Part 2

U660F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

32. INSTALL INPUT SHAFT SUB-ASSEMBLY

(a) Coat 3 new input shaft oil seal rings with ATF and install them to the input shaft.

Text in Illustration:

NOTICE:
Do not expand the gap of the oil seal ring too much.

(b) Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them on the oil pump assembly.

Text in Illustration:

Bearing Diameter: mm (in.):

NOTICE:
Be sure to install the thrust needle roller bearing in the correct direction.

(c) Install the input shaft to the oil pump assembly.

33. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY

(a) Using a snap ring expander, install the snap ring to the underdrive planetary gear assembly.

Text in Illustration:

(b) Using a snap ring expander, install the front planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded.

Text in Illustration:

34. INSTALL UNDERDRIVE PLANETARY RING GEAR

(a) Install the underdrive planetary ring gear to the underdrive planetary gear assembly.

Text in Illustration:

(b) Using needle-nose pliers, install the snap ring to the underdrive planetary ring gear.

Text in Illustration:

NOTICE:
Confirm that the snap ring is correctly located in the groove of the underdrive planetary ring gear.

35. INSTALL NO. 3 BRAKE HUB

(a) Coat the thrust needle roller bearing with ATF and install it on the underdrive planetary gear assembly.

Text in Illustration:

Bearing Diameter: mm (in.):

NOTICE:
Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(b) Coat the thrust needle roller race with MP grease and install it to the No. 3 brake hub.

Text in Illustration:

36. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Install the underdrive planetary gear assembly to the oil pump assembly.

37. INSTALL NO. 3 BRAKE DISC

(a) Install the 2 brake flanges, 3 brake discs and 2 brake plates to the oil pump assembly.

Text in Illustration:

NOTICE:
Make sure that the discs, plates and flanges are installed in the correct order.

(b) Using a screwdriver, install the snap ring to the oil pump assembly.

NOTICE:
* Confirm the snap ring is correctly located in the groove of the oil pump.
* Make sure that the snap ring ends are positioned as shown in the illustration (A).
38. INSPECT CLEARANCE OF NO. 3 BRAKE Transaxle Unit

39. INSTALL FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the transaxle case.

Text in Illustration:

(b) Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them on the underdrive planetary gear assembly.

Text in Illustration:

Bearing and Race Diameter: mm (in.):

NOTICE:
Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(c) Coat a new O-ring with ATF and install it to the oil pump.

Text in Illustration:

(d) Install the oil pump assembly to the transaxle case with the 7 bolts.

Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

40. INSTALL FRONT OIL PUMP BODY O-RING

41. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the differential gear lube apply tube to the transaxle housing.

NOTICE:
Insert the differential gear lube apply tube into the transaxle case until it makes contact with the stopper.

(b) Install the apply tube clamp to the differential gear lube apply tube with the bolt.

Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

NOTICE:
There should be clearance between the differential lube apply tube and apply tube clamp.

42. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE

(a) Install the shim to the transaxle housing.

(b) Using SST, install a new counter driven gear front tapered roller bearing outer race to the transaxle housing.

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07100

NOTICE:
Be sure to install the counter driven gear front tapered roller bearing outer race so that there is no clearance between the shim and the transaxle housing.

43. INSTALL TRANSAXLE HOUSING

(a) Remove packing material from the contact surfaces between the transaxle housing and case.

NOTICE:
Make sure that there is no ATF on the contact surfaces.

(b) Apply FIPG to the transaxle case.

Text in Illustration:

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

(c) Install the transaxle housing to the transaxle case with the 20 bolts.

Bolt A - Torque : 31 Nm (316 kgf-cm, 23 ft-lbf)

Bolt B - Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

44. ADJUST COUNTER DRIVEN GEAR PRELOAD

(a) Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm.

SST : 09564-33010

Turning torque:

Differential side bearing preload 3.3 to 6.0 N*m (34 to 61 kgf*cm, 29 to 53 in.*lbf)

(a) If the turning torque is not within the specified range, refer to the table below to select a shim of the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range.

Shim Thickness: mm (in.):

45. INSTALL NO. 1 CLUTCH DISC

(a) Install the clutch flange, 4 clutch discs and 4 clutch plates to the direct multiple disc clutch assembly.

Text in Illustration:

NOTICE:
Make sure that the flange, discs and plates are installed in the correct order.

(b) Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly.

NOTICE:
Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.

46. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC Transaxle Unit

47. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them to the direct multiple disc clutch assembly.

Bearing and Race Diameter: mm (in.):

Text in Illustration:

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

(b) Install the rear planetary sun gear assembly to the direct multiple disc clutch assembly.

48. INSTALL NO. 2 CLUTCH DISC

(a) Install the clutch flange, 3 clutch discs and 3 clutch plates to the direct multiple disc clutch assembly.

Text in Illustration:

NOTICE:
Make sure that the flange, discs and plates are installed in the correct order.

49. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING

(a) Coat a new O-ring with ATF and install it to the direct multiple disc clutch assembly.

Text in Illustration:

(b) Coat a new intermediate shaft oil seal with ATF and install it to the intermediate shaft.

Text in Illustration:

NOTICE:
Be sure to engage the claws on the direct multiple disc clutch assembly in the grooves on the No. 2 direct clutch piston.

(d) Using a screwdriver, install the snap ring to the direct multiple disc clutch assembly.

NOTICE:
* Position the opening of the snap ring as shown in the illustration.
* Confirm that the snap ring is correctly located in the groove of the direct multiple disc clutch assembly.
50. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC Transaxle Unit

51. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

(a) Coat the thrust needle roller bearing with ATF and install it on the transaxle case.

Text in Illustration:

Bearing Diameter: mm (in.):

(b) Install the direct multiple disc clutch assembly to the transaxle case.

Text in Illustration:

(c) Clean the contact surfaces of the transaxle case and rear transaxle cover sub-assembly.

(d) As shown in the illustration, place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension A).

(e) Using a vernier caliper and a straightedge, measure the distance shown in the illustration. (Dimension B)

(f) Calculate the end play value using the following formula:

End play = Dimension B - Dimension A

End play:

0.007 to 1.113 mm (0.000275 to 0.0438 in.)

52. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY

(a) Using SST and a hammer, install a new needle roller bearing into the rear transaxle cover sub-assembly.

SST : 09950-60010

09951-00220

SST : 09950-70010

09951-07100

Installation depth:

21.5 to 21.9 mm (0.846 to 0862 in.)

(b) Apply adhesive to the 2 "TORX" screws.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Using a "TORX" wrench (T30), install the rear transaxle cover plate to the rear transaxle cover sub-assembly with the 2 "TORX" screws.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(d) Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them on the transaxle case.

Bearing Diameter: mm (in.):

Text in Illustration:

(e) Coat 2 new oil seal rings with ATF and install them to the rear transaxle cover sub-assembly.

Text in Illustration:

(f) Coat 3 new O-rings with ATF and install them to the transaxle case.

NOTICE:
Ensure that the O-rings are not twisted.

(g) Remove packing material from the contact surfaces between the rear transaxle cover sub-assembly and transaxle case.

NOTICE:
Make sure that there is no ATF on the contact surfaces.

(h) Apply FIPG to the transaxle case.

Text in Illustration:

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

(i) Install the rear transaxle cover sub-assembly to the transaxle case with the 14 bolts.

Bolt A - Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

Bolt B - Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

(j) Install a new gasket to the refill plug.

(k) Install the refill plug to the rear transaxle cover sub-assembly.

Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)

(l) Coat 2 new O-rings with ATF and install them to the 2 No. 1 automatic transaxle case plugs.

(m) Install the 2 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)

53. INSPECT INPUT SHAFT END PLAY Transaxle Unit