Assembly
      G04088788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the connecting part of the transaxle case and the rear cover.
    4. As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using vernier calipers (Dimension C).
      Fig 47: Measuring Distance Between The Transaxle Case And Straightedge
      G04088789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using vernier calipers and a straightedge, measure the dimension shown in the illustration.
    6. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing.
    Fig 48: Measuring Dimension
    G04088790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    End play: 

    0.244 to 0.901 mm (0.0096 to 0.0355 in.) 

    NOTE: Make sure that the no-colored race side is facing the direct clutch assembly.

    HINT:

    End play = Dimension D - Dimension C

    Bearing thickness and diameter: mm (in.) 

    BEARING AND RACE DIAMETER

    Thickness Inside Outside
    3.6 (0.1417) 56.3 (2.217) 75.7 (2.980)
    3.8 (0.1496) 56.3 (2.217) 75.7 (2.980)
  30. INSTALL GOVERNOR APPLY GASKET NO. 1 
    1. Install 3 new governor apply gaskets No. 1 to the transaxle case.
    Fig 49: Installing Governor Apply Gasket No. 1
    G04088791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL BRAKE APPLY TUBE 
    1. Install the clamp to the brake apply tube.
      NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.
      Fig 50: Installing Clamp To Brake Apply Tube
      G04088792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clutch apply tube.
    3. Install the brake apply tube and a bolt to the transaxle case.

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    NOTE: The tube should be securely inserted until it reaches the stopper.
    Fig 51: Installing Brake Apply Tube And Bolt To Transaxle Case
    G04088793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL NEEDLE ROLLER BEARING 
    1. Using SST and a press, press the needle roller bearing into the transaxle rear cover.

      SST 09950-60010 (09951-00230, 09952-06010) 

      Press fit depth: 

      20.55 to 21.25 mm (0.8091 to 0.8366 in.) 

      Fig 52: Installing Needle Roller Bearing
      G04088794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • The engraved mark side of the bearing should face upward.
      • Repeat the press fit until the specified value is obtained.
    2. Coat a needle roller bearing with ATF.
  33. INSTALL REAR CLUTCH OIL SEAL RING OUTER 
    1. Coat 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover.
      NOTE: The snap ring should be fully engaged in the groove of the drum.
      Fig 53: Installing Rear Clutch Oil Seal Ring Outer
      G04088795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL TRANSAXLE CASE NO. 1 PLUG 
    1. Coat 4 new O-rings with ATF.
    2. Install the 4 O-rings to the 4 transaxle case No. 1 plugs.
    3. Install the 4 transaxle case No. 1 plugs to the transaxle rear cover.

    Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

    Fig 54: Installing Transaxle Case No. 1 Plug
    G04088796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY 
    1. Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
    2. Apply FIPG to the cover.
      Fig 55: Installing Transaxle Rear Cover Subassembly
      G04088797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent. 

      NOTE: Make sure that the FIPG is applied in a bead (section diameter: 1.2) so that the entire sealing surface will be evenly sealed. The FIPG should also protrude slightly from the flange after the assembly of the parts has been completed.
    3. Apply liquid sealer to the "A" bolt threads.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. 

    4. Install the 11 bolts.

    Torque: Bolt A 

    Fig 56: Installing Bolts
    G04088798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    19 N*m (190 kgf*cm, 14 ft.*lbf) 

    Other bolts: 

    25 N*m (250 kgf*cm, 18 ft.*lbf) 

  36. INSTALL UNDERDRIVE CLUTCH DISC NO.2 
    1. Coat the 4 discs with ATF.
    2. Install the 4 discs, 4 plates and flange to the transaxle case.
      NOTE: Be careful about the order of discs, plate and flange assembly.
      Fig 57: Installing Discs, Plates And Flange To Transaxle Case
      G04088799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
    NOTE: The snap ring should be fully engaged in the groove of the drum.
    Fig 58: Installing Snap Ring
    G04088800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE 
    1. Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi).
      Fig 59: Inspecting Pack Clearance Of Underdrive Brake
      G04088801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Pack clearance: 

      1.81 to 2.20 mm (0.0713 to 0.0866 in.) 

      HINT:

      Select an appropriate flange from the table below so that it will meet the specified value.

      Flange thickness: mm (in.) 

      FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 3.0 (0.118) 4 3.1 (0.122)
      2 3.2 (0.126) 5 3.3 (0.130)
      3 3.4 (0.134) - -
    2. Temporarily remove the snap ring and attach it to the flange.
    3. Reinstall the snap ring.
  38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    1. Install the underdrive clutch assembly to the 1-way clutch.
    2. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.
    Fig 60: Inspecting Underdrive 1-Way Clutch Assembly
    G04088802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    1. Install the outer race retainer to the 1-way clutch.
      NOTE: Fix the outer race retainer to the external tooth of the 1-way clutch firmly.
      Fig 61: Installing Outer Race Retainer To 1-Way Clutch
      G04088803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 1-way clutch to the transaxle case.
      NOTE: Make sure that the mark on the 1-way clutch outer race is visible.
      Fig 62: Installing 1-Way Clutch To Transaxle Case
      G04088804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transaxle case.
    NOTE: The snap ring should be fixed fully engaged in the groove of the transaxle case.
    Fig 63: Installing Snap Ring To Transaxle Case
    G04088805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY 
    1. Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch.

      Bearing and bearing race diameter: mm (in.) 

      BEARING AND BEARING RACE DIAMETER

        Inside Outside
      Bearing 37.73 (1.4854) 58.0 (2.2835)
      Race 29.9 (1.1772) 55.5 (2.185)
      Fig 64: Installing Underdrive Clutch Assembly
      G04088806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the underdrive clutch assembly to the transaxle case.
    NOTE: Do not damage the oil seal when installing the underdrive clutch drum sub-assembly.
  41. INSTALL PARKING LOCK PAWL 
    1. Install the pawl pin and spring to the parking lock pawl.
      Fig 65: Installing Pawl Pin And Spring To Parking Lock Pawl
      G04088807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.
    Fig 66: Installing Parking Lock Pawl, Shaft And Spring To Transaxle Case
    G04088808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Install the underdrive planetary gear assembly to the transaxle case.
      NOTE: Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assembly and install them securely.
      Fig 67: Installing Underdrive Planetary Gear Assembly To Transaxle Case
      G04088809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the parking lock pawl shaft.
      Fig 68: Installing Parking Lock Pawl Shaft
      G04088810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the pawl shaft clamp with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 69: Installing Pawl Shaft Clamp With Bolt
      G04088811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E).
      NOTE: Record dimension E for the following process.
      Fig 70: Measuring Gap Between Top Of Differential Drive Pinion In Underdrive Planetary Gear
      G04088812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below.
      NOTE: Record dimension F for the following process.

      HINT:

      Dimension F = Dimension (1) - Dimension (2)

    Fig 71: Measuring Places Of Transaxle Housing
    G04088813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL MULTIPLE DISC CLUTCH HUB 
    1. Install the thrust bearing race No. 1 to the transaxle case while checking its direction.

      Bearing race diameter: mm (in.) 

      BEARING RACE DIAMETER

        Inside Outside
      Bearing race 39.5 (1.555) 45.8 (1.803)
      Fig 72: Installing Thrust Bearing Race No. 1 To Transaxle Case
      G04088814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the thrust needle roller bearing and race with yellow petrolatum, install them onto the multiple disc clutch hub.

      Thrust bearing and race diameter: mm (in.) 

      THRUST BEARING AND RACE DIAMETER

        Inside Outside
      Thrust Bearing 36.4 (1.433) 52.2 (2.055)
      Fig 73: Installing Thrust Needle Roller Bearing
      G04088815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the needle roller bearing with ATF.
    4. Install the needle roller bearing to the multiple clutch hub.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER

        Inside Outside
      Bearing 23.6 (0.929) 44 (1.732)
    5. Install the multiple clutch hub to the transaxle case.
    Fig 74: Installing Multiple Clutch Hub To Transaxle Case
    G04088816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL FORWARD CLUTCH ASSEMBLY 
    1. Coat the thrust needle roller bearing with ATF.
    2. Install the thrust needle roller bearing to the forward clutch.

      Thrust bearing diameter: mm (in.) 

      THRUST BEARING DIAMETER

        Inside Outside
      Thrust Bearing 33.58 (1.3220) 51.9 (2.043)
      Fig 75: Installing Thrust Needle Roller Bearing To Forward Clutch
      G04088817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the thrust bearing properly so that the no colored race or blue ink jet race will be visible.
    3. Install the forward clutch to the forward clutch assembly.
    NOTE:
    • Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.
    • Be careful not to damage the bushing inside of the forward clutch hub during installation.
    Fig 76: Installing Forward Clutch To Forward Clutch Assembly
    G04088818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL OVERDRIVE BRAKE GASKET 
    1. Install 2 new overdrive brake gaskets.
    Fig 77: Installing Overdrive Brake Gaskets
    G04088819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL DIFFERENTIAL GEAR ASSEMBLY 
    1. Install the differential gear assembly to the transaxle case.
    Fig 78: Installing Differential Gear Assembly To Transaxle Case
    G04088820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL THRUST BEARING UNDERDRIVE RACE NO. 2 
    1. Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assembly.
      Fig 79: Installing Thrust Bearing Underdrive Race No.2
      G04088821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. Coat the thrust needle roller bearing with ATF.
    2. Calculate the end play value using the following formula and values of Dimension E and F that are measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No.2 which satisfies the specified end play value, and install the selected bearing race.
    Fig 80: Installing Thrust Needle Roller Bearing
    G04088822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    End play: 

    0.498 to 0.993 mm (0.01961 to 0.03909 in.) 

    HINT:

    End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 in.) - underdrive thrust bearing race No.2 thickness.

    Race thickness: mm (in.) 

    RACE THICKNESS

    F - E Thickness
    Less than 7.72 (0.3039) 3.5 (0.138)
    7.72 (0.3039) 3.8 (0.150)

    Bearing and bearing race diameter: mm (in.) 

    BEARING AND BEARING RACE DIAMETER

      Inside Outside
    Bearing 57.2 (2.252) 84.96 (3.345)
    Bearing race 56.4 (2.22) 83 (3.268)
  49. INSTALL OIL PUMP ASSEMBLY 
    1. Install the oil pump to the transaxle case with the 7 bolts.

      Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf) 

      Fig 81: Installing Oil Pump Assembly
      G04088823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the O-ring of oil pump with ATF.
    NOTE: Confirm that the input shaft rotates smoothly with the manual operation after installing the oil pump.
    Fig 82: Coating O-Ring Of Oil Pump With ATF
    G04088824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL TRANSAXLE HOUSING 
    1. Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
    2. Apply FIPG to the transaxle case.

      FIPG: 

      Part No. 08826-00090, THREE BOND 1281 or equivalent 

      Fig 83: Installing Transaxle Housing
      G04088825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing and 16 bolts to the transaxle case.

      Torque: Bolt A 

      25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Bolt B 

      33 N*m (337 kgf*cm, 24 ft.*lbf) 

      Bolt C 

      29 N*m (295 kgf*cm, 21 ft.*lbf) 

      Bolt D 

      22 N*m (226 kgf*cm, 16 ft.*lbf) 

      Fig 84: Installing Transaxle Housing
      G04088826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply seal packing or equivalent to bolts A and D.

      Seal packing: 

      THREE BOND 2403 or equivalent 

      Bolt length 

      Bolt A: 

      50 mm (1.969 in.) 

      Bolt B: 

      50 mm (1.969 in.) 

      Bolt C: 

      42 mm (1.654 in.) 

      Bolt D: 

      72 mm (2.835 in.) 

      NOTE: Tighten the bolts within 10 minutes of sealant application.
  51. INSPECT INPUT SHAFT END PLAY 
    1. Using a dial indicator, measure the input shaft end play.

    End play: 

    0.262 to 1.249 mm (0.0100 to 0.0494 in.) 

    Fig 85: Measuring Input Shaft End Play
    G04088827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. FIX AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Fix the transaxle assembly.
    Fig 86: Fixing Transaxle Assembly
    G04088828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Coat a new oil seal with MP grease.
    2. Install the oil seal to the transaxle case.

    SST 09950-60010 (09951-00230), 09950-70010 (09951-07100) 

    Oil seal installation depth: 

    0 +- 0.5 mm (0 +- 0.197 in. ) 

    Fig 87: Installing Oil Seal To Transaxle Case
    G04088829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Install the parking lock rod to the manual valve lever.
    Fig 88: Installing Parking Lock Rod To Manual Valve Lever
    G04088830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Install a new spacer and manual valve lever shaft to the transaxle case.
      NOTE: Do not damage the oil seal when installing the shaft to the transaxle case.
      Fig 89: Installing Spacer And Manual Valve Lever Shaft To Transaxle Case
      G04088831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, drive in a new pin.
      Fig 90: Driving In Pin
      G04088832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
    4. Using a pin punch, stake the spacer through the small hole.
    5. Check that the spacer does not turn.
    Fig 91: Identifying Hole Position
    G04088833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, install the retainer spring.
    NOTE: Hang the spring on the shaft firmly.
    Fig 92: Installing Retainer Spring
    G04088834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL PARKING LOCK PAWL BRACKET 
    1. Install the parking lock pawl bracket with the 2 bolts.

    Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) 

    Bolt length: 

    25 mm (0.984 in.) 

    Fig 93: Installing Parking Lock Pawl Bracket With Bolts
    G04088835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Make sure that the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.
  58. INSTALL MANUAL DETENT SPRING SUBASSEMBLY 
    1. Install the manual detent spring and cover with the 2 bolts.
    Fig 94: Installing Manual Detent Spring And Cover With Bolts
    G04088836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Make sure to install the manual detent spring and cover in this order.

    HINT:

    Tighten bolt A first, and then bolt B.

    Torque: Bolt A 

    20 N*m (205 kgf*cm, 15 ft.*lbf) 

    Bolt B 

    12 N*m (120 kgf*cm, 9 ft.*lbf) 

    Bolt length: 

    Bolt A: 

    27 mm (1.063 in.) 

    Bolt B: 

    16 mm (0.630 in.) 

  59. INSTALL B-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF, install it to the B-3 accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 95: Installing B-3 Accumulator Piston
      G04088837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF, install it to the transaxle case.
    NOTE: Install the springs to each accumulator piston, checking the identification color or each spring. Accumulator spring:
    Fig 96: Installing Springs To Accumulator Piston
    G04088838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    FREE LENGTH OUTER DIAMETER

    Free length Outer diameter mm (in.) Color
    Inner 62.00 (2.4409) / 15.50 (0.610) Purple
    Outer 74.23 (2.9224) / 21.70 (0.854) Purple
  60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON 
    1. Coat 2 new O-rings with ATF, install them to the reverse accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 97: Installing O-Rings To Reverse Accumulator Piston
      G04088839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF, install it to the transaxle case.
    NOTE: Install the springs to each accumulator piston, checking the identification color or each spring. Accumulator spring:
    Fig 98: Installing Springs To Accumulator Piston
    G04088840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    FREE LENGTH OUTER DIAMETER

    Free length Outer diameter mm (in.) Color
    60.96 (2.3999) / 14.10 (0.555) Yellow
  61. INSTALL C-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF, install it to the C-3 accumulator piston.
      NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.
      Fig 99: Installing O-Ring To C-3 Accumulator Piston
      G04088841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF, install it to the transaxle case.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring. Accumulator spring:
      Fig 100: Installing Piston To Transaxle Case
      G04088842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      FREE LENGTH OUTER DIAMETER

      Free length Outer diameter mm (in.) Color
      72.20 (2.8425) / 19.0 (0.748) Colorless
    3. Install the spring to the C-3 accumulator piston.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
      Fig 101: Installing Spring To C-3 Accumulator Piston
      G04088843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CHECK BALL BODY 
    1. Coat the check ball body with ATF.
    2. Install the check ball body and spring.
    NOTE: Be sure to place the spring in the hole in the check ball body. Be careful about the direction of the parts.
    Fig 102: Installing Check Ball Body And Spring
    G04088844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL BRAKE DRUM GASKET 
    1. Coat a new brake drum gasket with ATF, install it to the transaxle case.
      Fig 103: Installing Brake Drum Gasket
      G04088845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
  64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET 
    1. Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
    NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
    Fig 104: Installing Transaxle Case 2Nd Brake Gasket
    G04088846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL GOVERNOR APPLY GASKET NO. 1 
    1. Coat a new governor apply gasket No. 1 with ATF, and install it to the transaxle case.
    NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
    Fig 105: Installing Governor Apply Gasket No. 1
    G04088847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL TRANSMISSION WIRE 
    1. Coat a new O-ring with ATF, and install it to the transmission wire.
      NOTE: Make sure that the O-ring is not twisted, protruded, or pinched when installing the wire transmission to the transaxle case. Apply sufficient ATF to the O-ring before installation.
      Fig 106: Installing O-Ring To Transmission Wire
      G04088848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission wire retaining bolt.

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    Fig 107: Installing Transmission Wire Retaining Bolt
    G04088849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. CONNECT TRANSMISSION WIRE 
    1. Coat an O-ring of the ATF temperature sensor with ATF.
    2. Install the ATF temperature sensor with the lock plate and bolt.
      Fig 108: Installing ATF Temperature Sensor With Lock Plate And Bolt
      G04088850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) 

    3. Connect the 7 solenoid connectors.
    NOTE:
    • Connect the connectors A, B, C, D, E, F, G, in the order from shortest to longest.
    • Apply ATF to the bolt.
  68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts.

    Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

    Bolt length: 

    Bolt A: 

    41 mm (1.614 in.) 

    Bolt B: 

    Fig 109: Installing Valve Body To Transaxle Case With Bolts
    G04088851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    57 mm (2.244 in.) 

    Bolt C: 

    25 mm (0.984 in.) 

    NOTE:
    • Push the valve body against the accumulator piston spring and the check ball body to install the valve body.
    • When installing the valve body to the transaxle case, do not hold the solenoids.
    • Temporarily tighten the bolts marked with (1) in the illustration first because they are positioning bolts.
  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the oil strainer.
      NOTE: Make sure that the O-ring is not twisted or pinched. Apply sufficient ATF to the O-ring before installation.
      Fig 110: Installing O-Ring To Oil Strainer
      G04088852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil strainer and 3 bolts to the valve body.

    Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

    NOTE: Apply ATF to the bolts.
    Fig 111: View Of Oil Strainer And Bolts
    G04089507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY 
    1. Install the 2 magnets to the oil pan.
    2. Apply seal packing or equivalent to new 18 bolts.
      Fig 112: Installing Magnets To Oil Pan
      G04088854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing: 

      THREE BOND 2430 or equivalent 

    3. Install the oil pan and new oil pan gasket to the transaxle case with the 18 bolts.

    Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

    NOTE:
    • Tighten the bolts within 10 minutes of sealant application.
      Fig 113: Identifying Oil Pan Bolts
      G04088494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Completely remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket before installing the oil pan to the case.
  71. INSTALL TRANSAXLE CASE NO. 1 PLUG 
    1. Coat 4 new O-rings with ATF, and install them to the 4 transaxle case No. 1 plugs.
    2. Install the 4 transaxle case No. 1 plugs to the transaxle case.

    Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

    Fig 114: Installing Transaxle Case No. 1 Plug
    G04088856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. INSTALL SPEED SENSOR 
    1. Coat 2 new O-rings with ATF and install them to the 2 sensors.
    2. Install the 2 sensors to the transaxle case with the 2 bolts.

    Torque: 11.0 N*m (115 kgf*cm, 8 ft.*lbf) 

    Fig 115: Installing Sensors To Transaxle Case With Bolts
    G04088857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF, and install it to the elbow.
    2. Install the elbow to the transaxle case.

    Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf) 

    Fig 116: Installing Oil Cooler Tube Union
    G04088858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF, and install it to the union.
    2. Install the union to the transaxle case.
      3. Fig 117: Installing Oil Cooler Tube Union - Inlet Oil Cooler Union
      G04088859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  75. INSTALL BREATHER PLUG HOSE 
    1. Install the breather plug hose to the transaxle case firmly.
  76. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the 2 adjusting bolts.
    2. Install a new nut stopper and nut.

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

      Fig 118: Installing Nut Stopper And Nut
      G04088860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the control shaft lever.
      Fig 119: Installing Control Shaft Lever
      G04088861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
    5. Remove the control shaft lever.
      Fig 120: Removing Control Shaft Lever
      G04088862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Align the groove with the neutral basic line.
    7. Tighten the 2 bolts.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 121: Aligning Groove With Neutral Basic Line
      G04088863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a screwdriver, stake the nut with the nut stopper.
      Fig 122: Staking Nut With Nut Stopper
      G04088864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the control shaft lever, washer and nut.

    Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  77. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
    2. Install the bolt and speedometer driven hoke cover sub assembly to the transaxle assembly.
      Fig 123: Installing Control Shaft Lever, Washer And Nut
      G04088865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

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