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Reassembly [07/2015 - ]: Procedure

  1. BEARING POSITION 
    1. Check each bearing position and installation direction.

      HINT: 

      • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
      • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
        Serial Number Factory
        2########## for TMH Made
        3########## for TMMWV Made
      GTY675420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY669010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY426816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY442527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      FOR TMH MADE:

      Mark Front Race Diameter
      Inside / Outside mm (in.)      		 Thrust Bearing Diameter
      Inside / Outside mm (in.)      		 Rear Race Diameter
      Inside / Outside mm (in.)
      A - 57.7 (2.27) / 75.2 (2.96) -
      B - 29.1 (1.15) / 48.6 (1.91) 30.7 (1.21) / 48.3 (1.90)
      C - 62.6 (2.46) / 82.4 (3.24) 65.9 (2.59) / 80.3 (3.16)
      D 59.4 (2.34) / 77 (3.03) 53.1 (2.09) / 79 (3.11) -
      E - 56.1 (2.21) / 80.9 (3.19) -
      F - 61.2 (2.41) / 79 (3.11) -
      G - 28 (1.10) / 47.1 (1.85) 26.1 (1.03) / 44 (1.73)
      H 52.2 (2.06) / 70.4 (2.77) 48.9 (1.93) / 72.0 (2.83) -
      FOR TMMWV MADE:

      Mark Front Race Diameter
      Inside / Outside mm (in.)      		 Thrust Bearing Diameter
      Inside / Outside mm (in.)      		 Rear Race Diameter
      Inside / Outside mm (in.)
      A - 57.9 (2.28) / 75.2 (2.96) -
      B - 29.3 (1.15) / 48.5 (1.91) 33.1 (1.30) / 48 (1.89)
      C - 62.8 (2.47) / 82.2 (3.24) 66.7 (2.63) / 82.1 (3.23)
      D 59.7 (2.35) / 76.3 (3.00) 53.1 (2.09) / 78.6 (3.09) -
      E - 62.5 (2.46) / 80.8 (3.18) -
      F - 61.4 (2.42) / 78.6 (3.09) -
      G - 28.8 (1.13) / 46.9 (1.85) 26.3 (1.04) / 44.3 (1.74)
      H 51.9 (2.04) / 71.5 (2.81) 49.1 (1.93) / 71.8 (2.83) -
  2. INSTALL COUNTER DRIVE GEAR BEARING 
    NOTE:

    Perform this procedure only when replacement of the counter drive gear bearing or transaxle case is necessary.

    1. Using SST and a press, install a new counter drive gear bearing (outer race) and a new snap ring to the transaxle case.
      GTY111850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        1. 09951-01030
      • SST: 09950-70010 
        1. 09951-07100
  3. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE) 
    1. Using SST and a hammer, install a new front differential case rear tapered roller bearing (outer race) to the transaxle case.
      GTY660647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        1. 09951-00890
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Make sure to install the front differential case rear tapered roller bearing (outer race) so that there is no clearance between the front differential case rear tapered roller bearing (outer race) and transaxle case.

  4. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE) 
    1. Install the shim to the transaxle housing.
    2. Using SST and a hammer, install a new front differential case front tapered roller bearing (outer race) to the transaxle housing.
      GTY252944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60020 
        1. 09951-00890
      • SST: 09950-70010 
        1. 09951-07150
      NOTE:

      Make sure to install the front differential case front tapered roller bearing (outer race) so that there is no clearance between the front differential case front tapered roller bearing (outer race), shim and transaxle housing.

  5. INSTALL FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (INNER RACE) 
    1. Using SST and a press, install a new front differential case rear tapered roller bearing (inner race) to the front differential case.
      GTY475927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09726-36010 
      • SST: 09950-70010 
        1. 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).
      • Make sure to install the front differential case rear tapered roller bearing (inner race) so that there is no clearance between the front differential case rear tapered roller bearing (inner race) and front differential case.
  6. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (INNER RACE) 
    1. Using SST and a press, install a new front differential case front tapered roller bearing (inner race) to the front differential case.
      GTY476867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09710-30012 
        1. 09710-04081
      • SST: 09950-60010 
        1. 09951-00480
      • SST: 09950-70010 
        1. 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).
      • Make sure to install the front differential case front tapered roller bearing (inner race) so that there is no clearance between the front differential case front tapered roller bearing (inner race) and front differential case.
  7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.
    2. Install the front differential case to the transaxle case.
      GTY477609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case with the 20 bolts.
      GTY167719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

      Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf) 

      Bolt (B) 

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

    4. Using SST, turn the front differential case right and left 2 or 3 times to settle the bearings.
      GTY480328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 
    5. Using SST and a torque wrench, measure the turning torque of the differential side bearing while rotating SST at 10 rpm.
      • SST: 09564-33010 

      Turning Torque

      for TMH Made 

      0.8 to 1.4 N*m (8 to 14 kgf*cm, 7 to 12 in.*lbf)

      for TMMWV Made 

      1.1 to 1.9 N*m (11 to 19 kgf*cm, 10 to 17 in.*lbf)

      HINT: 

      • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
      • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
        Serial Number Factory
        2########## for TMH Made
        3########## for TMMWV Made

      If the turning torque is not within the specified range, refer to the table below to select a shim for the front differential case front tapered roller bearing (outer race) so that the turning torque is within the specified range.

      SHIM THICKNESS

      Thickness (mm (in.))
      2.000 (0.0787)
      2.025 (0.0797)
      2.050 (0.0807)
      2.075 (0.0817)
      2.100 (0.0827)
      2.125 (0.0837)
      2.150 (0.0846)
      2.175 (0.0856)
      2.200 (0.0866)
      2.225 (0.0876)
      2.250 (0.0886)
      2.275 (0.0896)
      2.300 (0.0906)
      2.325 (0.0915)
      2.350 (0.0925)
      2.375 (0.0935)
      2.400 (0.0945)
      2.425 (0.0955)
      2.450 (0.0965)
      2.475 (0.0974)
      2.500 (0.0984)
      2.525 (0.0994)
      2.550 (0.100)
      2.575 (0.101)
      2.600 (0.102)
      2.625 (0.103)
      2.650 (0.104)
      2.675 (0.105)
      2.700 (0.106)
      2.725 (0.107)
      2.750 (0.108)
      2.775 (0.109)
      2.800 (0.110)
      2.825 (0.111)
      2.850 (0.112)
      2.875 (0.113)
    6. Remove the 20 bolts and transaxle housing from the transaxle case.
    7. Remove the front differential case from the transaxle case.
  8. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (OUTER RACE) 
    1. Using SST and a hammer, install a new counter driven gear rear tapered roller bearing (outer race) to the transaxle case.
      GTY622684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00650
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

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

  9. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (OUTER RACE) 
    1. Install the shim to the transaxle housing.
      GTY624223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install a new counter driven gear front tapered roller bearing (outer race) to the transaxle housing.
      • SST: 09950-60020 
        1. 09951-00810
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

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

  10. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (INNER RACE) 
    1. Using SST and a press, install a new counter driven gear rear tapered roller bearing (inner race) to the counter driven gear.
      GTY322501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00420
      NOTE:

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

  11. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (INNER RACE) 
    1. Using SST and a press, install a new counter driven gear front tapered roller bearing (inner race) to the counter driven gear.
      GTY323511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00530
      NOTE:

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

  12. ADJUST COUNTER DRIVEN GEAR PRELOAD 
    1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.
    2. Install the counter driven gear to the transaxle case.
      GTY477613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the front differential case to the transaxle case.
      GTY477614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the transaxle housing to the transaxle case with the 20 bolts.
      GTY252393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

      Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf) 

      Bolt (B) 

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

    5. Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm.
      GTY475460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09564-33010 

      Turning Torque

      for TMH Made 

      Differential side bearing preload + 2.2 to 4.1 N*m (22 to 42 kgf*cm, 19 to 36 in.*lbf)

      for TMMWV Made 

      Differential side bearing preload + 3.2 to 5.7 N*m (33 to 58 kgf*cm, 28 to 50 in.*lbf)

      HINT: 

      • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
      • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
        Serial Number Factory
        2########## for TMH Made
        3########## for TMMWV Made

      If the turning torque is not within the specified range, refer to the table below to select a shim for the counter driven gear front tapered roller bearing (outer race) so that the turning torque is within the specified range.

      SHIM THICKNESS: MM (IN.)

      Thickness Thickness Thickness Thickness
      2.000 (0.0787) 2.275 (0.0896) 2.525 (0.0994) 2.775 (0.109)
      2.025 (0.0797) 2.300 (0.0906) 2.550 (0.100) 2.800 (0.110)
      2.050 (0.0807) 2.325 (0.0915) 2.575 (0.101) 2.825 (0.111)
      2.075 (0.0817) 2.350 (0.0925) 2.600 (0.102) 2.850 (0.112)
      2.100 (0.0827) 2.375 (0.0935) 2.625 (0.103) 2.875 (0.113)
      2.125 (0.0837) 2.400 (0.0945) 2.650 (0.104) 2.900 (0.114)
      2.150 (0.0846) 2.425 (0.0955) 2.675 (0.105) 2.925 (0.115)
      2.175 (0.0856) 2.450 (0.0965) 2.700 (0.106) 2.950 (0.116)
      2.200 (0.0866) 2.475 (0.0974) 2.725 (0.107) 2.975 (0.117)
      2.225 (0.0876) 2.500 (0.0984) 2.750 (0.108) 3.000 (0.118)
      2.250 (0.0886) - - -
    6. Remove the 20 bolts and transaxle housing from the transaxle case.
    7. Remove the front differential case from the transaxle case.
    8. Remove the counter driven gear from the transaxle case.
  13. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Coat the lip of a new manual valve lever shaft oil seal with MP grease.
      GTY636510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the manual valve lever shaft oil seal to the transaxle case.
      • SST: 09950-60010 
        1. 09951-00230
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

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

  14. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY 
    1. Install the manual valve lever shaft sub-assembly to the transaxle case.
      GTY452980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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. Using needle-nose pliers, install the manual valve lever shaft retainer spring to the manual valve lever shaft sub-assembly.
      GTY310898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Align the protrusions with the notches on the manual valve lever shaft sub-assembly and install the parking lock rod sub-assembly.
      GTY431459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Install the manual detent spring sub-assembly and cover to the transaxle case with the bolt.
      GTY310896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

      NOTE:

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

  17. INSTALL NO. 3 BRAKE PISTON 
    1. Coat the lip of the No. 3 brake piston with ATF.
      GTY675814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made
      *B for TMMWV Made
    2. Temporarily install the No. 3 brake piston to the transaxle case.
      GTY633925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made
      *B for TMMWV Made
    3. Temporarily install the pawl stopper plate to the transaxle case with the 2 bolts.
      GTY639943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made *B for TMMWV Made
      NOTE:

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

    4. Press the No. 3 brake piston into the transaxle case.
      GTY646970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made *B for TMMWV Made
      *1 Brake Piston Return Spring *2 No. 3 Brake Piston
      *3 Pawl Stopper Plate - -
      NOTE:

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

      HINT: 

      Use the installation surface of the brake piston return spring to press the No. 3 brake piston into the transaxle case.

    5. Install the brake piston return spring to the transaxle case.
      NOTE:

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

    6. Remove the 2 bolts and pawl stopper plate from the transaxle case.
      GTY655121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made
      *B for TMMWV Made
    7. Place SST on the brake piston return spring and compress the brake piston return spring using a press.
      GTY661981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made *B for TMMWV Made
      *1 Snap Ring - -
      • SST: 09387-00070 
      NOTE:

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

    8. Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration.
      NOTE:
      • Confirm that the snap ring is correctly located in the groove of the transaxle case.
      • Be sure to orient the snap ring so that the edges do not protrude into one of the cutouts on the brake piston return spring as shown in the illustration.
  18. INSTALL COUNTER DRIVE GEAR 
    1. Install 2 new counter drive gear bearings (balls and cage) to the counter drive gear bearing (outer race).
    2. Using SST, install the counter drive gear, a new counter drive gear bearing (inner race (front side)) and a new counter drive gear bearing (inner race (rear side)) to the transaxle case.
      GTY633431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-15030 
      • SST: 09527-17011 
      • SST: 09950-60020 
        1. 09951-00810
      • SST: 09950-70010 
        1. 09951-07100
      NOTE:

      There should not be any clearance between the counter drive gear bearing (inner race (front side)) and counter drive gear.

  19. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Using SST and a press, install the front planetary gear assembly to the transaxle case.
      GTY638618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09223-15030 
      • SST: 09527-17011 
      • SST: 09951-01100 
  20. INSTALL NO. 2 BRAKE PISTON 
    1. Coat 2 new O-rings with ATF and install them to the No. 2 brake piston.
      GTY669628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-ring
      NOTE:

      Ensure that the 2 O-rings are not twisted.

    2. Install the No. 2 brake piston to the transaxle case.
      GTY129006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the O-rings.

  21. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Install the 1st and reverse brake return spring sub-assembly to the transaxle case.
    2. Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring sub-assembly using a press.
      GTY647095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 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.

      GTY656210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 orient the snap ring so that the edges do not protrude into one of the cutouts on the transaxle case as shown in the illustration.
  22. INSTALL NO. 2 BRAKE DISC 
    1. Install the 5 No. 2 brake discs, 5 No. 2 brake plates and No. 2 brake flange to the transaxle case.
      GTY543890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc
      NOTE:

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

    2. Using a screwdriver, install the snap ring to the transaxle case.
      GTY112129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Confirm that the snap ring is correctly located in the groove of the transaxle case.
      • Be sure to orient the snap ring so that the edges do not protrude into one of the cutouts on the transaxle case as shown in the illustration.
  23. INSPECT CLEARANCE OF NO. 2 BRAKE PISTON 

    See step  15

  24. INSTALL PLANETARY RING GEAR FLANGE 
    1. Install the planetary ring gear flange to the planetary ring gear.
      GTY310642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 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.

  25. INSTALL PLANETARY RING GEAR 
    1. Install the outer race retainer to the one-way clutch assembly.
      GTY633067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear
    2. Install the planetary ring gear to the one-way clutch assembly.
      NOTE:

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

  26. INSTALL ONE-WAY CLUTCH ASSEMBLY 
    1. Coat the thrust needle roller bearing with ATF and install it to the front planetary gear assembly.
      GTY683594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Transaxle Case
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 56.1 (2.21) 80.9 (3.19)
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 62.5 (2.46) 80.8 (3.18)
      NOTE:

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

    2. Install the one-way clutch assembly with planetary ring gear to the transaxle case.
      NOTE:
      • Make sure that there is no clearance between the outer race retainer and claw on the one-way clutch assembly. If there is any clearance, the spring of the retainer should be deformed.
      • Ensure that there is no clearance between the one-way clutch assembly and transaxle case.
    3. Using a screwdriver, install the snap ring to the transaxle case.
      GTY112127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Confirm that the snap ring is correctly located in the groove of the transaxle case.
      • Be sure to orient the snap ring so that the edges do not protrude into one of the cutouts on the transaxle case as shown in the illustration.
  27. INSTALL PARKING LOCK PAWL 
    1. Install the parking lock pawl to the transaxle case with the parking lock pawl shaft.
      GTY656972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Parking Lock Pawl Shaft
      *2 Parking Lock Pawl
      *3 Spring
      *4 Parking Lock Pawl Pin
    2. Install the parking lock pawl pin to the transaxle case.
    3. Install the spring to the parking lock pawl.
      GTY124085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  28. INSTALL PARKING LOCK SLEEVE 
    1. Install the parking lock sleeve to the transaxle case.
      GTY453149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL PAWL STOPPER PLATE 
    1. Install the pawl stopper plate to the transaxle case with the 2 bolts.
      GTY436399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

  30. INSTALL PAWL SHAFT CLAMP 
    1. Install the pawl shaft clamp to the transaxle case with the bolt.
      GTY453147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

  31. INSTALL COUNTER DRIVEN GEAR 
    1. Install the counter driven gear to the transaxle case.
      GTY597313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL COUNTER DRIVE GEAR NUT 
    1. Turn the manual valve lever shaft sub-assembly 2 notches counterclockwise to set it to the P position as shown in the illustration.
      GTY520573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install a new counter drive gear nut to the front planetary gear assembly.
      GTY481382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00130 

      Torque: 120 N*m (1224 kgf*cm, 89 ft.*lbf) 

    3. Turn the manual valve lever shaft sub-assembly 2 notches clockwise to set it to the N position as shown in the illustration.
      GTY626492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the counter driven gear from the transaxle case.
    5. Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm.
      GTY475839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00130 

      Turning Torque

      0.1 to 0.2 N*m (1 to 2 kgf*cm, 0.9 to 1.8 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)

    6. Using SST and a hammer, stake the front planetary gear assembly.
      GTY474568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09930-00010 
    7. Install the counter driven gear to the transaxle case.
  33. INSTALL FRONT DIFFERENTIAL CASE 
    1. Install the front differential case to the transaxle case.
      GTY253124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL NO. 1 BRAKE PISTON 
    1. Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.
      GTY542618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-ring
      NOTE:

      Ensure that the O-rings are not twisted.

    2. Install the No. 1 brake piston to the front oil pump assembly.
      GTY142676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the O-rings.

  35. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Install the 3 2nd brake piston return spring sub-assemblies to the front oil pump assembly.
      GTY314331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the 3 2nd brake piston return spring sub-assemblies are installed to the protrusions on the front oil pump assembly.

  36. INSTALL NO. 1 BRAKE DISC 
    1. Install the 4 No. 1 brake discs, 4 No. 1 brake plates and No. 1 brake flange to the front oil pump assembly.
      GTY587434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc
      NOTE:
      • Make sure that the No. 1 brake discs, No. 1 brake plates, and No. 1 brake flange are installed in the correct order.
      • Be sure to install the No. 1 brake flange in the correct direction.
    2. Place SST on the No. 1 brake flange and compress the No. 1 brake flange using a press.
      • SST: 09387-00070 
      • SST: 09495-65040 
      NOTE:

      Stop the press when the 2nd brake piston return spring sub-assemblies is flush with the snap ring groove. This prevents the 2nd brake piston return spring sub-assembly from being deformed.

    3. Using a screwdriver, install the snap ring to the front oil pump assembly as shown in the illustration (#1).
      GTY505540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.
      • Make sure to align the protruding part of the snap ring with the cutout (#1) of the front oil pump assembly shown in the illustration to install the snap ring.
    4. Install the brake snap ring stopper to the front oil pump assembly.
      GTY204935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    5. Using a screwdriver, install the snap ring to the front oil pump assembly as shown in the illustration (#2).
      GTY509158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.
      • Make sure to align the protruding part of the snap ring with the cutout (#2) of the front oil pump assembly shown in the illustration to install the snap ring.
    6. Check that the brake snap ring stopper can be turned by hand.
      GTY320189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Snap Ring
      *2 Brake Snap Ring Stopper
      *a Correctly installed
      NOTE:

      If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or a snap ring may not have been completely located in the groove on the front oil pump assembly. Remove and reinstall the snap ring and brake snap ring stopper.

  37. INSPECT CLEARANCE OF NO. 1 BRAKE PISTON 

    See step  16

  38. INSTALL UNDERDRIVE PLANETARY SUN GEAR 
    1. Coat the thrust needle roller bearing with ATF and install it to the front oil pump assembly.
      GTY322761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Thrust Needle Roller Bearing
      *2 Underdrive Planetary Sun Gear
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 57.7 (2.27) 75.2 (2.96)
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 57.9 (2.28) 75.2 (2.96)
      NOTE:

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

    2. Install the underdrive planetary sun gear to the front oil pump assembly.
  39. INSTALL INPUT SHAFT SUB-ASSEMBLY 
    1. Coat 3 new input shaft oil seal rings with ATF and install them to the input shaft sub-assembly.
      GTY323480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring
      *4 Input Shaft Sub-assembly
      NOTE:

      Do not expand the gap of the input shaft oil seal rings excessively.

    2. Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them to the input shaft sub-assembly.
      THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 29.1 (1.15) 48.6 (1.91)
      Thrust needle roller race 30.7 (1.21) 48.3 (1.90)
      THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 29.3 (1.15) 48.5 (1.91)
      Thrust needle roller race 33.1 (1.30) 48 (1.89)
      NOTE:

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

    3. Install the input shaft sub-assembly to the front oil pump assembly.
      GTY312619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. Using a snap ring expander, install the snap ring to the underdrive planetary gear assembly.
      GTY447634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Planetary Sun Gear Sub-assembly
      *2 Underdrive Planetary Gear Assembly
      *3 Snap Ring
    2. Using a snap ring expander, install the planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded.
  41. INSTALL UNDERDRIVE PLANETARY RING GEAR 

    HINT: 

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

    1. Install the snap ring to the underdrive planetary ring gear.
      GTY455763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While compressing the snap ring with a screwdriver, install the underdrive planetary ring gear to the No. 3 brake hub.
      GTY456062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  42. INSTALL NO. 3 BRAKE HUB 
    1. Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them to the underdrive planetary gear assembly.
      GTY618086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 62.6 (2.46) 82.4 (3.24)
      Thrust needle roller race 65.9 (2.59) 80.3 (3.16)
      THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 62.8 (2.47) 82.2 (3.24)
      Thrust needle roller race 66.7 (2.63) 82.1 (3.23)
      NOTE:

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

    2. Install the No. 3 brake hub to the underdrive planetary gear assembly.
      GTY314612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Install the underdrive planetary gear assembly to the front oil pump assembly.
      GTY314589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL NO. 3 BRAKE DISC 
    1. Install the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates to the front oil pump assembly.
      GTY589495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc
      NOTE:

      Make sure that the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are installed in the correct order.

    2. Using a screwdriver, install the snap ring to the front oil pump assembly.
      GTY680780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.
      • Make sure that the snap ring ends are positioned as shown in the illustration (A).
  45. INSPECT CLEARANCE OF NO. 3 BRAKE PISTON 

    See step  17

  46. INSTALL FRONT OIL PUMP BODY O-RING 
    1. Coat a new front oil pump body O-ring with ATF and install it to the front oil pump body sub-assembly.
      GTY432310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the front oil pump body O-ring is installed correctly with the identification line facing outward and check that it is not twisted, protruding or damaged.

  47. INSTALL FRONT OIL PUMP ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the transaxle case.
      GTY617203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Thrust Needle Roller Bearing
      *2 O-ring
    2. Coat the thrust needle roller bearing with ATF.
    3. Install the thrust needle roller bearing to the counter drive gear nut.
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 53.1 (2.09) 79 (3.11)
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 53.1 (2.09) 78.6 (3.09)
      NOTE:

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

    4. Coat the thrust needle roller race with MP grease.
    5. Install the thrust needle roller race to the underdrive planetary gear assembly.
      GTY482524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Thrust Needle Roller Race
      THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller race 59.4 (2.34) 77 (3.03)
      THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller race 59.7 (2.35) 76.3 (3.00)
    6. Coat a new gasket with ATF and install it to the front oil pump assembly.
      GTY595553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Gasket
    7. Install the front oil pump assembly to the transaxle case with the 7 bolts.

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

  48. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Install the differential gear lube apply tube to the transaxle housing.
      GTY574184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insert the differential gear lube apply tube to the transaxle housing until it makes contact with the stopper.

    2. Install the clamp to the differential gear lube apply tube with the bolt.

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

      NOTE:

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

  49. INSTALL TRANSAXLE HOUSING 
    1. Clean and degrease the 3 bolts and installation holes in the transaxle case.
      GTY449999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove any remaining seal packing from the contact surfaces of the transaxle housing and transaxle case.
      NOTE:

      Make sure that there is no ATF on the contact surfaces of the transaxle housing and transaxle case.

    3. Apply FIPG to the transaxle case.
      GTY444244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a FIPG

      FIPG

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      NOTE:

      Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface of the transaxle case.

    4. Install the transaxle housing to the transaxle case with the 17 bolts.
      GTY431650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf) 

    5. Apply adhesive to 2 or 3 threads on the ends of the 3 bolts.
      GTY670871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper sealing of the 3 bolts, apply adhesive to the 3 bolts and install them within 10 minutes of adhesive application.

    6. Install the 3 bolts.
      GTY431648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

  50. INSTALL NO. 1 CLUTCH DISC (for TMH Made) 
    NOTE:

    for TMMWV Made: The direct multiple disc clutch assembly cannot be disassembled.

    HINT: 

    • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
    • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
      Serial Number Factory
      2########## for TMH Made
      3########## for TMMWV Made
    1. Install the No. 1 clutch flange, 4 No. 1 clutch discs and 4 No. 1 clutch plates to the direct multiple disc clutch assembly.
      GTY547513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Clutch Flange
      *2 No. 1 Clutch Plate
      *3 No. 1 Clutch Disc
      NOTE:

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

    2. Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly.
      GTY436426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.

  51. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC 

    See step  18

  52. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY 
    1. for TMH Made:
      1. Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them to the direct multiple disc clutch assembly.
        GTY322574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Thrust Needle Roller Bearing
        *2 Thrust Needle Roller Race
        THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER: MM (IN.)

        - Inside Outside
        Thrust needle roller bearing 28 (1.10) 47.1 (1.85)
        Thrust needle roller race 26.1 (1.03) 44 (1.73)
        NOTE:

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

      2. Install the rear planetary sun gear assembly to the direct multiple disc clutch assembly.
        GTY453152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using a brass bar and a hammer, install the snap ring to the direct multiple disc clutch assembly.
        GTY480357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        Use a piece of cloth to keep the snap ring from flying off.

    2. for TMMWV Made:
      1. Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them to the direct multiple disc clutch assembly.
        GTY312841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Thrust Needle Roller Bearing
        *2 Thrust Needle Roller Race
        THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER: MM (IN.)

        - Inside Outside
        Thrust needle roller bearing 28.8 (1.13) 46.9 (1.85)
        Thrust needle roller race 26.3 (1.04) 44.3 (1.74)
        NOTE:

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

    3. Install the rear planetary sun gear assembly to the direct multiple disc clutch assembly.
      GTY585839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brass bar and a hammer, install the snap ring to the direct multiple disc clutch assembly.
      GTY480356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use a piece of cloth to keep the snap ring from flying off.

  53. INSTALL NO. 2 CLUTCH DISC (for TMH Made) 
    NOTE:

    for TMMWV Made: The direct multiple disc clutch assembly cannot be disassembled.

    HINT: 

    • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
    • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
      Serial Number Factory
      2########## for TMH Made
      3########## for TMMWV Made
    1. Install the No. 2 clutch flange, 3 No. 2 clutch discs and 3 No. 2 clutch plates to the direct multiple disc clutch assembly.
      GTY578875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Clutch Plate
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Flange
      NOTE:

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

  54. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING (for TMH Made) 
    NOTE:

    for TMMWV Made: The direct multiple disc clutch assembly cannot be disassembled.

    HINT: 

    • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
    • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
      Serial Number Factory
      2########## for TMH Made
      3########## for TMMWV Made
    1. Install the No. 2 direct clutch piston to the direct multiple disc clutch assembly.
      GTY111585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to engage the claws on the direct multiple disc clutch assembly to the grooves on the No. 2 direct clutch piston.

    2. Using a screwdriver, install the direct multiple disc clutch snap ring to the direct multiple disc clutch assembly.
      GTY557134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Position the opening of the direct multiple disc clutch snap ring as shown in the illustration.
      • Confirm that the direct multiple disc clutch snap ring is correctly located in the groove of the direct multiple disc clutch assembly.
  55. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC 

    See step  19

  56. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the direct multiple disc clutch assembly.
      GTY627110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made
      *B for TMMWV Made
      *1 Intermediate Shaft Oil Seal
      *2 O-ring
    2. Coat a new intermediate shaft oil seal with ATF and install it to the direct multiple disc clutch assembly.
    3. Coat the thrust needle roller bearing with ATF and install it to the direct multiple disc clutch assembly.
      GTY634979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A for TMH Made *B for TMMWV Made
      *1 Direct Multiple Disc Clutch Assembly *2 Thrust Needle Roller Bearing
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 61.2 (2.41) 79 (3.11)
      THRUST NEEDLE ROLLER BEARING DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 61.4 (2.42) 78.6 (3.09)
    4. Install the direct multiple disc clutch assembly to the transaxle case.
    5. Clean the contact surfaces of the transaxle case and rear transaxle cover sub-assembly.
    6. Place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case and straightedge using a vernier caliper (Dimension (A)).
      GTY613577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Dimension (A)
    7. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (B)).
      GTY618472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Dimension (B)
    8. Calculate the end play value using the following formula:

      End play = Dimension (B) - Dimension (A) - Thrust needle roller bearing thickness

      End Play

      0.007 to 1.113 mm (0.000276 to 0.0438 in.)

  57. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY 
    1. Using SST and a hammer, install a new needle roller bearing to the rear transaxle cover sub-assembly.
      GTY462274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00220
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

      21.5 to 21.9 mm (0.846 to 0.862 in.)

    2. Apply adhesive to the 2 "TORX" screws.
      GTY652466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper installation of the 2 "TORX" screws, apply adhesive to the 2 "TORX" screws and install them within 10 minutes of adhesive application.

    3. Using a T30 "TORX" socket wrench, install the rear transaxle cover plate to the rear transaxle cover sub-assembly with the 2 "TORX" screws.
      GTY605458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

    4. Coat 2 new oil seal rings with ATF and install them to the rear transaxle cover sub-assembly.
      GTY669880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Seal Ring
      NOTE:

      Confirm that the 2 oil seal rings are correctly located in the grooves of the rear transaxle cover sub-assembly.

    5. Coat the thrust needle roller bearing and thrust needle roller race with MP grease and install them to the rear transaxle cover sub-assembly.
      GTY563942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race
      THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMH MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 48.9 (1.93) 72.0 (2.83)
      Thrust needle roller race 52.2 (2.06) 70.4 (2.77)
      THRUST NEEDLE ROLLER BEARING AND THRUST NEEDLE ROLLER RACE DIAMETER (FOR TMMWV MADE): MM (IN.)

      - Inside Outside
      Thrust needle roller bearing 49.1 (1.93) 71.8 (2.83)
      Thrust needle roller race 51.9 (2.04) 71.5 (2.81)
    6. Coat 3 new O-rings with ATF and install them to the transaxle case.
      GTY574117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Ensure that the O-rings are not twisted.

    7. Clean and degrease the 2 bolts and installation holes in the transaxle case.
      GTY449997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove any remaining seal packing from the contact surfaces of the rear transaxle cover sub-assembly and transaxle case.
      NOTE:

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

    9. Apply FIPG to the transaxle case.
      GTY478851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a FIPG

      FIPG

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      NOTE:

      Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface of the transaxle case.

    10. Install the rear transaxle cover sub-assembly to the transaxle case with the 12 bolts.
      GTY608525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) 

    11. Apply adhesive to 2 or 3 threads on the ends of the 2 bolts.
      GTY670870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper installation of the 2 bolts, apply adhesive to the 2 bolts and install them within 10 minutes of adhesive application.

    12. Install the 2 bolts.
      GTY677052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (172 kgf*cm, 12 ft.*lbf) 

    13. Install a new gasket to the refill plug.
      GTY184933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Install the refill plug to the rear transaxle cover sub-assembly.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

    15. Coat 3 new O-rings with ATF and install them to the 3 No. 1 automatic transaxle case plugs.
      GTY435666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    16. Install the 3 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.

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

  58. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY 

    See step  2

  59. INSTALL TRANSAXLE CASE GASKET 
    1. Coat 2 new transaxle case gaskets with ATF and install them to the transaxle case.
      GTY574116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. Coat the O-ring of the transmission wire with ATF.
    2. Insert the pin of the manual valve lever shaft sub-assembly into the groove on the end of the manual valve and install the transmission valve body assembly to the transaxle case with the 11 bolts.
      GTY610045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Manual Valve Lever Shaft Sub-assembly
      *2 Manual Valve
      *a Positioning Bolt

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

      Bolt Length

      Bolt (A) 

      25 mm (0.984 in.)

      Bolt (B) 

      30 mm (1.18 in.)

      Bolt (C) 

      35 mm (1.38 in.)

      Bolt (D) 

      45 mm (1.77 in.)

      Bolt (E) 

      55 mm (2.17 in.)

      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.
      • Be sure to insert the pin of the manual valve lever shaft sub-assembly into the groove on the end of the manual valve.
      • First, temporarily tighten the bolts marked (*a) in the illustration because they are positioning bolts.
  61. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the valve body oil strainer assembly.
      GTY319919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-ring
      NOTE:

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

    2. Install the valve body oil strainer assembly to the transmission valve body assembly with the 2 bolts.
      GTY425039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  62. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Install the 2 transmission oil cleaner magnets to the automatic transaxle oil pan sub-assembly as shown in the illustration.
      GTY584960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transmission Oil Cleaner Magnet
    2. Install a new automatic transaxle oil pan gasket to the automatic transaxle oil pan sub-assembly.
    3. Clean and degrease the bolt and installation hole in the transaxle case.
      GTY449998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the automatic transaxle oil pan sub-assembly with automatic transaxle oil pan gasket to the transaxle case with the 17 bolts.
      GTY435475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 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 automatic transaxle oil pan gasket before installation.

    5. Apply adhesive to 2 or 3 threads on the end of the bolt.
      GTY670870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper installation of the bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

    6. Install the bolt.
      GTY656225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

    7. Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle oil pan sub-assembly.
      GTY427589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 1.7 N*m (17 kgf*cm, 15 in.*lbf) 

    8. Using a 6 mm hexagon socket wrench, install the overflow plug and a new gasket to the automatic transaxle oil pan sub-assembly.
      GTY430587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  63. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new transaxle case oil seal with MP grease.
    2. Using SST and a hammer, install the transaxle case oil seal to the transaxle case.
      GTY630466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09316-10010 
      • SST: 09950-70010 
        1. 09951-07100

      Standard Depth

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

      NOTE:

      Check that the transaxle case oil seal is installed in the correct direction.

  64. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Coat the lip of a new front transaxle case oil seal with MP grease.
      GTY472486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, install the front transaxle case oil seal to the transaxle housing.
      • SST: 09308-14010 

      Standard Depth

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

      NOTE:

      Check that the front transaxle case oil seal is installed in the correct direction.

  65. INSTALL NO. 2 TRANSAXLE CASE PLUG 
    1. Install 3 new gaskets to the 3 No. 2 transaxle case plugs.
    2. Apply adhesive to the 3 No. 2 transaxle case plugs.
      GTY647119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper installation of the 3 No. 2 transaxle case plugs, apply adhesive to the 3 No. 2 transaxle case plugs and install them within 10 minutes of adhesive application.

    3. Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs to the transaxle housing.
      GTY313827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

  66. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Coat 3 new O-rings with ATF and install them to the 3 No. 1 transaxle case plugs.
      GTY321935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3 No. 1 transaxle case plugs to the transaxle case.

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

  67. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF and install it to the oil cooler tube union (inlet oil cooler union).
      GTY431524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil cooler tube union (inlet oil cooler union) to the transaxle case.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

  68. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF and install it to the oil cooler tube union (outlet oil cooler union).
      GTY431525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil cooler tube union (outlet oil cooler union) to the transaxle case.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

  69. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Align the protrusions of the park/neutral position switch assembly.
      GTY363345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Protrusion
    2. Install the park/neutral position switch assembly to the transaxle case with the 2 bolts.
      GTY314595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      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 park/neutral position switch assembly straight along the manual valve lever shaft sub-assembly while being careful not to deform the plate spring that supports the manual valve lever shaft sub-assembly. If the plate spring is deformed, the park/neutral position switch assembly cannot be reinstalled correctly.
      • After installing the park/neutral position switch assembly, confirm that the 2 protrusions on the park/neutral position switch assembly are aligned.
    3. Install the transmission control shaft lever to the manual valve lever shaft sub-assembly with the washer and nut.
      GTY384508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  70. INSTALL BREATHER PLUG HOSE 
    1. Coat a new O-ring with ATF and install it to the No. 2 breather plug (ATM).
    2. Install the No. 1 breather plug (ATM) and No. 2 breather plug (ATM) to the breather plug hose.
      GTY314605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Breather Plug (ATM)
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug (ATM)
      *4 O-ring
    3. Install the breather plug hose to the transaxle case.
      GTY435314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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