Part 2

U340E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT (for Hatchback): REASSEMBLY - (Continued)

39. 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 to 8 kgf/cm2, 57 to 114 psi).

Pack clearance:

0.847 to 1.247 mm (0.0333 to 0.0491 in.)

NOTICE:
If the clearance is outside the specifications, select a new 2nd brake brake flange.

HINT
There are 4 different of flanges available thicknesses.

Flange Thickness:





40. INSTALL 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING





(a) Using a screwdriver, install the 2nd coast and overdrive brake flange hole snap ring to the transaxle case.

41. INSTALL 1-WAY CLUTCH ASSEMBLY





(a) Install the No. 2 planetary carrier thrust washer and the 1-way clutch assembly to the rear planetary sun gear assembly.

42. INSPECT 1-WAY CLUTCH ASSEMBLY

(a) Hold the rear planetary sun gear and turn the 1-way clutch assembly and check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.





Text in Illustration





If the 1-way clutch assembly does not operate normally, replace them.

43. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING





(a) Install the rear planetary sub gear thrust needle roller bearing and the No. 1 planetary carrier thrust washer to the rear planetary sun gear assembly.

44. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY





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

45. 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 assembly.

46. INSTALL DIRECT CLUTCH HUB





(a) Install the direct clutch hub to the transaxle case.

47. INSTALL THRUST NEEDLE ROLLER BEARING





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

48. INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC

(a) Install the 2 2nd coast and overdrive brake discs, 2 No. 2 2nd coast and overdrive brake flanges and the 2nd coast and overdrive brake flange to the transaxle case.





Text in Illustration





49. INSTALL DIRECT CLUTCH DRUM O-RING

(a) Coat a new direct clutch drum O-ring with Toyota Genuine ATF WS, and install it to the direct clutch drum sub-assembly.





NOTICE:
Do not damage the O-ring.

50. INSTALL DIRECT CLUTCH PISTON O-RING

(a) Coat 2 new direct clutch piston O-rings with Toyota Genuine ATF WS, and install them to the direct clutch piston sub-assembly.





NOTICE:
Do not damage the O-rings.

51. INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY

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





NOTICE:
Do not damage the O-ring.

52. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

(a) Coat the direct clutch piston sub-assembly with Toyota Genuine ATF WS, and install it to the intermediate shaft.





NOTICE:
Do not damage the O-ring.

53. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Install the direct clutch return spring sub-assembly to the direct clutch piston sub-assembly.





(b) Place SST on the direct clutch return spring sub-assembly and compress the springs with a press.

SST : 09387-00020

(c) Using a snap ring expander, install the snap ring to the direct clutch drum sub-assembly.

NOTICE:
* Stop pressing the press when the spring seat is lowered to 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring seat from deforming.
* Do not expand the snap ring excessively.

54. INSTALL DIRECT CLUTCH DISC

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





Text in Illustration





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

55. INSTALL REVERSE CLUTCH DISC

(a) Coat the 2 No. 3 clutch plates, 2 reverse clutch discs and the reverse clutch flange with Toyota Genuine ATF WS, and install them to the intermediate shaft.





Text in Illustration





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

56. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft assembly and the rear clutch drum 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:

0.86 to 1.26 mm (0.0339 to 0.0496 in.)

NOTICE:
If the clearance is outside the specifications, select a new reverse clutch flange.

HINT
There are 4 different of flanges available thicknesses.

Flange Thickness:





57. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

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





(b) Using SST and a dial indicator, measure the direct 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 the compressed air is applied. Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a stamping machine 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 outside the specifications, select a new direct clutch flange.

HINT
There are 4 different of flanges available thicknesses.

Flange Thickness:





58. INSTALL INTERMEDIATE SHAFT ASSEMBLY





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

59. 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 straightedge using a vernier caliper. (Dimension A)

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





Calculate the piston stroke value using the following formula. Select a 2nd coast and overdrive brake flange which meets the piston stroke value and install it.

HINT
Pack clearance = Dimension A - Dimension B

Pack clearance:

2.091 to 2.491 mm (0.0823 to 0.0981 in.)

NOTICE:
If the clearance is outside the specifications, select a new 2nd coast and overdrive brake flange.

HINT
There are 4 different of flanges available thicknesses.

Flange Thickness:





60. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING





(a) Install the rear clutch drum thrust needle roller bearing to the intermediate shaft assembly.

61. INSPECT INTERMEDIATE SHAFT ASSEMBLY

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

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

(b) Using a dial indicator, measure the clearance of the intermediate shaft assembly.





Standard clearance:

0.204 to 0.966 mm (0.00803 to 0.03803 in.)

If the clearance is outside the specifications, replace the rear clutch drum thrust needle roller bearing.

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

62. INSTALL TRANSAXLE CASE GASKET





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

63. INSTALL REAR TRANSAXLE COVER NEEDLE ROLLER BEARING

(a) Coat a new rear transaxle cover needle roller bearing with Toyota Genuine ATF WS.





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

SST : 09950-60010

09951-00190

09952-06010

SST : 09950-70010

09951-07100

Standard clearance:

25.2 mm (0.992 in.)

64. INSTALL CLUTCH DRUM OIL SEAL RING

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





Dimension A:

5.0 mm (0.197 in.)

(b) Coat the 3 clutch drum oil seal rings with Toyota Genuine ATF WS, and install them to the rear transaxle cover.

65. INSTALL 2ND COAST AND OVERDRIVE O-RING

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





NOTICE:
Do not damage the O-ring.

66. INSTALL 2ND COAST AND OVERDRIVE BRAKE PISTON

(a) Coat the 2nd coast and overdrive brake piston with Toyota Genuine ATF WS, and install it to the rear transaxle cover.





NOTICE:
Do not damage the O-ring.

67. INSTALL OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Install the overdrive brake return spring sub-assembly to the rear transaxle cover.





(b) Using SST and a press, shorten the overdrive brake return spring sub-assembly, then install the snap ring.





SST : 09387-00070

NOTICE:
* Stop the press when the overdrive brake piston is lowered to 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove, to prevent the overdrive brake piston from being deformed.
* Do not expand the snap ring excessively.

68. INSTALL REAR TRANSAXLE COVER PLUG

(a) Coat 4 new O-rings with Toyota Genuine ATF WS, 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 (75 kgf-cm, 65 in-lbf)

NOTICE:
Do not damage the O-ring.

69. INSTALL REAR TRANSAXLE COVER ASSEMBLY





(a) Apply seal packing to the transaxle case.

Text in Illustration





Seal Packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
* Remove any oil from the contact surfaces.
* Assemble the parts within 10 minutes of application. Otherwise, the seal packing material must be removed and reapplied.

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





Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

70. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY





(a) Install the forward clutch hub sub-assembly to the transaxle case.