Part 5

AUTOMATIC TRANSAXLE UNIT Continued

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

48. INSPECT 2ND BRAKE PISTON

49. INSTALL 1 WAY CLUTCH ASSEMBLY
(a) Using a screwdriver, align the flukes of the discs in the 2nd brake.

(b) Align the spline of the 1 way clutch assembly with the flukes of the discs and install the 1 way clutch assembly to the 2nd brake discs.

50. INSPECT 2ND BRAKE HUB INSTALLATION DISTANCE

51. INSTALL SUN GEAR INPUT DRUM ASSEMBLY
(a) Coat the planetary carrier thrust washer No. 3 with petroleum jelly and install it on the planetary sun gear sub-assembly.

(b) By turning the planetary sun gear sub-assembly clockwise, install it in to the 1 way clutch assembly.

52. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Coat the thrust needle roller bearing with petroleum jelly and install it on to the front planetary gear assembly.

Bearing:

(b) Install the front planetary gear assembly.

53. INSTALL FRONT PLANETARY RING GEAR
(a) Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them onto the front planetary gear assembly.

Bearing and race:

(b) Install the front planetary ring gear to the transaxle case.

HINT: If the front planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.

(c) Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the tip of ring gear flange.

Bearing and race:

54. INSTALL 2ND COAST BRAKE BAND ASSEMBLY
(a) Place the 2nd coast brake band assembly in to the transaxle case.
(b) Install the pin to the transaxle case.

55. INSTALL INPUT SHAFT ASSEMBLY
(a) Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch assembly.

Assembled bearing and race:

(b) Coat the clutch drum thrust washer with petroleum jelly and install it onto the direct clutch drum with the oil groove facing upward.

(d) Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.

HINT: If the flukes of the discs are meshed correctly, the end of the bushing with the direct clutch will be flush with the surfaces of the forward clutch.

(e) Place the direct clutch assembly and forward clutch assembly in to the transaxle case.
(f) While rotating the forward clutch assembly to mesh the front planetary ring gear and discs, install them.

(g) Check the distance between A and B.
Distance: Approximately 3 mm (0.118 in.)

56. INSTALL 2ND COAST BRAKE PISTON
(a) Coat the 2 new O-rings with ATF and install the 2 O-rings to the 2nd coast brake cover.

(b) Install the compression spring, 2nd coast brake piston and 2nd coast brake cover in to the bore.

58. INSTALL GOVERNOR PRESSURE TUBE
(a) Using a plastic hammer, install the governor pressure tube to the transaxle case.

NOTICE: Be careful not to bend or damage the tube.

59. INSTALL TRANSAXLE APPLY TUBE CLAMP NO.3
(a) Install the transaxle apply tube clamp No. 3 with the bolt.
Torque: 5.5 Nm (56 kgf/cm, 49 in. lbs.)

60. INSTALL OIL PUMP ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the oil pump assembly.

(b) Place the oil pump assembly through the input shaft, and align the bolt holes of the pump body with those of the transaxle case.
(c) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the input shaft through the direct clutch drum.

NOTICE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.

(d) Install the 6 bolts.
Torque: 25 Nm (255 kgf/cm, 18 ft. lbs.)

61. INSPECT INPUT SHAFT ASSEMBLY
62. INSPECT INPUT SHAFT ENDPLAY

63. INSTALL GOVERNOR APPLY GASKET NO.2
(a) Install the governor apply gasket No. 2 to the transaxle case.

64. INSTALL TRANSMISSION CASE PLATE NO.1
(a) Install the transmission case plate No. 1 with the bolt.
Torque: 10 Nm (102 kgf/cm, 7 ft. lbs.)

65. INSTALL FRONT DIFFERENTIAL ASSEMBLY
(a) Install the front differential assembly to the transaxle case.

66. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case.
(b) Apply FIPG to the transaxle housing.
FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Apply adhesive to the bolt B threads.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Install the 17 bolts.
Torque: 30 Nm (304 kgf/cm, 22 ft. lbs.)

HINT: Each bolt length is indicated in the illustration.

Bolt length:
Bolt A: 30 mm (1.18 in.)
Bolt B: 35 mm (1.38 in.)

67. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Using SST, rotate the differential in both directions to snug the bearing down.
SST 09564-32011
(b) Using SST and a torque wrench, measure the preload of the side bearing.
SST 09564-32011
Torque:
New bearing preload (at starting) 0.8 to 1.4 Nm (8 to 14 kgf/cm, 7.1 to 12.4 in. lbs.)
Used bearing preload (at starting) 0.4 to 0.7 Nm (4 to 7 kgf/cm, 3.5 to 6.2 in. lbs.)

If the preload is not within the specified range, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim according to the following table.

Adjusting shim thickness:

HINT: The preload will change about 0.3 to 0.4 Nm (3 to 4 kgf/cm, 2.6 to 3.5 in. lbs.) according to a change in shim thickness of 0.05 mm (0.0020 in.)

68. INSTALL MANUAL VALVE LEVER SHAFT
(a) Using a 14 mm (0.55 in.) socket wrench and hammer, drive in a new manual valve lever shaft oil seal.
(b) Apply MP grease to the seal lip.

(c) Install the parking lock rod sub-assembly to the manual valve lever sub-assembly.
(d) Slide in the manual valve lever shaft and install the washer plate, a new spacer and manual valve lever sub-assembly.

(e) Install the retainer spring.

HINT: Make sure there is a washer between the retaining spring and case.

(f) Using a pin punch and hammer, drive in the slotted spring pin.
(g) Position the spacer and stake it.

69. INSTALL ACCUMULATOR PISTON AND SPRING
(a) Coat 8 new O-rings with ATF and install them to the accumulator pistons 2 each.
(b) Install the accumulator pistons and compression springs to the transaxle case as shown in the illustration.

70. INSTALL BRAKE DRUM GASKET
(a) Install a new brake drum gasket until it makes contact with the 2nd brake drum.

71. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install the new governor apply gasket No. 1 to the transaxle case.

72. INSTALL CHECK BALL BODY
(a) Install the check ball body and compression spring to the transaxle case.

73. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF and install the transmission wire to the transaxle case.

(b) Install the bolt.
Torque: 5.5 Nm (56 kgf/cm, 49 in. lbs.)

74. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Connect the manual valve connecting rod to the manual valve lever.

(b) Install the transmission valve body assembly with the 17 bolts.

HINT: Each bolt length is indicated in the illustration.

Torque: 10 Nm (102 kgf/cm, 7 ft. lbs.)

Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 28 mm (1.10 in.)
Bolt C: 50 mm (1.97 in.)

75. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
(a) Install the manual detent spring sub-assembly and manual detent spring cover with the bolt.
Torque: 10 Nm (102 kgf/cm, 7 ft. lbs.)

76. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Install the valve body oil strainer assembly and a new oil strainer gasket with the 3 bolts.

HINT: Each bolt length is indicated in the illustration.

Torque: 10 Nm (102 kgf/cm, 7 ft. lbs.)

Bolt length:
Bolt A: 12 mm (0.47 in.)
Bolt B: 20 mm (0.79 in.)

77. INSTALL TRANSMISSION OIL CLEANER MAGNET
(a) Install the 2 transmission oil cleaner magnets to the automatic oil pan sub-assembly.

78. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
(a) Install a new automatic transaxle oil pan gasket to the automatic transaxle oil pan sub-assembly and install them to the transaxle.
(b) Tighten the 18 bolts.
Torque: 5.3 Nm (54 kgf/cm, 47 in. lbs.)

79. INSTALL OIL COOLER TUBE UNION
(a) Coat 2 new O-rings with ATF and install 2 new O-rings to the 2 oil cooler tube unions.
(b) Install the 2 oil cooler tube unions to the transaxle case.
Torque: 30 Nm (304 kgf/cm, 22 ft. lbs.)

80. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Install the park / neutral position switch assembly to the manual valve lever shaft.
(b) Place a new lock washer and tighten the nut.
Torque: 12 Nm (122 kgf/cm, 8 ft. lbs.)
(c) Temporarily install the 2 bolts.

(d) Temporarily install the transmission control shift lever.
(e) Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
(f) Remove the transmission control shift lever.

(g) Align the groove with neutral basic line.
(h) Tighten the 2 bolts.
Torque: 5.5 Nm (56 kgf/cm, 49 in. lbs.)

(i) Using a screwdriver, stake the nut with the lock washer.

81. INSTALL TRANSMISSION CONTROL SHAFT LEVER
(a) Install the transmission control shaft lever with the nut and washer.
Torque: 12 Nm (122 kgf/cm, 8 ft. lbs.)

82. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the transaxle case No. 1 plug and a new O-ring to the transaxle case.

83. INSTALL BREATHER PLUG NO.1 (ATM)
(a) Install the breather plug No. 1 and a new O-ring to the transaxle case.

84. INSTALL BREATHER PLUG HOSE