Part 4
AUTOMATIC TRANSAXLE UNIT ContinuedCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
21. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
(a) Install the underdrive 1 way clutch assembly to the transaxle case.
22. INSTALL UNDERDRIVE 1 WAY CLUTCH RETAINER
(a) In the place shown in the illustration (the space between the 1 way clutch outer race and case), push the underdrive 1 way clutch retainer in until you hear a "click".
23. INSTALL UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY
(a) Coat the underdrive clutch drum thrust washer with petroleum jelly and install it on to underdrive 1 way clutch assembly.
(b) Align the flukes of discs in the underdrive brake.
(c) Install the underdrive clutch drum sub-assembly.
(d) Turn the underdrive clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clockwise.
(e) Install the assembled bearing and race, with the thrust needle roller bearing facing upward.
Assembled bearing and race:
24. INSPECT HEIGHT OF CLUTCH ASSEMBLY
25. INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH
26. INSTALL UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY
(a) Remove the underdrive planetary sun gear from the counter shaft assembly.
(b) Remove the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race.
(c) Install the underdrive planetary sun gear sub-assembly to the transaxle case.
(d) Coat the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race with petroleum jelly and install it on the transaxle case.
27. INSTALL COUNTER SHAFT ASSEMBLY
(a) Align the flukes of the discs in the underdrive clutch.
(b) Install the needle roller bearing with the bearing facing upward.
Bearing and race:
(c) Install the counter shaft assembly to the transaxle case.
28. INSPECT HEIGHT OF COUNTER SHAFT
29. INSTALL COUNTER DRIVE GEAR BEARING
(a) Install the new counter drive gear bearing to the counter drive gear.
(b) Install the new snap ring to the counter drive gear bearing.
SST 09350-32014 (09351-32120)
30. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, install the counter drive gear.
SST 09350-32014 (09351-32150, 09351-32130)
31. INSTALL INTERMEDIATE SHAFT SUB-ASSEMBLY
(a) Install the intermediate shaft sub-assembly to the transaxle case.
(b) Using SST to hold the counter drive gear, install the new counter drive gear nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 180 Nm (1,835 kgf/cm, 133 ft. lbs.)
32. INSPECT DRIVE GEAR PRELOAD
33. TIGHTEN COUNTER DRIVE GEAR NUT
34. INSTALL COUNTER DRIVEN GEAR
(a) Install the thrust needle roller bearing to the transaxle case.
: Bearing:
(b) Using SST and a press, press in the counter driven gear.
SST 09350-32014 (09351-32100, 09351-32140)
(c) Using SST to hold the counter shaft assembly, tighten a new counter driven gear nut.
SST 09350-32014 (09351-32032)
Torque: 180 Nm (1,835 kgf/cm, 133 ft. lbs.)
35. INSPECT END PLAY OF COUNTER SHAFT
36. TIGHTEN COUNTER DRIVEN GEAR NUT
(a) Using a pin punch and hammer, stake the counter driven gear nut.
37. INSTALL TRANSMISSION CASE COVER REAR
(a) Remove any packing material and be careful not to get oil on the contacting surfaces of the transmission case cover rear or transaxle case.
(b) Apply FIPG sealant to the transmission case cover rear.
FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(c) Install and tighten the 13 bolts.
Torque: 10 Nm (102 kgf/cm, 7 ft. lbs.)
HINT: Each bolt length is indicated in the illustration.
Bolt length:
Bolt A: 25 mm (0.98 in.)
Bolt B: 32 mm (1.26 in.)
38. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY
39. INSTALL 1ST AND REVERSE BRAKE PISTON
(a) Coat the 2 new O-rings with ATF and install 2 new O-rings to the 1st & reverse brake piston.
(b) Place the 1st & reverse brake piston into the bore of the case, facing the spring seats upward.
NOTICE: Be careful not to damage the O-rings.
40. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Install the 1st & reverse brake return spring sub-assembly and snap ring in place.
(b) Place SST on the 1st & reverse brake return spring sub-assembly, and compress the 1st & reverse brake return spring sub-assembly with a press.
SST 09350-32014 (09351-32040)
(c) Using snap ring pliers, install the snap ring.
HINT: Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is aligned with the spring retainer claw.
41. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Install the 1st & reverse brake clutch discs and plates in order.
HINT: 6 plates and 6 discs.
Install in order: D = Disc P = Plate
P - D - P - D - P - D - P - D - P - D - P - D
(b) Install the outer flange with the flat side facing downward.
(c) Using a screwdriver, install the snap ring to the transaxle case.
HINT: Be sure the snap ring end gap is not aligned with one of the cutouts.
42. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
43. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the intermediate shaft sub-assembly.
Bearing and race:
(b) Coat the planetary carrier thrust washer No. 2 with petroleum jelly and install it on to the rear planetary gear assembly.
HINT: Make sure that the different lug shapes match the corresponding openings on the gear.
(c) Align the spline of the rear planetary gear assembly with the flukes of the discs and install the rear planetary gear assembly in to the 1st & reverse brake discs.
(d) Check the part "A" of the rear planetary gear assembly is below the upper surface of the flange.
SST 09350-32014 (09351-32050)
(e) Place the 1 way clutch No. 2 assembly into the case, with the shiny side facing upward.
(f) Install the 1 way clutch No. 2 assembly onto the inner race while turning the rear planetary gear assembly clockwise with SST.
SST 09350-32014 (09351-32050)
(g) Check that the rear planetary gear assembly turns freely clockwise and locks if turned counterclockwise.
(h) Coat the planetary carrier thrust washer No. 2 with petroleum jelly and install it on to the rear planetary gear assembly.
(i) Be sure the end gap of the snap ring is not aligned with one of the cutouts.
44. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the flange with the flat side facing upward.
(b) Install the 3 2nd brake clutch discs and 3 plates in order to the transaxle case.
Install in order:
D = Disc P = Plate
D - P - D - P - D - P
45. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
(a) Install each of the 2nd brake piston return spring sub-assembly over the protrusions in the transaxle case.
46. INSTALL 2ND COAST BRAKE BAND GUIDE PLATE
(a) Install the 2nd coast brake band guide plate and brake band guide plate retainer so that its tip touches the transaxle case.
(b) Install the bolt.
Torque: 5.5 Nm (56 kgf/cm, 49 in. lbs.)
47. INSTALL SECOND BRAKE PISTON ASSEMBLY
(a) Align the groove of the drum with the bolt and place the 2nd brake piston assembly in to the transaxle case.
(b) Place both ends of the snap ring in the groove, and then set the snap ring in to the transaxle case.
(c) While compressing the piston return springs over the drum with hammer handles, install the snap ring.
HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.