Part 3

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

71. INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING

(a) Install the forward clutch hub thrust needle roller bearing to the forward clutch hub sub-assembly.

72. INSTALL INPUT SHAFT OIL SEAL RING

(a) Coat a new input shaft oil seal ring with Toyota Genuine ATF WS, and install it to the input shaft sub-assembly.

73. INSTALL FORWARD CLUTCH PISTON O-RING

(a) Coat a new forward clutch piston O-ring with Toyota Genuine ATF WS, and install it to the forward clutch piston.

74. INSTALL FORWARD CLUTCH PISTON

(a) Install the forward clutch piston to the input shaft sub-assembly.

NOTICE:
Do not damage the O-ring.

75. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Install the forward clutch return spring sub-assembly and the No. 1 clutch balancer to the input shaft sub-assembly.

(b) Using SST, a press and snap ring expander, install the snap ring to the input shaft sub-assembly.

SST : 09320-89010

76. INSTALL FRONT CLUTCH CLUTCH DISC

(a) Install the 4 No. 1 clutch plates, 4 front clutch clutch discs and the forward clutch flange.

Text in Illustration

(b) Using a screwdriver, install the snap ring to the input shaft sub-assembly.

77. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

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

Pack clearance:

1.406 to 1.806 mm (0.0554 to 0.0711 in.)

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

HINT
There are 4 different of flanges available thicknesses.

Flange Thickness:

78. INSTALL STATOR SHAFT THRUST NEEDLE ROLLER BEARING

(a) Install the stator shaft thrust needle roller bearing to the input shaft assembly.

79. INSTALL INPUT SHAFT ASSEMBLY

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

80. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets to the transaxle case.

81. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear assembly to the transaxle case.

82. INSTALL OIL PUMP ASSEMBLY

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

Torque : 22 Nm (225 kgf-cm, 16 ft-lbf)

83. INSPECT INPUT SHAFT ASSEMBLY

(a) Make sure that the input shaft turns smoothly.

If the input shaft assembly does not operate normally, replace it.

84. INSPECT INPUT SHAFT END PLAY

(a) Measure the end play in the axial direction.

End play:

0.37 to 1.29 mm (0.0146 to 0.0508 in.)

If the end play is not as specified, replace the thrust needle roller bearing.

85. INSTALL TRANSAXLE HOUSING

(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) Apply adhesive to 2 or 3 threads on the end of the 3 bolts B.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) 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)

86. INSTALL C-2 ACCUMULATOR PISTON

(a) Coat 2 new C-2 accumulator piston O-rings with Toyota Genuine ATF WS, and install them to the C-2 accumulator piston.

NOTICE:
Do not damage the O-ring.

(b) Install the C-2 accumulator piston compression spring and the C-2 accumulator piston.

Accumulator Spring:

87. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat 2 new C-3 accumulator piston O-rings with Toyota Genuine ATF WS, and install them to the C-3 accumulator piston.

NOTICE:
Do not damage the O-ring.

(b) Install the C-3 accumulator piston compression spring and the C-3 accumulator piston.

Accumulator Spring:

88. INSTALL B-2 ACCUMULATOR PISTON

(a) Coat 2 new B-2 accumulator piston O-rings with Toyota Genuine ATF WS, and install them to the B-2 accumulator piston.

NOTICE:
Do not damage the O-ring.

(b) Install the B-2 accumulator piston compression spring and the B-2 accumulator piston.

Accumulator Spring:

89. INSTALL CHECK BALL BODY

(a) Install the check ball body compression spring and the check ball body to the transaxle case.

90. INSTALL BRAKE DRUM GASKET

(a) Install a new brake drum gasket to the transaxle case.

91. INSTALL TRANSAXLE CASE GASKET

(a) Coat a new transaxle case gasket with Toyota Genuine ATF WS, and install it to the transaxle case.

92. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with Toyota Genuine ATF WS, and install it to the transaxle case.

93. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with Toyota Genuine ATF WS, and install it to the transmission wire.

(b) Pass the transmission wire through the transaxle case.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

94. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Align the groove of the manual valve with the pin of the manual valve lever.

(b) Temporarily install the transmission valve body assembly with the 13 bolts.

Bolt Length

Text in Illustration

Bolt Length

(d) Check that the manual valve lever comes into contact with the center of the roller at the tip of the manual detent spring.

(e) Tighten the 15 bolts.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

(f) Connect the 5 solenoid connectors.

(g) Install the transmission wire with the lock plate and bolt.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

Bolt length:

55 mm (2.165 in.)

95. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new oil strainer gasket with Toyota Genuine ATF WS, and install it to the valve body oil strainer assembly.

(b) Install the valve body oil strainer assembly to the with the 3 bolts.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

96. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 2 oil cleaner magnets to the automatic transaxle oil pan sub-assembly.

(b) Apply adhesive to 2 or 3 threads on the end of the 2 bolts A.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the automatic transaxle oil pan sub-assembly and a new automatic transaxle oil pan gasket with the 19 bolts.

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

Bolt B - Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)

(d) Install the drain plug and a new gasket to the automatic transaxle oil pan sub-assembly.

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

97. INSTALL BREATHER PLUG

(a) Install the breather plug to the transaxle case.

98. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

(a) Install the transmission breather hose sub-assembly to the breather plug.

99. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 5 new O-rings with Toyota Genuine ATF WS, and install them to the No. 1 transaxle case plugs.

(b) Install the 4 No. 1 transaxle case plugs to the transaxle housing and the transaxle case.

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

(c) Install the No. 1 transaxle case plug to the transaxle case.

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

100. INSTALL OIL COOLER TUBE UNION

(a) Coat 2 new O-rings with Toyota Genuine ATF WS, and install them to the 2 oil cooler tube unions.

(b) Install the 2 oil cooler tube unions to the transaxle case.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

101. INSTALL TRANSMISSION REVOLUTION SENSOR

(a) Coat a new O-ring with Toyota Genuine ATF WS, and install it to the transmission revolution sensor.

(b) Install the transmission revolution sensor to the transaxle case with the bolt.

Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)

102. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch assembly.

(b) Temporarily install the 2 bolts.

(c) Replace the lock plate with a new one and install the nut, lock plate and washer.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

(d) Temporarily install the transmission control shaft lever.

(e) Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.

(f) Remove the transmission control shaft lever.

(g) Align the groove with the neutral basic line.

Text in Illustration

(h) Hold the switch in this position and tighten the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(i) Using a screwdriver, stake the nut with the lock plate.

103. INSTALL TRANSMISSION CONTROL SHAFT LEVER

(a) Install the transmission control shaft lever with the nut and washer.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)