Part 2

U660F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY - (Continued)

22. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING

(a) Using SST and a press, install a new counter driven gear front tapered roller bearing to the counter driven gear sub-assembly.

SST : 09950-60010

09951-00530

NOTICE:
Be sure to install the counter driven gear front tapered roller bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

23. INSTALL COUNTER DRIVEN GEAR

(a) Install the counter driven gear sub-assembly to the transaxle case.

24. INSTALL COUNTER DRIVE GEAR NUT

(a) Turn the manual shaft lever 2 notches counterclockwise to set it to the P position as shown in the illustration.

(b) Using SST, install a new counter drive gear nut.

SST : 09387-00130

Torque : 120 Nm (1223 kgf-cm, 88 ft-lbf)

(c) Turn the manual shaft lever 2 notches clockwise to set it to the N position as shown in the illustration.

(d) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm.

SST : 09387-00130

Turning torque:

0.1 to 0.2 N*m (1 to 2 kgf*cm, 0.9 to 1.9 in.*lbf)

If the measured value is not within the specified range, gradually tighten the nut until the turning toque falls within the specified range.

Maximum torque:

180 N*m (1835 kgf*cm, 132 ft.*lbf)

(e) Using SST and a hammer, stake the planetary gear assembly.

SST : 09930-00010

25. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH Differential Case

26. INSTALL FRONT DIFFERENTIAL CASE

(a) Install the front differential case to the transaxle case.

27. INSTALL NO. 1 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.

Text in Illustration

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

(b) Install the No. 1 brake piston to the oil pump assembly.

NOTICE:
Be careful not to damage the O-rings.

28. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install the 3 2nd brake piston return springs to the oil pump assembly.

NOTICE:
Make sure that the 3 2nd brake piston return springs are installed onto the protrusions on the oil pump assembly.

29. INSTALL NO. 1 BRAKE DISC

(a) Install the 4 brake discs, 4 brake plates and brake flange to the oil pump assembly.

Text in Illustration

NOTICE:
* Make sure that the discs, plates, and flange are installed in the correct order.
* Be sure to install the flange in the correct direction.

(b) Place SST on the flange and compress the flange using a press.

SST : 09387-00070

SST : 09495-65040

NOTICE:
Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.

(c) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#1).

NOTICE:
* Confirm the snap ring is correctly located in the groove of the oil pump.
* Make sure to align the protruding part of the snap ring with the indented part (#1) of the front oil pump and gear body assembly shown in the illustration to install the snap ring.

(d) Install the brake snap ring stopper to the oil pump assembly.

NOTICE:
Be sure to install the brake snap ring stopper in the correct direction.

(e) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#2).

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the oil pump.
* Make sure to align the protruding part of the snap ring with the indented part (#2) of the front oil pump and gear body assembly shown in the illustration to install the snap ring.

(f) Check that the brake snap ring stopper can be turned by hand.

NOTICE:
If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or the snap ring may not have been completely located in the groove on the oil pump. Remove and reinstall the snap ring and the brake snap ring stopper.

30. INSPECT CLEARANCE OF NO. 1 BRAKE Transaxle Unit

31. INSTALL UNDERDRIVE PLANETARY SUN GEAR

(a) Coat the thrust needle roller bearing with ATF, and install it to the oil pump 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) Install the underdrive planetary sun gear to the oil pump assembly.

Text in Illustration

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)

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.