Блок Автоматической Трансмиссии Повторная Сборка. Corolla ZZE150

Check bearing position and installation direction.

Coat the front differential case and bearing with ATF and install them to the transaxle case.

Install the transaxle housing with the 14 bolts.

Момент затяжки:

Bolt A:

29 Н*м{296 кгс*см, 21 фунт-сила-футов}

Bolt B:

22 Н*м{224 кгс*см, 16 фунт-сила-футов}

Using SST and a small torque wrench, measure the preload of the differential gear.

Preload:

Bearing	Standard
New	0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm, 8.7 to 13.9 in.*lbf)
Used	0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf)

Adjusting shim thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
01	1.90 (0.0748)	11	2.40 (0.0945)
02	1.95 (0.0768)	12	2.45 (0.0965)
03	2.00 (0.0787)	13	2.50 (0.0984)
04	2.05 (0.0807)	14	2.55 (0.1004)
05	2.10 (0.0827)	15	2.60 (0.1024)
06	2.15 (0.0846)	16	2.65 (0.1043)
07	2.20 (0.0866)	17	2.70 (0.1063)
08	2.25 (0.0885)	18	2.75 (0.1082)
09	2.30 (0.0906)	19	2.80 (0.1102)
10	2.35 (0.0925)

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, drive in a new oil seal.

SST

09387-00010
09950-70010(09951-07100)

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, drive in a new oil seal.

SST

09726-27012(09726-02041)
09950-70010(09951-07150)

Oil seal drive in depth:

2.2 to 3.2 mm (0.087 to 0.126 in.)

Install the No. 1 transaxle case plate onto the transaxle case.

Using SST and a hammer, install the front drive pinion rear tapered roller bearing to the transaxle case.

SST

09950-60010(09951-00610)
09950-70010(09951-07150)

Install the thrust bearing to the transaxle housing.

Using SST and a press, install a new front drive pinion front tapered roller bearing to the transaxle housing.

SST

09950-60010(09951-00650)
09950-70010(09951-07150)

Install the differential gear lube apply tube to the transaxle housing.

Install the bearing lock plate to the transaxle housing with the bolt.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Using a screwdriver, install the counter drive gear hole snap ring to the transaxle case.

Using SST and a hammer, install the counter drive gear bearing outer race LH to the transaxle case.

SST

09950-60020(09951-00890)
09950-70010(09951-07150)

Install the counter drive gear bearing LH to the transaxle case.

Using SST and a hammer, install the counter drive gear bearing outer race RH to the transaxle case.

SST

09950-60020(09951-00890)
09950-70010(09951-07150)

Install the counter drive gear bearing RH to the transaxle case.

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, install a new manual valve lever shaft oil seal.

SST

09950-60010(09951-00220)
09950-70010(09951-07100)

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.020 to 0.020 in.)

Using SST and a press, install the differential drive pinion to the counter driven gear.

SST

09950-60010(09951-00350)
09950-70010(09951-07150)

ПРИМЕЧАНИЕ:

When replacing the counter driven gear, replace the counter drive gear in the transaxle case as well.

Press in the differential drive pinion until it comes into contact with the counter driven gear.

Using SST and a plastic hammer, install a new differential drive pinion plug to the differential drive pinion.

SST

09221-25026(09221-00071)

Standard clearance:

2.5 to 3.5 mm (0.0984 to 0.1378 in.)

Install the counter driven gear and drive pinion thrust bearing to the transaxle case.

Coat the parking lock pawl shaft with ATF.

Install the parking lock pawl, parking lock pawl shaft torsion spring and parking lock pawl shaft to the transaxle case.

ПРИМЕЧАНИЕ:

Check that the parking lock pawl moves smoothly.

Install the manual valve lever shaft to the transaxle case.

ПРИМЕЧАНИЕ:

Do not damage the oil seal lip.

Install the parking lock rod to the manual valve lever.

Coat the manual valve lever sub-assembly with ATF.

Install the manual valve lever and a new manual valve lever spacer to the manual valve lever shaft.

Using a pin punch and hammer, drive in the pin.

Turn the spacer and lever shaft to align the small hole for locating the staking position mark on the lever shaft.

Using a pin punch, stake the spacer through the small hole.

Check that the spacer does not turn.

Install the manual valve lever shaft retainer spring to the manual valve lever shaft.

Install the parking lock pawl bracket, parking lock rod and cam guide sleeve to the transaxle case with the 3 bolts.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Using SST and a press, install the counter drive gear to the transaxle case.

SST

09223-15030
09527-17011
09950-60010(09951-00650)
09950-70010(09951-07150)

Using SST and a press, install the planetary gear assembly to the transaxle case.

SST

09950-60010(09951-00480)
09223-15030
09527-17011
09950-70010(09951-07150)

Fix the counter driven gear with the parking lock pawl.

Using SST, install a new lock washer and nut.

SST

09387-00120

Момент затяжки:

280 Н*м{2855 кгс*см, 207 фунт-сила-футов}

Using SST and a small torque wrench, measure the rotating torque while turning the counter drive gear at 60 turns per minute.

SST

09387-00120

Rotating torque:

0.20 to 0.49 N*m (2.0 to 5.0 kgf*cm, 1.8 to 4.3 in.*lbf)

Using SST and a hammer, stake the lock nut washer.

SST

09930-00010

Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.

Coat the No. 2 1st and reverse brake piston with ATF, and install it to the transaxle case.

ПРИМЕЧАНИЕ:

Do not damage the oil seal lip.

Install the 1st and reverse brake return spring sub-assembly to the transaxle case.

Using SST, a press and a screwdriver, install the snap ring.

SST

09387-00070

Install the 4 plates, 4 discs and flange to the transaxle case.

Using a screwdriver, install the snap ring.

Using SST and a dial indicator, measure the first and reverse brake clearance while pressing the disc and plate from the rear side.

SST

09350-36010(09350-06110)

Pack clearance:

0.806 to 1.206 mm (0.0317 to 0.0475 in.)

ПРИМЕЧАНИЕ:

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

УКАЗАНИЕ:

There are 4 different flange thicknesses.

Flange thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
-	3.4 (0.134)	2	3.8 (0.150)
1	3.6 (0.142)	3	4.0 (0.157)

Check that the 1st and reverse brake piston moves when compressed air is applied (392 kPa, 4.0 kgf/cm², 57 psi) to the oil hole.

Install the planetary sun gear and needle roller bearing to the planetary gear assembly.

Install the outer retainer to the No. 2 one-way clutch.

Install the one-way clutch and 2nd brake piston assembly to the rear planetary gear assembly.

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

Install the rear planetary gear assembly to the transaxle case.

Using a screwdriver, install the snap ring.

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

Install the 2nd brake piston sleeve to the transaxle case.

Install the 4 discs, 2 flanges and 3 No. 1 flanges to the transaxle case.

Using a screwdriver, install a snap ring to the transaxle case.

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.)

ПРИМЕЧАНИЕ:

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

УКАЗАНИЕ:

There are 4 different flange thicknesses.

Flange thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)

Using a screwdriver, install a snap ring to the transaxle case.

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

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

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.

Install the thrust bearing and a washer to the rear planetary sun gear.

Install the rear planetary sun gear assembly.

Install the thrust bearing to the rear planetary sun gear.

Install the direct clutch hub.

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.

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

Install the intermediate shaft assembly to the transaxle case.

As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straight edge using vernier calipers. (Dimension A)

As shown in the illustration, place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and straight edge using vernier calipers. (Dimension B)
Calculate the piston stroke value using the following formula. Select a flange which meets the piston stroke value and install it.

Pack clearance:

2.091 to 2.491 mm (0.0823 to 0.0981 in.)

ПРИМЕЧАНИЕ:

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

УКАЗАНИЕ:

There are 4 different flange thicknesses.

Flange thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
4	4.0 (0.1575)	6	4.4 (0.1732)
5	4.2 (0.1654)	7	4.6 (0.1811)

Install the bearing to the intermediate shaft.

Install the transaxle rear cover with the 11 bolts.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

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

Standard clearance:

0.204 to 0.966 mm (0.008 to 0.038 in.)

УКАЗАНИЕ:

There are 2 different trust needle roller bearing thicknesses.

Remove the 11 bolts and the transaxle rear cover.

Install 4 new gaskets to the transaxle case.

Apply seal packing to the transaxle case.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Install the rear transaxle cover with the 11 bolts.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Install the forward clutch hub sub-assembly onto the transaxle case.

Install the bearing to the forward clutch hub.

Install the bearing to the input shaft assembly.

Install the input shaft assembly to the transaxle case.

Install 2 new gaskets to the transaxle case.

Install the differential gear assembly to the transaxle case.

Install the oil pump with the 7 bolts.

Момент затяжки:

22 Н*м{224 кгс*см, 16 фунт-сила-футов}

Make sure that the input shaft turns smoothly.

Measure the end play in the axial direction.

End play:

0.374 to 1.292 mm (0.0147 to 0.0509 in.)

Apply seal packing to the transaxle case.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Install the transaxle housing with the 14 bolts.

Момент затяжки:

Bolt A:

29 Н*м{296 кгс*см, 21 фунт-сила-футов}

Bolt B:

22 Н*м{224 кгс*см, 16 фунт-сила-футов}

Coat 2 new O-rings with ATF and install them to the C-2 accumulator piston.

ПРИМЕЧАНИЕ:

Do not damage the O-rings.

Install the spring and C-2 accumulator piston.

Accumulator spring:

Spring	Free length/ Outer diameter mm (in.)	Color
C-2	66.90 (2.6339) 17.20 (0.6772)	-

Coat 2 new O-rings with ATF and install them to the C-3 accumulator piston.

ПРИМЕЧАНИЕ:

Do not damage the O-rings.

Install the spring and C-3 accumulator piston.

Accumulator spring:

Spring	Free length/ Outer diameter mm (in.)	Color
C-3	87.30 (3.4370) 18.70 (0.7362)	Orange

Coat 2 new O-rings with ATF and install them to the B-2 accumulator piston.

ПРИМЕЧАНИЕ:

Do not damage the O-rings.

Install the spring and B-2 accumulator piston.

Accumulator spring:

Spring	Free length/ Outer diameter mm (in.)	Color
B-2	66.90 (2.6339) 15.50 (0.6102)	White

Install the spring and check ball body.

Install a new brake drum gasket.

Coat a new transaxle case gasket with ATF, and install it to the transaxle case.

Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.

Coat a new O-ring with ATF, and install it to the transmission wire.

Insert the transmission wire to the transaxle.

Install the transmission wire with the bolt.

Момент затяжки:

5.4 Н*м{55 кгс*см, 48 фунт-сила-дюймов}

Align the groove of the manual valve with the pin of the manual valve lever.

Temporarily install the valve body with the 13 bolts.

Bolt length:

Bolt A: 32 mm (1.26 in.)
Bolt B: 22 mm (0.87 in.)
Bolt C: 55 mm (2.17 in.)
Bolt D: 45 mm (1.77 in.)

Temporarily install the detent spring and detent spring cover with the 2 bolts.

Bolt length:

Bolt A: 14 mm (0.55 in.)
Bolt B: 45 mm (1.77 in.)

Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring.

Tighten the 15 bolts.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Connect the 5 solenoid connectors.

Install the ATF temperature sensor with the lock plate and bolt.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Bolt length:

55 mm (2.17 in.)

Coat a new O-ring with ATF, and install it to the oil strainer.

Install the valve body oil strainer assembly to the automatic transaxle with the 3 bolts.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Install the 2 magnets to the oil pan.

Install a new oil pan gasket to the oil pan.

Install the oil pan with the 19 bolts.

Момент затяжки:

7.8 Н*м{80 кгс*см, 69 фунт-сила-дюймов}

Install the breather plug to the transaxle case.

Install the breather plug hose to the breather plug.

Coat 5 new O-rings with ATF, and install them to the No. 1 transaxle case plugs.

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

Момент затяжки:

7.4 Н*м{76 кгс*см, 66 фунт-сила-дюймов}

Install the No. 1 transaxle case plug to the transaxle case.

Момент затяжки:

7.4 Н*м{76 кгс*см, 66 фунт-сила-дюймов}

Coat 2 new O-rings with ATF, and install them into the 2 oil cooler tube unions.

Install the 2 oil cooler tube unions to the transaxle case.

Момент затяжки:

27 Н*м{275 кгс*см, 20 фунт-сила-футов}

Coat a new O-ring with ATF, and install it to the speed sensor.

Install the speed sensor to the transaxle case with the bolt.

Момент затяжки:

5.4 Н*м{55 кгс*см, 48 фунт-сила-дюймов}

Install the park/neutral position switch assembly to the automatic transaxle.

Temporarily install the 2 bolts.

Replace the lock plate with a new one and tighten the manual valve shaft nut.

Момент затяжки:

6.9 Н*м{70 кгс*см, 61 фунт-сила-дюймов}

Temporarily install the control shaft lever.

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

Remove the control shaft lever.

Align the groove with the neutral basic line.

Hold the switch in this position and tighten the 2 bolts.

Момент затяжки:

5.4 Н*м{55 кгс*см, 48 фунт-сила-дюймов}

Using a screwdriver, stake the nut with the lock plate.

Install the control shaft lever with the nut and washer.

Момент затяжки:

13 Н*м{133 кгс*см, 10 фунт-сила-футов}

Coat a new O-ring with ATF and install it to the speedometer driven hole cover sub-assembly.

Install the speedometer driven hole cover sub-assembly to the transaxle housing.

Момент затяжки:

7.0 Н*м{71 кгс*см, 62 фунт-сила-дюймов}