Part 1
U340E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT (for Hatchback): REASSEMBLY
1. BEARING POSITION
2. INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD
(a) Coat the differential gear assembly and the front differential case tapered roller bearing with Toyota Genuine ATF WS and install them to the transaxle case.
(b) Install the transaxle housing with the 14 bolts.
Bolt A - Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
Bolt B - Torque : 22 Nm (225 kgf-cm, 16 ft-lbf)
(c) Using SST and a torque wrench, measure the preload of the differential case tapered roller bearing.
SST : 09564-32011
Standard preload (at Starting):
If the preload is not within the specifications, remove the front differential case rear tapered roller bearing from the transaxle case.
Select a new front differential rear case shim in accordance with the following table.
Front Differential Rear Case Shim Thickness:
3. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat the lip of a new transaxle case oil seal with MP grease.
(b) Using SST and a hammer, drive in the transaxle case oil seal.
SST : 09710-20011
09710-06071
SST : 09950-70010
09951-07100
Oil seal drive in depth:
5.4 to 6.4 mm (0.213 to 0.252 in.)
4. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Coat the lip of a new front transaxle case oil seal with MP grease.
(b) Using SST and a hammer, drive in the front transaxle case oil seal.
SST : 09554-14010
SST : 09950-70010
09951-07150
Oil seal drive in depth:
1.5 to 2.5 mm (0.0591 to 0.0984 in.)
5. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat the lip of a new manual valve lever shaft oil seal with MP grease.
(b) Using SST and a hammer, install a new manual valve lever shaft oil seal.
SST : 09950-60010
09951-00220
SST : 09950-70010
09951-07100
Oil seal drive in depth:
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
6. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, install the counter drive gear hole snap ring to the transaxle case.
7. INSTALL COUNTER DRIVE GEAR BEARING
(a) Using SST and a hammer, install the counter drive gear bearing outer race to the transaxle case.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07150
(b) Using SST and a hammer, install the counter drive gear bearing outer race to the transaxle case.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07150
(c) Install the 2 counter drive gear bearing inner races and 2 angular balls to the transaxle case.
8. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Install the No. 1 transaxle case plate to the transaxle case.
Text in Illustration
(b) Using SST and a hammer, install the new front drive pinion rear tapered roller bearing to the transaxle case.
SST : 09950-60010
09951-00610
SST : 09950-70010
09951-07150
9. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the drive pinion thrust bearing RH to the transaxle housing.
(b) Using SST and a press, install a new front drive pinion front tapered roller bearing to the transaxle housing.
SST : 09950-60010
09951-00650
SST : 09950-70010
09951-07150
10. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube to the transaxle housing.
11. INSTALL BEARING LOCK PLATE
(a) Install the bearing lock plate to the transaxle housing with the bolt.
Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)
12. INSTALL DIFFERENTIAL DRIVE PINION PLUG
(a) Using SST and a plastic hammer, install a new differential drive pinion plug to the differential drive pinion sub-assembly.
SST : 09221-25026
09221-00071
Standard clearance:
2.5 to 2.6 mm (0.0984 to 0.1023 in.)
13. INSTALL DIFFERENTIAL DRIVE PINION SUB-ASSEMBLY
(a) Install the differential drive pinion sub-assembly and the drive pinion thrust bearing LH to the transaxle case.
14. INSTALL PARKING LOCK PAWL
(a) Coat the parking lock pawl shaft with Toyota Genuine ATF WS.
(b) Install the parking lock pawl, parking lock pawl shaft torsion spring and the parking lock pawl shaft to the transaxle case.
NOTICE:
Check that the parking lock pawl moves smoothly.
15. INSTALL MANUAL VALVE LEVER SHAFT
(a) Install the manual valve lever shaft to the transaxle case.
NOTICE:
Do not damage the oil seal lip.
16. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod sub-assembly to the manual valve lever sub-assembly.
17. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Coat the manual valve lever sub-assembly with Toyota Genuine ATF WS.
(b) Install the manual valve lever sub-assembly and a new manual valve lever shaft spacer to the manual valve lever shaft.
(c) Using a pin punch 3 mm and hammer, drive in the manual valve lever shaft spring pin.
(d) Turn the manual valve lever shaft spacer and the manual valve lever shaft to align the small hole for locating the staking position in the manual valve lever shaft spacer with the staking position mark on the manual valve lever shaft.
(e) Using a punch, stake the manual valve lever shaft spacer through the small hole.
(f) Check that the manual valve lever shaft spacer does not turn.
18. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
(a) Install the manual valve lever shaft retainer spring to the manual valve lever shaft.
19. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock rod sub-assembly, parking lock cam guide and the parking lock pawl bracket to the transaxle case with the 3 bolts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
20. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON O-RING
(a) Coat 2 new No. 2 1st and reverse brake piston O-rings with Toyota Genuine ATF WS, and install them to the No. 2 1st and reverse brake piston.
NOTICE:
Do not damage the O-ring.
21. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON
(a) Coat the No. 2 1st and reverse brake piston with Toyota Genuine ATF WS, and install it to the transaxle case.
NOTICE:
Do not damage the O-ring.
22. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Install the 1st and reverse brake return spring sub-assembly to the transaxle case.
(b) Using SST, a press and a screwdriver, install the snap ring to the transaxle case.
SST : 09387-00070
23. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, install the counter drive gear to the transaxle case.
SST : 09223-15030
SST : 09527-17011
SST : 09950-60010
09951-00650
SST : 09950-70010
09951-07150
24. INSTALL PLANETARY GEAR ASSEMBLY
(a) Using SST and a press, install the planetary gear assembly to the transaxle case.
SST : 09950-60010
09951-00480
SST : 09223-15030
SST : 09527-17011
SST : 09950-70010
09951-07150
25. INSTALL COUNTER DRIVE GEAR NUT
(a) Fix the counter driven gear with the parking lock pawl.
(b) Using SST, install a new counter drive gear lock nut washer and the counter drive gear nut.
SST : 09387-00121
Torque : 280 Nm (2855 kgf-cm, 207 ft-lbf)
(c) Using SST and a torque wrench, measure the rotating torque while turning the counter drive gear at 60 turns per minute.
SST : 09387-00121
Rotating torque:
0.20 to 0.49 N*m (2 to 5 kgf*cm, 2 to 4 in.*lbf)
(d) Using SST and a hammer, stake the counter drive gear lock nut washer.
SST : 09930-00010
26. INSTALL 1ST AND REVERSE BRAKE DISC
(a) Install the 4 1st and reverse brake plates, 4 1st and reverse brake discs and the 1st and reverse brake flange to the transaxle case.
Text in Illustration
(b) Using a screwdriver, install the snap ring to the transaxle case.
27. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
(a) Using SST and a dial indicator, measure the 1st and reverse brake clearance while pressing the 1st and reverse brake disc and the 1st and reverse brake plate from the rear side.
SST : 09350-36010
09350-06110
Pack clearance:
0.806 to 1.206 mm (0.0317 to 0.0475 in.)
NOTICE:
If the clearance is outside the specifications, select a new 1st and reverse brake flange.
HINT
There are 4 different of flanges available thicknesses.
Flange Thickness:
(b) Check that the 1st and reverse brake piston moves when compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) is applied to the oil hole.
28. INSTALL FRONT PLANETARY SUN GEAR
(a) Install the front planetary sun gear and the front planetary gear thrust needle roller bearing to the planetary gear assembly.
29. INSTALL 2ND BRAKE CYLINDER O-RING
(a) Coat 2 new 2nd brake cylinder O-rings with Toyota Genuine ATF WS, and install them to the 2nd brake cylinder.
NOTICE:
Do not damage the O-ring.
30. INSTALL 2ND BRAKE PISTON
(a) Coat the 2nd brake piston with Toyota Genuine ATF WS, and install it to the 2nd brake cylinder.
CAUTION:
Do not damage the O-rings when pressing the 2nd brake piston into the 2nd brake cylinder by hand.
31. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
(a) Install the 2nd brake piston return spring sub-assembly to the 2nd brake cylinder.
(b) Place SST on the 2nd brake piston return spring sub-assembly, and compress the 2nd brake piston return spring sub-assembly with a press.
SST : 09387-00060
(c) Using a screwdriver, install the snap ring.
NOTICE:
Make sure that the end gap of the snap ring is not aligned with the piston return spring claw.
32. INSTALL OUTER RACE RETAINER
(a) Install the outer race retainer to the No. 2 1-way clutch.
33. INSTALL NO. 2 1-WAY CLUTCH
(a) Install the No. 2 1-way clutch and the 2nd brake piston assembly to the rear planetary gear assembly.
34. INSTALL REAR PLANETARY GEAR THRUST NEEDLE ROLLER BEARING
(a) Install the No. 2 thrust bearing race, rear planetary gear thrust needle roller bearing and the thrust bearing race to the rear planetary gear assembly.
35. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Install the rear planetary gear assembly to the transaxle case.
(b) Using a screwdriver, install the snap ring to the transaxle case.
36. INSPECT NO. 2 1-WAY CLUTCH
(a) Check that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.
Text in Illustration
If the No. 2 1-way clutch does not operate normally. replace it.
37. INSTALL 2ND BRAKE PISTON SLEEVE
(a) Install the 2nd brake piston sleeve to the transaxle case.
38. INSTALL 2ND BRAKE BRAKE DISC
(a) Install the 3 2nd brake brake discs, 3 No. 1 2nd brake brake flanges and the 2nd brake brake flange to the transaxle case.
Text in Illustration
(b) Using a screwdriver, install the snap ring to the transaxle case.