Part 3
AUTOMATIC TRANSAXLE UNIT ContinuedCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
13. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE
(a) Using a dial indicator, measure the underdrive brake pack clearance.
Pack clearance: 1.15 to 1.97 mm (0.0453 to 0.0786 in.)
If clearance is non-standard, check the disc.
14. INSPECT UNDERDRIVE CLUTCH DISC NO.2
(a) Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.
HINT:
^ If the lining of the disc is peeling off or discolored, even if a part of the printed numbers are defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.
15. INSPECT HEIGHT OF CLUTCH ASSEMBLY
(a) Using vernier calipers, check the height from the sleeve to the inner race.
Height: 17.3 to 18.2 mm (0.681 to 0.717 in.)
16. INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH
(a) Set a dial indicator and measuring terminal (SST) together.
SST 09350-32014 (09351-32190)
(b) While applying and releasing compressed air (392 to 785 Cps, 4 to 8 kgf/cm2, 57 to 114 psi), measure the underdrive clutch piston stroke.
Piston stroke: 1.5 to 1.9 mm (0.059 to 0.075 in.)
If the piston stroke is less than the limit, parts may have been misassembled. Check them.
If the piston stroke is non-standard, select another flange.
HINT: There are 4 different thickness for the flange.
Flange thickness:
17. INSPECT HEIGHT OF COUNTER SHAFT
(a) Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.
Height: 30.3 to 32.5 mm (1.193 to 1.280 in.)
18. INSPECT DRIVE GEAR PRELOAD
(a) Using a torque wrench, measure the starting torque of the counter drive gear.
Torque:
Starting torque 0.11 to 0.70 Nm (1.1 to 7.1 kgf/cm, 0.9 to 6.1 in. lbs.)
Rotating torque 0.04 to 0.30 Nm (0.4 to 3.0 kgf/cm, 0.3 to 2.6 in. lbs.)
If the torque exceeds the limit, replace the spacer.
19. INSPECT END PLAY OF COUNTER SHAFT
(a) Using a dial indicator, measure the end play of the counter shaft.
End play: 0.2 to 0.9 mm (0.008 to 0.035 in.)
20. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY
(a) Make sure that the intermediate shaft sub-assembly turns smoothly.
21. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
(a) Using a feeler gauge, measure the first & reverse brake pack clearance.
Pack clearance: 1.19 to 2.25 mm (0.0469 to 0.0886 in.)
If the pack clearance is non-standard, parts have been misassembled. Check them.
22. INSPECT 2ND BRAKE PISTON
(a) Using compressed air, check that the 2nd brake piston moves smoothly.
23. INSPECT 2ND BRAKE HUB INSTALLATION DISTANCE
(a) Check the distance between the surface of the 2nd brake hub and rear planetary gear.
Distance: Approximately 5 mm (0.20 in.)
24. INSPECT PISTON STROKE OF 2ND COAST BRAKE
(a) Apply a small amount of paint to the piston rod at the point where it meets the case.
(b) Using SST, measure the piston stroke while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2, 57 to 114 psi).
SST 09240-00020
Piston stroke: 1.5 to 3.0 mm (0.059 to 0.118 in.)
If the piston stroke exceeds the limit, select a new piston rod.
25. INSPECT INPUT SHAFT ASSEMBLY
(a) Measure the thrust play in the axial direction.
Thrust play: 0.3 to 0.9 mm (0.012 to 0.035 in.)
If the play is not as specified, select and replace the race for the end of the input shaft assembly.
HINT: There are 3 different thickness for races, if necessary, select one of them.
Race thickness:
26. INSPECT INPUT SHAFT ENDPLAY
(a) Make sure that the input shaft rotates smoothly.
REASSEMBLY
1. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, install a new front drive pinion rear tapered roller bearing in to the differential case.
SST 09710-30031 (09710-03161)
(b) Place the plate washer onto the transaxle case.
(c) Using SST and a press, press a new front drive pinion rear tapered roller bearing outer race in to the transaxle case.
SST 09350-32014 (09351-32111, 09351-32130)
2. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the speedometer drive gear to the differential case.
(b) Using SST and a press, install the new front drive pinion front tapered roller bearing in to the differential case.
SST 09350-32014 (09351-32090, 09351-32130)
(c) Using SST and a press, press a new front drive pinion front tapered roller bearing outer race in to the transaxle housing.
SST 09350-32014 (09351-32111, 09351-32130)
3. INSTALL TRANSAXLE CASE OIL SEAL
(a) Using SST and a hammer, drive in a new transaxle case oil seal.
SST 09350-32014 (09351-32111, 09351-32130)
(b) Coat the lip of transaxle case oil seal with MP grease.
4. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, drive in a new transaxle housing oil seal.
SST 09350-32014 (09351-32130, 09351-32150)
(b) Coat the lip of transaxle housing oil seal with MP grease.
5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
(a) Using SST and a press, install the underdrive cylindrical roller bearing to the transaxle housing.
SST 09350-32014 (09351-32140)
(b) Install the roller bearing retainer with a new seal washer and the bolt to the transaxle housing.
Torque: 17 Nm (173 kgf/cm, 13 ft. lbs.)
6. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Using a plastic hammer, install the differential gear lube apply tube to the transaxle housing.
NOTICE: Be careful not to bend or damage the tube.
7. INSTALL TRANSMISSION LUBE APPLY TUBE
(a) Using a plastic hammer, install the transmission lube apply tube to the transaxle housing.
NOTICE: Be careful not to bend or damage the tube.
8. INSTALL TRANSAXLE APPLY TUBE CLAMP NO.2
(a) Install the transaxle apply tube clamp No. 2 with the bolt to the transaxle housing.
Torque: 5.5 Nm (56 kgf/cm, 49 in. lbs.)
9. INSTALL TRANSAXLE APPLY TUBE CLAMP NO.1
(a) Install the 2 transaxle apply tube clamps No. 1 with the 2 bolts to the transaxle housing.
Torque: 5.5 Nm (56 kgf/cm, 49 in. lbs.)
10. INSTALL COUNTER DRIVEN GEAR CYLINDRICAL ROLLER BEARING
(a) Using SST and a press, install the counter driven gear cylindrical roller bearing to the transaxle case.
SST 09350-32014 (09351-32090)
11. INSTALL TRANSMISSION CASE PLATE NO.3
(a) Install the transmission case plate No. 3 with the bolt to the transaxle case.
Torque: 10 Nm (102 kgf/cm, 7 ft. lbs.)
12. INSTALL B-4 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF and install them to the B-4 accumulator piston.
(b) Install the B-4 accumulator piston and compression spring to the transaxle case.
(c) Clean the threads of the screws and case with white gasoline.
(d) Install a new transmission case plate No. 2 gasket and transmission case plate No. 2 in place to the transaxle case.
(e) Install and tighten the 2 bolts.
Torque: 10 Nm (102 kgf/cm, 7 ft. lbs.)
(f) Apply adhesive or equivalent to the 7 screws.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(g) Using a "TORX" wrench, install the 7 screws.
Torque: 7.5 Nm (76 kgf/cm, 66 in. lbs.)
13. INSTALL CAM GUIDE SLEEVE
(a) Install the cam guide sleeve to the transaxle case.
14. INSTALL PARKING LOCK SLEEVE
(a) Install the spring guide sleeve with the protruding portion facing up.
15. INSTALL PARKING LOCK PAWL
(a) Place the pawl stopper plate on the protruding portion of the lock sleeve to the transaxle case.
(b) Install the spring guide sleeve and torsion spring with the 2 bolts.
Torque: 13 Nm (130 kgf/cm, 9 ft. lbs.)
(c) Install the parking lock pawl to the transaxle case.
(d) Install the parking lock pawl shaft and pawl shaft clamp with a bolt.
Torque: 5.5 Nm (56 kgf/cm, 49 in. lbs.)
16. INSTALL UNDERDRIVE BRAKE PISTON
(a) Coast 2 new O-rings with ATF and Install the 2 O-rings to the underdrive brake piston.
(b) Place the underdrive brake piston into the case with the cup side up, being careful not to damage the O-rings.
17. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Install the underdrive brake return spring sub-assembly to the transaxle case.
18. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Install the 3 plates, 3 underdrive clutch discs No. 2 and flange in order.
Install in order:
D = Disc P = Plate F = Flange
P - D - P - D - P - D - F
HINT: Install the flange with the flat side facing downward.
(b) Place SST on the flange, and compress the flange with a press.
SST 09350-32014 (09351-32070)
(c) Using a screwdriver, install the underdrive clutch flange No. 2 hole snap ring to the transaxle case.
HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.
19. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE
20. INSTALL OVERDRIVE CLUTCH DRUM OIL SEAL RING
(a) Coat 2 new overdrive clutch drum oil seal rings with ATF and install the 2 overdrive clutch drum oil seal rings to the transaxle case.