Part 2

U341E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY (Continued..)

36. INSTALL REAR PLANETARY GEAR THRUST NEEDLE ROLLER BEARING

(a) Install the No. 2 thrust bearing race, the planetary gear thrust needle roller bearing and thrust bearing race to the rear planetary gear assembly.





37. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the rear planetary gear assembly to the transaxle case.





(b) Using a screwdriver, install the snap ring.

38. INSPECT NO. 2 ONE-WAY CLUTCH

(a) Check that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.





39. INSTALL 2ND BRAKE PISTON SLEEVE

(a) Install the 2nd brake piston sleeve to the transaxle case.





40. INSTALL 2ND BRAKE DISC

(a) Install the 4 discs, 3 No. 1 2nd brake flanges and 2 2nd brake flanges to the transaxle case.





(b) Using a screwdriver, install the 2 snap rings to the transaxle case.





41. INSPECT PACK CLEARANCE OF 2ND BRAKE

(a) Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm2, 57 to 114 psi).





Pack clearance:

0.85 to 1.24 mm (0.0334 to 0.0488 in.)

NOTICE:
If the clearance is not within the specified range, select a new brake flange.

HINT
There are 4 different thicknesses of flanges available.

Flange Thickness:





42. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the No. 2 thrust washer to the rear planetary gear assembly.





(b) Install the one-way clutch assembly to the rear planetary sun gear assembly.

43. INSPECT ONE-WAY CLUTCH ASSEMBLY

(a) Hold the rear planetary sun gear, turn the one-way clutch and check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.





44. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING

(a) Install the thrust needle roller bearing and the washer to the rear planetary sun gear.





45. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Install the rear planetary sun gear assembly.





46. INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING

(a) Install the rear No. 2 planetary sun gear thrust needle roller bearing to the rear planetary sun gear.





47. INSTALL DIRECT CLUTCH HUB

(a) Install the direct clutch hub.





48. INSTALL THRUST NEEDLE ROLLER BEARING

(a) Install the No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race to the direct clutch hub.





49. INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC

(a) Measure the flange thickness. (Dimension A)





(b) Install the 2 discs, 2 No. 2 flanges and flange to the transaxle case.





50. INSTALL DIRECT CLUTCH DRUM O-RING

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





NOTICE:
Do not damage the O-ring.

51. INSTALL DIRECT CLUTCH PISTON O-RING

(a) Coat 2 new O-rings with ATF and install them to the direct clutch piston.





NOTICE:
Do not damage the O-rings.

52. INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY

(a) Coat the direct clutch drum with ATF.

(b) Align a cutout on the intermediate shaft assembly with the matchmark on the direct clutch drum and install the direct clutch drum to the intermediate shaft assembly.





NOTICE:
Do not damage the O-ring or the lip of the clutch drum.

53. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

(a) Coat the direct clutch piston with ATF and install it to the intermediate shaft.





NOTICE:
Do not damage the O-ring or the direct clutch piston.

54. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Install the direct clutch return spring onto the direct clutch piston.





(b) Place SST on the piston return spring and compress the springs with a press.

SST : 09387-00020

(c) Using snap ring pliers, install the snap ring to the direct clutch drum.

NOTICE:
* Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.

55. INSTALL DIRECT CLUTCH DISC

(a) Coat the 3 rear clutch flanges, 3 discs and direct clutch flange with ATF and install them to the intermediate shaft.





(b) Install the snap ring to the intermediate shaft.

56. INSTALL REVERSE CLUTCH DISC

(a) Coat the 3 plates, 3 discs and flange with ATF, and install them to the intermediate shaft.





(b) Install the snap ring to the intermediate shaft.

57. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft and thrust needle roller bearing to the rear transaxle cover.





(b) Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

Pack clearance:

0.62 to 1.16 mm (0.0244 to 0.0456 in.)

NOTICE:
If the clearance is not within the specified range, select a new clutch flange.

HINT
There are 4 different thicknesses of flanges available.

Flange Thickness:





58. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

(a) Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.





(b) Using a dial indicator and measuring terminal (SST), measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

SST : 09350-36010

09350-06110

HINT
The direct and reverse clutch will come out as compressed air is applied.

Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch.

Pack clearance:

0.62 to 1.02 mm (0.0244 to 0.0402 in.)

NOTICE:
If the clearance is not within the specified range, select a new clutch flange.

HINT
There are 4 different flange thicknesses.

Flange Thickness:





59. INSTALL INTERMEDIATE SHAFT ASSEMBLY

(a) Install the intermediate shaft assembly to the transaxle case.





60. INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE

(a) As shown in the illustration, place a straightedge on the transaxle case and measure the distance between the 2nd coast and overdrive brake flange and the straightedge using a vernier caliper. (Dimension B)





(b) As shown in the illustration, place a straightedge on the overdrive brake piston and measure the distance between the transaxle rear cover and straightedge using a vernier caliper. (Dimension C)





Calculate the piston stroke value using the following formula.

Formula:

(Dimension A + Dimension B) - Dimension C

Pack clearance:

2.10 to 2.49 mm (0.0826 to 0.0980 in.)

NOTICE:
If the clearance is not within the specified range, select a new brake flange.

HINT
There are 4 different thicknesses of flanges available.

Flange Thickness:





61. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING

(a) Install the bearing to the intermediate shaft.





62. INSPECT INTERMEDIATE SHAFT ASSEMBLY

(a) Install the rear transaxle cover with the 11 bolts.





Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

(b) Using a dial indicator, measure the intermediate shaft end play.





End play:

0.21 to 0.96 mm (0.00826 to 0.0377 in.)

If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.

HINT
There are 2 different thicknesses of trust needle roller bearings available.





(c) Remove the 11 bolts and the rear transaxle cover.

63. INSTALL TRANSAXLE CASE GASKET

(a) Install 4 new gaskets to the transaxle case.





64. INSTALL REAR TRANSAXLE COVER NEEDLE ROLLER BEARING

(a) Coat a new needle roller bearing with ATF.





(b) Using SST and a press, install the needle roller bearing into the rear transaxle cover.

SST : 09950-60010

09951-00190

09952-06010

SST : 09950-70010

09951-07100

Standard clearance:

25.1 mm (0.988 in.)

65. INSTALL CLUTCH DRUM OIL SEAL RING

(a) Compress the 3 oil seal rings from both sides to reduce dimension A.





Dimension A:

5.0 mm (0.197 in.)

(b) Coat 3 oil seal rings with ATF and install them to the rear transaxle cover.

66. INSTALL 2ND COAST AND OVERDRIVE O-RING

(a) Coat 2 new O-rings with ATF and install them to the 2nd coast and overdrive brake piston.





NOTICE:
Do not damage the O-rings.

67. INSTALL 2ND COAST AND OVERDRIVE BRAKE PISTON

(a) Coat the piston with ATF and install it to the rear transaxle cover.





NOTICE:
Do not damage the O-rings.

68. INSTALL OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using SST and a press, install the overdrive brake return spring and snap ring to the rear transaxle cover.





SST : 09387-00070

NOTICE:
* Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.

69. INSTALL REAR TRANSAXLE COVER PLUG

(a) Coat 4 new O-rings with ATF, and install them to the 4 rear transaxle cover plugs.





(b) Install the 4 rear transaxle cover plugs to the rear transaxle cover.

Torque : 7.4 Nm (76 kgf-cm, 66 in-lbf)

NOTICE:
Do not damage the O-rings.

70. INSTALL REAR TRANSAXLE COVER ASSEMBLY

(a) Apply seal packing to the transaxle case.





Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(b) Install the rear transaxle cover with the 11 bolts.





Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)