Part 2

AUTOMATIC TRANSAXLE UNIT

REASSEMBLY (Continued)

Bearing and race diameter: mm (inch):

30. INSTALL OVERDRIVE DIRECT CLUTCH O-RING
(a) Coat a new O-ring with ATF, and install it to the direct clutch drum.

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

31. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY
(a) Coat the direct clutch drum with ATF, and install it to the intermediate shaft.

NOTICE:
^ Be careful not to damage the O-ring.
^ Be careful not to damage the lip seal of the direct clutch drum.

32. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
(a) Coat the overdrive direct clutch piston with ATF, and install it to the overdrive direct clutch drum subassembly.

NOTICE: Be careful not to damage the lip seal of the direct clutch piston.

33. INSTALL OVERDRIVE CLUTCH RETURN SPRING SUBASSEMBLY
(a) Install the overdrive clutch return spring subassembly to the overdrive direct clutch drum subassembly.

NOTICE: When installing the spring subassembly, ensure that all springs are fitted in the piston correctly.

(b) Coat the clutch balancer with ATF.

(c) Install the clutch balancer to the overdrive direct clutch drum subassembly.

NOTICE:
^ Be careful not to damage the lip seal of the direct clutch balancer.
^ Ensure that the clutch balancer is not pinched and there are no other defects at the sealing lip.
^ Apply enough ATF to the sealing lip prior to installation.

(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to the direct clutch drum.

NOTICE:
^ Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 inch) from the snap ring groove. This prevents the spring seat from being deformed.
^ Do not expand the snap ring excessively.

(f) Position the end gap of the snap ring in the piston as shown in the illustration.

NOTICE: Ensure that the end gap of the snap ring is not aligned with any of the stoppers.

34. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 3 discs with ATF.
(b) Install the 3 plates, 3 discs and flange to the intermediate shaft.

NOTICE: Be careful about the order of the discs, plates and flange.

(c) Using a screwdriver, install the snap ring.

NOTICE: The snap ring should be securely engaged in the groove of the drum.

35. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
(a) Coat the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft.

NOTICE:
^ Install the cushion plate with the mark on the white surface facing the plate.
^ Be careful about the order of discs, plates and flange.

(c) Using a screwdriver, install the snap ring.

NOTICE: The snap ring should be securely engaged in the groove of the drum.

36. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
37. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH

38. INSTALL DIRECT CLUTCH ASSEMBLY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.

NOTICE: 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.

(c) Clean the contact surfaces of the transaxle case and the rear cover.
(d) As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers (Dimension C).

(e) Using vernier calipers and a simple straight edge, measure the dimension shown in the illustration.
(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the specified end play value and install it.
End play: 0.199 to 0.970 mm (0.0078 to 0.0382 inch)

NOTICE: Make sure that the non-colored race side is facing the direct clutch assembly.

HINT: End play = Dimension D - Dimension C

Bearing thickness and diameter: mm (inch):

39. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 3 new No. 1 governor apply gaskets to the transaxle case.

40. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.

NOTICE: 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.

(b) Install the clutch apply tube.

(c) Install the brake apply tube to the transaxle case with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: Each pipe should be securely inserted until it reaches the stopper.

41. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing to the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010, 09951-00360)
Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 inch)

NOTICE:
^ Face the inscribed mark side of the bearing race up.
^ Keep pressing until the specified value is obtained.

(b) Coat the needle roller bearing with ATF.

42. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.

NOTICE: The rear clutch oil seal rings should be securely engaged in the grooves of the drum.

43. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 4 new O-rings to the 4 No. 1 transaxle case plugs.
(b) Install the 4 No. 1 transaxle case plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)

44. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY
(a) Remove any packing material and keep the contact surfaces of the transaxle rear cover and the transaxle case away from oil.
(b) Apply FIPG to the cover.
FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

NOTICE: Apply FIPG in a continuous line (width 1.2 mm (0.047 inch)) along the sealing surface.

(c) Apply liquid sealer to the threads of bolt A.
Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(d) Install the 11 bolts.
Torque:
Bolt A 19 Nm (190 kgf-cm, 14 ft. lbs.)
Other bolts 25 Nm (250 kgf-cm, 18 ft. lbs.)

45. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Coat the 3 discs with ATF.
(b) Install the 3 discs, 3 plates and flange to the transaxle case.

NOTICE: Be careful about the order of discs, plates and flange.

(c) Using a screwdriver, install the snap ring.

NOTICE: The snap ring should be securely engaged in the groove of the drum.

46. INSPECT PACK CLEARANCE OF NO. 2 UNDERDRIVE CLUTCH
47. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY

48. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the one-way clutch.

NOTICE: Securely install the outer race retainer onto the external tooth of the one-way clutch.

(b) Install the one-way clutch to the transaxle case.

NOTICE: Ensure that the outer race retainer and the mark on the transaxle case are aligned.

(c) Using a screwdriver, install the snap ring to the transaxle case.

NOTICE: The snap ring should be securely engaged in the groove of the transaxle case.

49. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with ATF, and install them onto the underdrive clutch.

Bearing and bearing race diameter: mm (inch):

(b) Install the underdrive clutch assembly to the transaxle case.

NOTICE: When installing the underdrive clutch drum subassembly, do not damage the oil seal ring.

50. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock pawl.

(b) Temporarily install the parking lock pawl, pin and spring to the transaxle case as shown in the illustration.

51. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
(a) Install the underdrive planetary gear assembly to the transaxle case.

NOTICE: Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly and securely assemble them.

(b) Install the parking lock pawl shaft.

(d) Using a straight edge 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 case and housing (Dimension E).

NOTICE: Note down dimension E because it is necessary for the following process.

(e) As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the following formula.

NOTICE: Note down dimension F because it is necessary for the following process.

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

52. INSTALL MULTIPLE DISC CLUTCH HUB
(a) Install the No. 1 thrust bearing race to the transaxle case while checking its direction.

Bearing race diameter: mm (inch):

(b) Coat the thrust needle roller bearing and race with ATF, and install them onto the multiple disc clutch hub.

Thrust bearing and race diameter: mm (inch):

(d) Install the needle roller bearing to the multiple disc clutch hub.

Bearing diameter: mm (inch):

(e) Install the multiple disc clutch hub to the transaxle case.

53. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward clutch.

Thrust bearing diameter: mm (inch):

NOTICE: Install the thrust bearing properly so that the temper colored side of the race will be visible.

(c) Install the forward clutch to the forward clutch assembly.

NOTICE:
^ Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely.
^ Be careful not to damage the bush inside the forward clutch hub during installation.

54. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.

55. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assembly to the transaxle case.

56. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
(a) Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly.

57. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula and values of Dimensions E and F that ware 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 it.
End play: 0.198 to 0.693 mm (0.00779 to 0.02728 inch)

HINT: End play = Dimension F - Dimension E - Thrust bearing thickness 2.5 mm (0.0984 inch) - Underdrive thrust bearing race No. 2 thickness.

Race thickness: mm (inch):

Bearing and bearing race diameter: mm (inch):

58. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)

(b) Coat the O-ring of the oil pump with ATF.

NOTICE: Confirm the input shaft rotates smoothly with the manual operation after installing the oil pump.

59. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and keep the contact surfaces of the transaxle case and transaxle housing away from oil.
(b) Apply FIPG to the transaxle case.
FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

(c) Install the transaxle housing to the transaxle case with the 16 bolts.
Torque:
Bolt A 22 Nm (225 kgf-cm, 16 ft. lbs.)
Bolt B 29 Nm (296 kgf-cm, 21 ft. lbs.)
Bolt C 29 Nm (296 kgf-cm, 21 ft. lbs.)

HINT: Apply seal packing or equivalent to bolts A and C.

Seal packing: Toyota Genuine Seal Packing 1344, Three Bond 1344 or Equivalent

Bolt length
Bolt A: 50 mm (1.969 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 42 mm (1.654 inch)

NOTICE: Apply seal packing to new bolts and tighten them within 10 minutes of application.