Automatic Transaxle Unit: Reassembly

BEARING POSITION

Fig 1: Locating Bearing Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard bearing position

BEARING DIAMETER REFERENCE

Mark	Front Race Diameter Inside / Outside	Thrust Bearing Diameter Inside / Outside	Rear Race Diameter Inside / Outside
A	-	57.2 mm (2.252 in.) / 84.96 mm (3.3449 in.)	56.4 mm (2.220 in.) / 83.0 mm (3.268 in.)
B	-	37.73 mm (1.4854 in.) / 58.0 mm (2.283 in.)	29.9 mm (1.177 in.) / 55.5 mm (2.185 in.)
C	-	33.85 mm (1.3327 in.) / 52.2 mm (2.055 in.)	-
D	-	23.5 mm (0.925 in.) / 44.0 mm (1.732 in.)	-
E	-	36.3 mm (1.429 in. ) / 52.2 mm (2.055 in.)	34.5 mm (1.358 in.) / 48.5 mm (1.909 in.)
F	-	34.6 mm (1.362 in.) / 52.2 mm (2.055 in.)	-
G	40.3 mm (1.587 in.) / 58.0 mm (2.283 in.)	38.6 mm (1.520 in.) / 60.0 mm (2.362 in.)	38.6 mm (1.520 in.) / 58.0 mm (2.283 in.)
H	-	53.6 mm (2.110 in.) / 69.6 mm (2.740 in.)	-
I	-	33.8 mm (1.331 in.) / 48.2 mm (1.898 in.)	30.3 mm (1.193 in.) / 46.0 mm (1.811 in.)
J	-	53.6 mm (2.110 in.) / 70.18 mm (2.763 in.) or 69.6 mm (2.740 in.)	-

INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
1. Install the apply tube and clamp to the transaxle housing with the bolt.
  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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
1. Install a new oil seal ring to the transaxle housing.
  
  Fig 3: Installing Underdrive Output Shaft Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
1. Using SST and a press, press in the underdrive cylindrical roller bearing.
  SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 4: Pressing In Underdrive Cylindrical Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
1. Install 2 new oil seal rings to the transaxle.
  
  Fig 5: Installing Underdrive Clutch Drum Oil Seal Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL UNDERDRIVE BRAKE PISTON
1. Wind a vinyl tape around SST at the place 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.)
  SST 09950-60010 (09951-00320)
  
  NOTE: Clean SST to remove deposited oil before winding a vinyl tape.
  
  Fig 6: Installing Underdrive Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the needle-roller bearing to the transaxle until the wound vinyl tape contacts the transaxle case.
  SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
  
  Fig 7: Pressing In Needle-Roller Bearing To Transaxle Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
  
  Fig 8: Installing O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the underdrive brake piston to the transaxle.
  
  Fig 9: Installing Underdrive Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, a snap ring expander and press, press in the piston return spring and snap ring to the transaxle.
  SST 09387-00020
  
  NOTE: Do not apply excessive pressure.
INSTALL NO. 2 BREATHER PLUG

Fig 10: Pressing In Piston Return Spring And Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
1. Using a screwdriver, press in the snap ring to the transaxle.
  
  Fig 11: Pressing In Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COUNTER DRIVE GEAR
1. Using SST and a press, press in the 2 bearings outer races to the transaxle.
  SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
  
  Fig 12: Pressing In Bearings Outer Races
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in the tapered roller bearing to the counter drive gear until the bearing race contacts with the snap ring.
  NOTE: Do not apply excessive pressure.
  
  SST 09649-17010
  
  Fig 13: Pressing In Tapered Roller Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the counter drive gear and bearing to the transaxle.
  SST 09950-70010 (09951-07150), 09950-60020 (09951-00750)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 14: Installing Counter Drive Gear And Bearing To Transaxle
  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-ring to the 1st and reverse brake piston.
  
  Fig 15: Installing O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle.
  
  Fig 16: Installing Reverse Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using SST, a press and snap ring expander, press the piston return spring and snap ring to the transaxle.
  SST 09387-00070
  NOTE:
  - Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deform.
  - Do not expand the snap ring excessively.
    
    Fig 17: Compressing Return Spring Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY RING GEAR
1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
  
  Fig 18: Installing Front Planetary Ring Gear And Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PLANETARY GEAR ASSEMBLY
1. Install the front planetary gear assembly to the brake hub.
  
  Fig 19: Installing Front Planetary Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press-fit the front planetary gear.
  SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)
  
  NOTE: Do not apply excessive pressure.
  
  Fig 20: Pressing-Fit Front Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the washer, as shown in the illustration.
  
  Fig 21: Installing Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, install the nut.
  SST 09387-00030, 09387-00080
  
  Torque: 280 N*m (2,855 kgf*cm, 206 ft.*lbf)
  
  Fig 22: 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 within the specified value, gradually tighten the nut until it reaches the specified value.
  SST 09387-00080
  
  Torque: Turning torque at 60 rpm
  
  0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) for new
  
  0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 27 to 4.4 in.*lbf) for used
  
  Fig 23: Measuring Turning Torque Of Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
6. Using a chisel and hammer, stake the front planetary gear washer.
  
  Fig 24: Staking Front Planetary Gear Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SUN GEAR

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

Standard bearing and race diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	34.6 mm (1.362 in.)	52.2 mm (2.055 in.)
Race	40.3 mm (1.587 in.)	58.0 mm (2.283 in.)
Bearing	38.6 mm (1.52 in.)	60.0 mm (2.362 in.)

Fig 25: Installing Thrust Bearings, Bearing Race And Front Planetary Sun Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY GEAR ASSEMBLY

Coat the bearing race with ATF, and install it to the rear planetary gear assembly.

Standard bearing race diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Race	38.6 mm (1.520 in.)	58.0 mm (2.83 in.)

Fig 26: Installing Rear Planetary Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the No. 2 thrust washer.

Fig 27: Installing No. 2 Thrust Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the rear planetary gear to the rear planetary ring gear.

Fig 28: Installing Rear Planetary Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install the snap ring.

Fig 29: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

Install the 5 plates and 5 discs.
Install in order: P - D - P - D - P - D - P - D - P - D

HINT:

P = Plate

D = Disc

Fig 30: Installing Plates And Discs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).

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

0.745 to 1.21 mm (0.0293 to 0.0476 in.)

HINT:

Piston stroke = Dimension A - Flange thickness

Standard flange thickness

FLANGE THICKNESS REFERENCE

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

Fig 31: Measuring Distance Between Disc Surface And Contact Surface Of 2Nd Brake Cylinder And Transaxle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the flange.

Fig 32: Installing Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2ND BRAKE PISTON ASSEMBLY
1. Install the 2nd brake piston to the transaxle.
2. Install the snap ring and measure the inside diameter.
  Standard inside diameter: More than 167 mm (6.57 in.)
  NOTE:
  - Because the taper snap ring has the positioning direction, check it when installing.
  - When the diameter does not satisfy the specified value, replace the snap ring with a new one.
    
    Fig 33: Installing 2Nd Brake Piston Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1-WAY CLUTCH SLEEVE OUTER
1. Install the 1-way clutch outer sleeve to the 2nd brake cylinder.
  NOTE: Check the positioning direction of the outer sleeve.
  
  Fig 34: Installing 1-Way Clutch Sleeve Outer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 1-WAY CLUTCH ASSEMBLY

Install the inner race to the 1-way clutch.
NOTE: Check the direction of the inner race.

Fig 35: Installing 1-Way Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check the rotating direction of the 1-way clutch for the lock or free operation, as shown in illustration.

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

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

Standard bearing diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	53.6 mm (2.110 in.)	69.6 mm (2.740 in.)

NOTE: Install the thrust bearing properly so that no-colored race will be visible.

Fig 37: Installing Thrust Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

Coat the No. 1 thrust washer with petroleum jelly, and install it onto the rear planetary sun gear.

Fig 38: Installing Rear Planetary Sun Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

Standard bearing diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	33.8 mm (1.331 in)	48.2 mm (1.898 in.)

Fig 39: Installing Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the rear planetary sun gear to the rear planetary gear.

Fig 40: Installing Rear Planetary Sun Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL 2ND BRAKE CLUTCH DISC

Install the 3 discs and 3 plates to the transaxle.
Standard install in order: P - D - P - D - P - D

HINT:

P = Plate

D = Disc
Temporarily install the snap ring.

Fig 41: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a vernier caliper, measure the distance between the disc surface and snap ring surface.

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

Standard pack clearance: 0.50 to 0.91 mm (0.0197 to 0.0358 in.)

HINT:

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

Standard flange thickness

FLANGE THICKNESS REFERENCE

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

Fig 42: Measuring Distance Between Disc Surface And Snap Ring Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
NOTE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

Fig 43: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL DIRECT CLUTCH

Install the bearing race to the direct clutch.

Standard bearing race diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing race	30.3 mm (1.193 in.)	46.0 mm (1.811 in.)

Fig 44: Installing Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the direct clutch and thrust bearing to the rear planetary sun gear.
NOTE: The disc in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

Fig 45: Installing Direct Clutch And Thrust Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Clean the connector part of the transaxle case and rear cover.
As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension B).

Fig 46: Measuring Distance Between Transaxle Case And Straightedge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Measure the 2 places of the rear cover as shown in the illustration. Calculate a dimension C using the following formula.
HINT:

Dimension C = Dimension (1) - Dimension (2)

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

End play: 0.198 to 0.936 mm (0.00780 to 0.03685 in.)

NOTE: Make sure that the colored race side is facing the direct clutch assembly.

HINT:

End play = Dimension C - Dimension B

Fig 47: Calculating End Play Value

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard bearing thickness and diameter

BEARING DIAMETER REFERENCE

Thickness	Inside	Outside
3.58 mm (0.1409 in.)	53.6 mm (2.110 in.)	69.6 mm (2.740 in.)
3.88 mm (0.1528 in.)	53.6 mm (2.110 in.)	70.18 mm (2.768 in.)

INSTALL NO. 1 GOVERNOR APPLY GASKET
1. Install 2 new governor apply gaskets.
  
  Fig 48: Installing Governor Apply Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT CLUTCH APPLY TUBE
1. Install the clamp to the front clutch apply tube.
  NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.
  
  Fig 49: Installing Front Clutch Apply Tube
  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 pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.
  
  Fig 50: Installing Brake Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 apply tubes and to the transaxle with the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  NOTE: Each pipe should be securely inserted until it reaches the stopper.
  
  Fig 51: Installing Apply Tubes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Install 2 new O-rings to the 2 plugs.
2. Install the 2 plugs to the transaxle rear cover.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 52: Installing No. 1 Transaxle Case Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY
1. Using SST and a press, press in the bearing.
  SST 09950-60010 (09951-00230, 09952-06010)
  
  Standard depth: 12.05 to 12.75 mm (0.4744 to 0.5020 in.)
  NOTE:
  - Face the inscribed mark side of the bearing race up.
  - Repeat the press-fit until the specified value is obtained.
2. Apply adhesive to the 2 screws.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
  
  Fig 53: Applying Adhesive
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a T30 "torx" socket wrench, install the transaxle rear cover plate with the 2 screws.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 54: Installing Transaxle Rear Cover Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
  
  Fig 55: Installing Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle.
6. Apply FIPG to the cover.
  Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
7. Coat the needle roller bearing with ATF.
  
  Fig 56: Applying FIPG To Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Apply adhesive to the threads of the bolts labeled A.
  Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
9. Install the 11 bolts.
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A.
  
  25 N*m (255 kgf*cm, 18 ft.*lbf) for other bolt
  
  SST 09950-60010 (09951-00230, 09952-06010)
  
  Fig 57: Installing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

Install the 3 discs and 3 plates to the transaxle.
Install in order: P - D - P - D - P - D

HINT:

D = Disc

P = Plate
Using a screwdriver, install the snap ring.

Fig 58: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard pack clearance: 1.59 to 2.20 mm (0.0626 to 0.0866 in.)

HINT:

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

Standard flange thickness

FLANGE THICKNESS REFERENCE

Mark	Thickness	Mark	Thickness
1	3.0 mm (0.118 in.)	3	3.4 mm (0.134 in.)
2	3.2 (0.126 in.)	-	-

Fig 59: Installing Dial Indicator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily remove the snap ring and attach the flange. Restore the snap ring.

INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY (See INSPECTION )
INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
1. Install the outer race retainer to the 1-way clutch.
  
  Fig 60: Installing Outer Race Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 1-way clutch to the transaxle.
  NOTE: Make sure that the mark on the 1-way clutch outer race is visible.
  
  Fig 61: Installing 1-Way Clutch To Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, install the snap ring to the transaxle.
  
  Fig 62: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE CLUTCH ASSEMBLY

Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.

Standard race diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	37.73 mm (1.4854 in.)	58.0 mm (2.283 in.)
Race	29.9 mm (1.177 in.)	55.5 mm (2.185 in.)

Install the underdrive clutch to the transaxle.

Fig 63: Installing Underdrive Clutch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL UNDERDRIVE PLANETARY GEAR
1. Install the pawl pin and spring to the parking lock pawl.
  
  Fig 64: Installing Pawl Pin And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.
  
  Fig 65: Installing Parking Lock Pawl
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the underdrive planetary gear to the transaxle.
  NOTE: Engage all the discs of underdrive clutch and the hub splines of the underdrive planetary gear firmly and assemble them securely.
  
  Fig 66: Installing Underdrive Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the parking lock pawl shaft.
  
  Fig 67: Installing Parking Lock Pawl Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the pawl shaft clamp with the bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
  
  Fig 68: Installing Pawl Shaft Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).
  NOTE: Make a note of dimension D as it is necessary for the following process.
  
  Fig 69: Measuring Dimension E
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula.
  NOTE: Make a note of dimension E as it is necessary for the following process.
  
  HINT:
  
  Dimension E = Dimension (1) - Dimension (2)
  
  Fig 70: Identifying Dimension 1 And 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MULTIPLE DISC CLUTCH HUB

Install the bearing race to the transaxle while checking its direction.

Standard bearing race diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing race	34.5 mm (1.358 in.)	48.5 mm (1.909 in.)

Fig 71: Installing Multiple Disc Clutch Hub

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the thrust bearing and race with petroleum jelly, and install them onto the multiple disc clutch hub.

Standard thrust bearing and race diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	36.3 mm (1.429 in.)	52.2 mm (2.055 in.)

Fig 72: Installing Thrust Bearing And Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the bearing to the multiple clutch hub.

Standard bearing diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	23.5 mm (0.925 in.)	44.0 mm (1.732 in.)

Install the forward clutch hub to the transaxle.

Fig 73: Installing Forward Clutch Hub
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FORWARD CLUTCH ASSEMBLY

Install the thrust bearing to the forward clutch.

Standard bearing diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	33.85 mm (1.3327 in.)	52.2 mm (2.055 in.)

NOTE: Install the thrust bearing properly so that the race "B" will be visible.

Fig 74: Installing Thrust Bearing

Install the forward clutch to the multiple clutch hub.
NOTE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

Fig 75: Installing Forward Clutch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OVERDRIVE BRAKE GASKET
1. Install 2 new overdrive brake gaskets.
  
  Fig 76: Installing Overdrive Brake Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIFFERENTIAL GEAR ASSEMBLY
1. Install the differential gear to the transaxle.
  
  Fig 77: Installing Differential Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
1. Install the thrust bearing race to the underdrive planetary gear.
  
  Fig 78: Installing Thrust Bearing Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL THRUST NEEDLE ROLLER BEARING

Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing 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 it.

End play: 0.498 to 0.993 mm (0.0196 to 0.0390 in.)

HINT:

End play = Dimension E - Dimension D - thrust bearing thickness 3.28mm (0.1291 in.) - underdrive thrust bearing race thickness.

Standard race thickness

RACE THICKNESS REFERENCE

E - D	Thickness
Less than 7.64 mm (0.3008 in.)	3.5 mm (0.138 in.)
7.64 mm (0.3008 in.)	3.8 m (0.150 in.)

Fig 79: Calculating End Play Value

Standard bearing and bearing race diameter

BEARING DIAMETER REFERENCE

Item	Inside	Outside
Bearing	57.2 mm (2.252 in.)	84.96 mm (3.3449 in.)
Bearing race	56.4 mm (2.220 in.)	83.0 mm (3.268 in.)

INSTALL OIL PUMP ASSEMBLY
1. Install the oil pump to the transaxle with the 7 bolts.
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
  
  Fig 80: Installing Oil Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the O-ring of the oil pump with ATF.
  
  Fig 81: Coating O-Ring Of Oil Pump With ATF
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE HOUSING
1. Remove any packing material and be careful not to get oil on the contacting surface of the transaxle housing.
2. Apply FIPG to the transaxle.
  Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
  
  Fig 82: Applying FIPG
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transaxle housing to the transaxle with the 16 bolts.
  Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A 29 N*m (296 kgf*cm, 21 ft.*lbf) for bolt B and C
  
  HINT:
  
  Each bolt length is indicated below.
  
  Bolt length:
  
  50 mm (1.969 in.) for bolt A
  
  50 mm (1.969 in.) for bolt B
  
  42 mm (1.654 in.) for bolt C
  
  Fig 83: Installing Transaxle Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Because the bolt labeled A are seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.
  
  Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Install 2 new O-rings to the 2 plugs.
2. Install the 2 plugs to the transaxle housing.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
INSPECT INPUT SHAFT END PLAY (See INSPECTION )

Fig 84: Inspecting Input Shaft End Play
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
FIX AUTOMATIC TRANSAXLE ASSEMBLY

Fig 85: Fixing Automatic Transaxle Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
1. Coat a new oil seal with ATF.
2. Install the oil seal to the transaxle.
  
  Fig 86: Installing 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 87: Installing Parking Lock Rod
  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.
  
  Fig 88: Installing Manual Valve Lever Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, tap in a new pin.
  
  Fig 89: Taping In New Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the spacer and lever shaft to align the small hole for locating the staking position mark on the lever shaft.
4. Using a pin punch, stake the spacer through the small hole.
5. Check that the spacer does not turn.
  
  Fig 90: Staking Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
1. Using needle-nose pliers, install the retainer spring.
  
  Fig 91: Installing 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.)
  
  Fig 92: Installing Parking Lock Pawl Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
1. Install the manual detent spring with the 2 bolts.
  NOTE: Make sure to install the manual detent spring and cover in this order.
  
  Torque: 20 N*m (204 kgf*cm, 16 ft.*lbf) for bolt A
  
  12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
  
  HINT:
  
  Each bolt length is indicated below.
  
  27 mm (1.063 in.) for bolt A
  
  16 mm (0.630 in.) for bolt B
  
  Fig 93: Identifying Manual Detent Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL B-3 ACCUMULATOR PISTON

Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.

Fig 94: Installing B-3 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston with ATF, install it to the transaxle.

Standard accumulator spring

SPRING DIAMETER REFERENCE

Spring	Free length Outer diameter	Color
B-3 Inner	60.24 mm (2.3716 in.) 15.9 (0.626 in.)	Yellowish green
B-3 Outer	74.61 mm (2.9374 in.) 21.7 mm (0.854 in.)	Blue

Fig 95: Installing Piston

INSTALL C-1 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF, and install them to the C-1 accumulator piston.

Fig 96: Installing C-1 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston with ATF, and install it to the transaxle.

Standard accumulator spring

SPRING DIAMETER REFERENCE

Spring	Free length Outer diameter	Color
	81.53 mm (3.2098 in.) 18.5 mm (0.728 in.)	Pink

Fig 97: Installing Piston

INSTALL C-3 ACCUMULATOR PISTON

Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.

Fig 98: Installing C-3 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat the piston with ATF, install it to the transaxle case.

Standard accumulator spring

SPRING DIAMETER REFERENCE

Spring	Free length Outer diameter	Color
C - 3	90.49 mm (3.5626 in.) 19.2 mm (0.756 in.)	White

Fig 99: Installing Piston

Install the spring from the C-3 accumulator piston.

Fig 100: Installing Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CHECK BALL BODY
1. Install the check ball body and spring.
  
  Fig 101: Installing Check Ball Body And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE DRUM GASKET
1. Coat a new brake drum gasket with ATF, and install it to the transaxle.
  
  Fig 102: Installing 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.
  
  Fig 103: Installing Transaxle Case 2Nd Brake Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 GOVERNOR APPLY GASKET
1. Coat a new governor apply gasket No. 1 with ATF, and install it to the transaxle.
  
  Fig 104: Installing No. 1 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 transaxle solenoid wire.
  
  Fig 105: Installing Transmission Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the solenoid wire retaining bolt
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 106: Installing Solenoid Wire Retaining Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION VALVE BODY ASSEMBLY
1. Align the groove of the manual valve with the pin of lever.
2. Install the 17 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  NOTE:
  - Push the valve body against the accumulator piston spring and the check ball body to install it.
  - Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.
  HINT:
  
  Each bolt length is indicated below.
  
  Bolt length:
  
  25 mm (0.984 in.) for bolt A
  
  41 mm (1.614 in.) for bolt B
  
  45 mm (1.771 in.) for bolt C
  
  Fig 107: Tightening Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 5 solenoid connectors.
4. Coat the O-ring of the temperature sensor with ATF.
5. Install the ATF temperature sensor with the lock plate and bolt.
  Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
  
  Fig 108: Installing ATF Temperature Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE BODY OIL STRAINER ASSEMBLY
1. Coat a new O-ring with ATF.
2. Install the O-ring to the oil strainer.
  
  Fig 109: Installing O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil strainer with the 3 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 110: Installing Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
1. Install the 3 magnets in the oil pan.
2. Install a new oil pan gasket to the oil pan.
  
  Fig 111: Installing Automatic Transaxle Oil Pan Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil pan to the transaxle with the 18 bolts.
  Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
  
  NOTE: Because the bolts are seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.
  
  Fig 112: Installing Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 TRANSAXLE CASE PLUG
1. Coat 4 new O-rings with ATF, and install them to the 4 plugs.
2. Install the 4 plugs to the transaxle case.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 113: Installing No. 1 Transaxle Case Plug
  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 with the 2 bolts.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  Fig 114: Installing Sensors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER INLET TUBE UNION
1. Coat a new O-ring with ATF, and install it to the union.
2. Install the union to the transaxle.
  Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
  
  Fig 115: Installing Oil Cooler Inlet Tube Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER OUTLET TUBE UNION
1. Coat a new O-ring with ATF, and install it to the union.
2. Install the union to the transaxle.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Install the park/neutral position switch to the manual valve shaft.
2. Temporarily install the 2 bolts.
3. Install a new lock plate and tighten the manual valve shaft nut.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 117: Installing Park/Neutral Position Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install the control shaft lever.
  
  Fig 118: Installing Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
6. Remove the control shaft lever.
  
  Fig 119: Removing Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Align the groove with neutral basic line.
8. Hold the switch in this position and tighten the 2 bolts.
  Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
  
  Fig 120: Testing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using a screwdriver, stake the nut with the lock plate.
  
  Fig 121: Staking Nut With Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the control shaft lever with the washer and nut.
  Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
  
  Fig 122: Installing Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002