Part 3

A246E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY - Continued

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 (Transaxle Unit)

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:
mm (in.)

(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-lbf)
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.

48. INSPECT 2ND BRAKE PISTON (Transaxle Unit)

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 (Transaxle Unit)

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:
mm (in.)

(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:
mm (in.)

(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:
mm (in.)

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:
mm (in.)

(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:
Approx. 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.

(c) Using SST, install the snap ring.
SST: 09350-32014
09351-32050
57. INSPECT PISTON STROKE OF 2ND COAST BRAKE (Transaxle Unit)

58. INSTALL GOVERNOR PRESSURE TUBE

(a) Using a plastic hammer, install the governor pressure tube to the transaxle case.

NOTE: 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-lbf)
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.

NOTE: 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-lbf)

61. INSPECT INPUT SHAFT ASSEMBLY (Transaxle Unit)

62. INSPECT INPUT SHAFT ENDPLAY (Transaxle Unit)

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-lbf)
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-lbf)

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
New bearing preload (at starting) - Torque: 0.8 to 1.4 Nm (8 to 14 kgf-cm, 7.1 to 12.4 in-lbf)
Used bearing preload (at starting) - Torque: 0.4 to 0.7 Nm (4 to 7 kgf-cm, 3.5 to 6.2 in-lbf)
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:
mm (in.)

HINT: The preload will change about 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) according to a change in shim thickness of 0.05mm (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.