Automatic Transaxle Unit: Reassembly

BEARING POSITION

Fig 1: Identifying Bearing Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

BEARING SPECIFICATIONS

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)	-

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 And Transaxle Apply Tube Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Transaxle Case No 1 Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  NOTE: Do not apply excessive pressure to the bearing.
  
  Fig 5: Pressing In Underdrive Cylindrical Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Coat the needle roller bearing with ATF.
  
  Fig 7: Wrapping Vinyl Tape Around SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Pressing In Needle-Roller Bearing To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
  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.
  
  Fig 9: Locating O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  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.
    
    Fig 11: View Of SST And Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BREATHER PLUG NO. 2 (ATM)
INSTALL COUNTER DRIVE GEAR BEARING
1. Coat the counterdrive 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
  NOTE:
  - Do not apply excessive pressure to the bearing.
  - Press-fit the bearing outer race until it contacts the transaxle case.
    
    Fig 12: Installing Bearing Outer Race Using SST And Press
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a snap ring expander, install the snap ring.
  NOTE: The white mark side of the snap ring should face upward.
  
  Fig 13: Removing/Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR
1. Coat the couterdrive 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
  Courtesy 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 Using SST And Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  - Apply sufficient ATF to the O-ring prior to assembling.
    
    Fig 16: Locating 2 O-Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 1st And Reverse Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Using SST
  Courtesy 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.
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: View Of Front Planetary Ring Gear, Snap Ring And Brake Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY GEAR ASSEMBLY
1. Install the front planetary gear assembly to the brake hub.
  
  Fig 20: View Of Front Planetary Gear Assembly And Brake Hub
  Courtesy 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: Installing Front Planetary Gear Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install a new washer as shown in Fig 22.
  
  Fig 22: Installing Washer
  Courtesy 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: Removing/Installing Front Planetary Gear Nut
  Courtesy 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.
  SST 09387-00080
  
  Standard:
  
  Turning torque at 60 rpm
  
  Bearing:
  
  New Bearing:
  
  Fig 24: Measuring Turning Torque Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SUN GEAR

Coat the 2 thrust bearings with ATF.

Install the 2 thrust bearings, the bearing race and the input sun gear to the front planetary gear assembly.

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.

Fig 26: Installing Input Sun Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

THRUST BEARING AND BEARING RACE DIAMETER SPECIFICATIONS

	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)

INSTALL REAR PLANETARY GEAR ASSEMBLY
1. Install the rear planetary gear assembly to the rear planetary ring gear.
  
  Fig 27: Identifying Rear Planetary Gear Assembly
  Courtesy 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: Removing/Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Fig 29.
  
  Fig 29: Installing Plates And Discs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).

Select an appropriate flange so that the pack clearance will meet the specified value.

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 SPECIFICATIONS

Mark	Thickness
1	1.8 (0.071)
2	1.9 (0.075)
3	2.0 (0.079)
4	2.1 (0.083)
5	2.2 (0.087)
6	2.3 (0.091)
7	2.4 (0.094)
8	2.5 (0.098)

Fig 30: Measuring (Dimension A)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the flange.

Fig 31: Installing Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL SECOND BRAKE PISTON ASSEMBLY
1. Install the second brake piston assembly to the transaxle case.
  
  Fig 32: Installing Second Brake Piston Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the snap ring and measure the inside diameter.
  Inside diameter:
  
  Greater than 167 mm (6.57 in.)
  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.
    
    Fig 33: Removing/Installing Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 1-WAY CLUTCH ASSEMBLY

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: Identifying 1-Way Clutch Inner Race And 1-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the rotating direction of 1-way clutch for the lock or free operation as shown in Fig 36.

Fig 36: Checking Free Operation Of 1-Way Clutch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.

Bearing diameter: mm (in.)

BEARING DIAMETER SPECIFICATIONS

	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 1-Way Clutch And Thrust Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Identifying Planetary Carrier Thrust Washer No 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

Coat the planetary carrier thrust washer No.2 with yellow petrolatum, and install the washer onto the rear planetary sun gear.

Fig 39: View Of Planetary Carrier Thrust Washer No. 2 And Rear Planetary Sun Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

Bearing diameter: mm (in.)

BEARING DIAMETER SPECIFICATIONS

	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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Identifying Rear Planetary Sun Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 Discs And Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF 2ND BRAKE

Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).

Select an appropriate flange so that the pack clearance will meet the specified value.

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 SPECIFICATIONS

Mark	Thickness
1	3.0 (0.118)
2	3.1 (0.122)
3	3.2 (0.126)
4	3.3 (0.130)
5	3.4 (0.134)
6	3.5 (0.138)
7	3.6 (0.142)
8	-

Fig 43: Measuring Dimension B

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY

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.
Coat the thrust bearing with ATF.

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.

Fig 45: Installing Overdrive Direct Clutch Hub Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bearing and race diameter: mm (in.)

BEARING AND RACE DIAMETER SPECIFICATIONS

	Inside	Outside
Bearing, A	24.7 (0.972)	39.5 (1.555)
Race, B	23.6 (0.929)	38.0 (1.496)

INSTALL DIRECT CLUTCH ASSEMBLY

Coat the thrust bearing with ATF.
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: Identifying Thrust Bearing And Direct Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean the connecting part of the transaxle case and the rear cover.
As shown in Fig 47, 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 Dimension C
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using vernier calipers and a straightedge, measure the dimension shown in Fig 47.

Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing.

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

Fig 48: Measuring Dimension D

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bearing thickness and diameter: mm (in.)

BEARING THICKNESS AND DIAMETER SPECIFICATIONS

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)

INSTALL GOVERNOR APPLY GASKET NO. 1
1. Install 3 new governor apply gaskets No.1 to the transaxle case.
  
  Fig 49: Identifying Governor Apply Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Install the clutch apply tube.
  
  Fig 50: Installing Clamp To Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Brake Apply And Clutch Apply Tubes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
  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.
  
  Fig 52: Installing Needle Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying 3 Rear Clutch Oil Seal Rings At Transaxle Rear Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Transaxle Case No. 1 Plugs At Transaxle Rear Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY
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.
  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.
  
  Fig 55: Applying FIPG To Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  
  19 N*m (190 kgf*cm, 14 ft.*lbf)
  
  Other bolts:
  
  25 N*m (250 kgf*cm, 18 ft.*lbf)
  
  Fig 56: Installing 11 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy 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: Removing/Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE

Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).

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 SPECIFICATIONS

Mark	Thickness
1	3.0 (0.118)
2	3.2 (0.126)
3	3.4 (0.134)
4	3.1 (0.122)
5	3.3 (0.130)
-	-

Temporarily remove the snap ring and attach it to the flange.
Reinstall the snap ring.

Fig 59: Measuring Underdrive Brake Pack Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Checking Underdrive Clutch Assembly Rotation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: View Of 1-Way Clutch Outer Race Retainer
  Courtesy 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: Locating Mark On 1-Way Clutch Outer Race
  Courtesy 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: Removing/Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE CLUTCH ASSEMBLY

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 SPECIFICATIONS

	Inside	Outside
Bearing	37.73 (1.4854)	58.0 (2.2835)
Race	29.9 (1.1772)	55.5 (2.185)

Fig 64: View Of U/D Clutch Assembly, Thrust Bearing And Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the underdrive clutch assembly to the transaxle case.
NOTE: Do not damage the oil seal when installing the underdrive clutch drum sub-assembly.

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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in Fig 66.
  
  Fig 66: Identifying Parking Lock Pawl, Shaft And Spring To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Underdrive Planetary Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the parking lock pawl shaft.
  
  Fig 68: Installing Parking Lock Pawl Shaft
  Courtesy 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: View Of Pawl Shaft Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a straightedge and vernier calipers as shown in Fig 70, 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 Dimension E
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. As shown in Fig 71, 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: Identifying Dimension 1 And 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MULTIPLE DISC CLUTCH HUB

Install the thrust bearing race No.1 to the transaxle case while checking its direction.

Bearing race diameter: mm (in.)

BEARING RACE DIAMETER SPECIFICATIONS

	Inside	Outside
Bearing race	39.5 (1.555)	45.8 (1.803)

Fig 72: Installing Thrust Bearing Race No.1

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 SPECIFICATIONS

	Inside	Outside
Thrust Bearing	36.4 (1.433)	52.2 (2.055)

Coat the needle roller bearing with ATF.

Fig 73: Installing Thrust Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the needle roller bearing to the multiple clutch hub.

Bearing diameter: mm (in.)

BEARING DIAMETER SPECIFICATIONS

	Inside	Outside
Bearing	23.6 (0.929)	44 (1.732)

Install the multiple clutch hub to the transaxle case.

Fig 74: Installing Needle Roller Bearing To Multiple Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FORWARD CLUTCH ASSEMBLY

Coat the thrust needle roller bearing with ATF.

Install the thrust needle roller bearing to the forward clutch.

Thrust bearing diameter: mm (in.)

THRUST BEARING DIAMETER SPECIFICATIONS

	Inside	Outside
Thrust Bearing	33.58 (1.3220)	51.9 (2.043)

NOTE: Install the thrust bearing properly so that the no colored race or blue ink jet race will be visible.

Fig 75: Installing Thrust Needle Roller Bearing

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: View Of Forward Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OVERDRIVE BRAKE GASKET
1. Install 2 new overdrive brake gaskets.
  
  Fig 77: Identifying 2 O/D Brake Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL GEAR ASSEMBLY
1. Install the differential gear assembly to the transaxle case.
  
  Fig 78: View Of Differential Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THRUST BEARING UNDERDRIVE RACE NO. 2
1. Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assembly.
  
  Fig 79: Identifying Thrust Bearing Underdrive Race No. 2, Differential Gear Assembly And Forward Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL THRUST NEEDLE ROLLER BEARING

Coat the thrust needle roller bearing with ATF.

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.

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.

Fig 80: Identifying Thrust Needle Roller Bearing, Differential Gear Assembly And Forward Clutch Assembly

Race thickness: mm (in.)

RACE THICKNESS SPECIFICATIONS

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 SPECIFICATIONS

	Inside	Outside
Bearing	57.2(2.252)	84.96(3.345)
Bearing race	56.4(2.22)	83(3.268)

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: Identifying Oil Pump To Transaxle Case With Bolts
  Courtesy 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: Installing O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Applying FIPG To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transaxle housing and 16 bolts to the transaxle case.
  
  Fig 84: Installing Transaxle Housing With 16 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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)
  
  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.
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX AUTOMATIC TRANSAXLE ASSEMBLY
1. Fix the transaxle assembly.
  
  Fig 86: Fixing Automatic Transaxle Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Manual Valve Lever Shaft Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK ROD SUB-ASSEMBLY
1. Install the parking lock rod to the manual valve lever.
  
  Fig 88: Identifying Parking Lock Rod Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, drive in a new pin.
  
  Fig 90: Removing/Installing Drive Pin
  Courtesy 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.
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: Identifying Manual Valve Lever Shaft Retainer Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
  
  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.
  
  Fig 93: Installing Parking Lock Pawl Bracket With 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
1. Install the manual detent spring and cover with the 2 bolts.
  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)
  
  Fig 94: Identifying Manual Detent Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.)

INSTALL B-3 ACCUMULATOR PISTON

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: Identifying O-Ring And B-3 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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:

ACCUMULATOR SPRING SPECIFICATIONS

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

Fig 96: Installing Piston In To Transaxle Case

INSTALL REVERSE CLUTCH ACCUMULATOR PISTON

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 In To Reverse Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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:

ACCUMULATOR SPRING SPECIFICATIONS

Free length Outer diameter mm (in.)	Color
60.96 (2.3999) / 14.10 (0.555)	Yellow

Fig 98: Installing Piston In To Transaxle Case

INSTALL C-3 ACCUMULATOR PISTON

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: Identifying C-3 Accumulator Piston And O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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:

ACCUMULATOR SPRING SPECIFICATIONS

Free length Outer diameter mm (in.)	Color
72.20 (2.8425) / 19.0 (0.748)	Colorless

Fig 100: Coating Piston With ATF

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: Identifying C3 Accumulator Piston Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: View Of Check Ball, Body And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE DRUM GASKET
1. Coat a new brake drum gasket with ATF, 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 103: Identifying Brake Drum Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating Transaxle Case 2nd Brake Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Governor Apply Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Coating New O-Ring With ATF
  Courtesy 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  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.
    
    Fig 108: Connecting Transmission Wire
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 109: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
  
  Bolt length:
  
  Bolt A:
  
  41 mm (1.614 in.)
  
  Bolt B:
  
  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 Fig 109 first because they are positioning bolts.
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: View Of O-Ring And Oil Strainer
  Courtesy 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
1. Install the 2 magnets to the oil pan.
2. Apply seal packing or equivalent to new 18 bolts.
  Seal packing:
  
  THREE BOND 2430 or equivalent
  
  Fig 112: Installing 2 Magnets To Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  - 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.
    
    Fig 113: Identifying Oil Pan Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating 4 Transaxle Case No.1 Plugs To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Speed Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Elbow And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
INSTALL BREATHER PLUG HOSE
1. Install the breather plug hose to the transaxle case firmly.
  
  Fig 117: Identifying Union And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Park/Neutral Switch Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the control shaft lever.
  
  Fig 119: Installing Control Shaft Lever
  Courtesy 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: Identifying Control Shaft Lever
  Courtesy 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Using a screwdriver, stake the nut with the nut stopper.
  
  Fig 122: Staking Nut With Nut Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Install the control shaft lever, washer and nut.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
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 hole cover sub assembly to the transaxle assembly.
  Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
  
  Fig 123: Identifying Control Shaft Lever, Washer And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002