Automatic Transaxle Unit Reassembly

Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

NOTICE:

Make sure to insert the pipe to the stopper.

Install a new O-ring to each No. 1 transaxle case plugs.

Install the 2 No. 1 transaxle case plugs to the transaxle rear housing.

Torque:

7.4 N*m{75 kgf*cm, 65 in.*lbf}

Coat a new oil seal ring with ATF and install it to the transaxle housing.

Coat the underdrive cylindrical roller bearing with ATF.

Using SST and a press, install the underdrive cylindrical roller bearing.

SST

09950-60020
09950-70010(09951-00780,09951-07100)

NOTICE:

Do not apply excessive pressure to it.

Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.

NOTICE:

1. Do not expand the gap of the oil seal ring excessively.
   
2. Securely engage the hooks. Confirm that the rings rotate smoothly.
   

Wrap vinyl tape around SST 4.0 mm (0.157 in.) above the bottom end until the thickness of the wrapped tape is about 5.0 mm (0.197 in.).

NOTICE:

Clean SST to remove deposited oil before wrapping the vinyl tape.

Coat a new needle roller bearing with ATF.

Using SST and a press, install the needle roller bearing to the transaxle case.

SST

09950-60010(09951-00320)
09950-70010(09951-07100)

NOTICE:

When the wrapped vinyl tape contacts the transaxle case, stop the press.

Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.

NOTICE:

1. Install the O-rings carefully so that they are not twisted or pinched.
   
2. Apply sufficient ATF to the O-rings prior to installation.
   

Coat the underdrive brake piston with ATF.

Install the underdrive brake piston to the transaxle case.

NOTICE:

Be careful not to damage the O-rings.

Place SST on the return spring and compress the return spring with a press.

SST

09387-00020

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

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   
3. After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.
   
4. The snap ring should be securely engaged in the groove of the transaxle case.
   

Install the snap ring to the transaxle case.

Using SST and a press, install the bearing outer race (rear side) to the transaxle case.

SST

09316-12010
09950-60020(09951-00810)
09950-70010(09951-07150)

NOTICE:

1. Ensure that the snap ring is securely installed.
   
2. Do not apply excessive pressure to the bearing outer race.
   

Using SST and a press, install the bearing outer race (front side) to the transaxle case.

SST

09316-12010
09502-24010
09523-36010
09950-60020(09951-00810)
09950-70010(09951-07150)

NOTICE:

1. Do not apply excessive pressure to the bearing outer race.
   

1. Install the bearing outer race with a press while holding the bearing outer race with SST (09502-24010, 09523-36010).
   

Install the 2 angular balls to the transaxle case.

Coat the counter drive gear with ATF.

Using SST and a press, install the tapered roller bearing inner race (front side) to the counter drive gear.

SST

09649-17010
09950-70010(09951-07150)

NOTICE:

Do not apply excessive pressure to the bearing inner race.

Using SST and a press, install the counter drive gear and bearing inner race (rear side) to the transaxle case.

SST

09223-15030
09527-17011
09950-60020(09951-00720)
09950-70010(09951-07150)

NOTICE:

Do not apply excessive pressure to the counter drive gear and bearing inner race.

Coat 2 new O-rings with ATF.

Install the 2 O-rings to the 1st and reverse brake piston.

NOTICE:

1. Install the O-rings carefully so that they are not twisted or pinched.
   
2. Apply sufficient ATF to the O-rings prior to installation.
   

Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.

NOTICE:

Be careful not to damage the O-rings.

Install the return spring.

Place SST on the return spring and compress the return spring with a press.

SST

09387-00070

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

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   
3. After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.
   
4. The snap ring should be securely engaged in the groove of the cylinder.
   

Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.

NOTICE:

Confirm that the snap ring is engaged in the groove of the brake hub correctly.

Install the front planetary gear assembly to the brake hub.

Using SST and a press, press-fit the front planetary gear assembly.

SST

09950-60010(09951-00500)
09950-70010(09951-07100)

NOTICE:

1. Do not apply excessive pressure to the front planetary gear assembly.
   
2. Press the inner race of the counter drive angular ball bearing (front side), counter drive gear, and front planetary gear assembly to the position where no pre-load is applied to each tapered roller bearing (left and right).
   

Install a new washer as shown in the illustration.

Using SST, install the nut.

SST

09387-00030
09387-00080

Torque:

185 N*m{1886 kgf*cm, 136 ft.*lbf}

Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. If the measured value is not within the specified range, gradually tighten the nut until the turning torque falls within the specified range.

SST

09387-00080

Torque:

350 N*m{3569 kgf*cm, 258 ft.*lbf}(a limit)

Bearing Turning Torque:

0.19 to 0.4 N*m (1.9 to 4.1 kgf*cm, 1.7 to 3.5 in.*lbf)

HINT:

Use a torque wrench with a fulcrum length of 160 mm (6.30 in.) to measure the turning torque.

Using a chisel and hammer, stake the front lock washer.

Coat the 2 thrust bearings with ATF.

Install the input sun gear, 2 thrust needle roller bearings, 2 No. 2 thrust bearing races, and No. 3 thrust bearings to the transaxle case.

NOTICE:

1. Ensure that the parts are installed in the correct order and direction.
   

Install the rear planetary gear assembly to the brake hub.

Using a screwdriver, install the snap ring.

NOTICE:

Confirm that the snap ring is engaged in the groove of the 1st and reverse brake hub correctly.

Coat the 5 discs with ATF.

Install the 5 plates and 5 discs.

NOTICE:

Be sure to install the plates and disks in the correct order.

Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).

Select an appropriate flange so that the pack clearance will be within the specified range.

Pack clearance:

0.745 to 1.21 mm (0.0293 to 0.0476 in.)

HINT:

Piston stroke = Dimension A - Flange thickness

Install the flange.

Coat the 2nd brake piston with ATF, and install it to the 2nd brake cylinder.

Install the 2nd brake piston return spring sub-assembly.

NOTICE:

Ensure that all springs are fitted in the piston correctly.

Place SST on the piston return spring, and compress it with a press.

SST

09387-00060

Using a screwdriver, install the snap ring.

NOTICE:

Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.

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

Install the snap ring and measure the inside diameter.

Inside diameter:

More than 172 mm (6.77 in.)

NOTICE:

1. Make sure to install the tapered snap ring in the correct direction.
   
2. If the diameter does not meet the specified value, replace the snap ring with a new one.
   
3. After installing the snap ring, confirm that there is no clearance between the 2nd brake cylinder and the contact surface of the cylinder in the transaxle case.
   

Install the one-way clutch sleeve to the 2nd brake cylinder assembly.

NOTICE:

Check the positioning direction of the outer sleeve.

Coat the No. 1 planetary carrier thrust washer with ATF, and install it onto the planetary sun gear assembly.

NOTICE:

After installing the washer, confirm that the projections on the washer are securely fitted in the holes of the planetary sun gear assembly.

Install the one-way clutch inner race to the one-way clutch.

NOTICE:

1. Check the direction of the inner race.
   
2. Confirm that the identification mark can be seen.
   

Make sure that the one way clutch turns freely counterclockwise and locks when turned clockwise.

Install the one-way clutch and thrust needle roller bearing to the one-way clutch sleeve outer.

NOTICE:

Install the thrust bearing properly so that uncolored race will be visible.

Coat the No. 2 planetary carrier thrust washer with ATF, and install it onto the rear planetary sun gear.

Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

Install the rear planetary sun gear assembly to the rear planetary gear.

NOTICE:

After installing the rear planetary sun gear assembly, confirm that the B1 discs engage.

Coat the 3 discs with ATF.

Install the 3 discs and 3 plates to the transaxle case.

Install the snap ring.

Using a vernier caliper, measure the distance between the disc surface and snap ring surface (Dimension B).

Select an appropriate flange so that the pack clearance will be within the specified range.

Pack clearance:

0.53 to 0.91 mm (0.0209 to 0.0358 in.)

HINT:

Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.0630 in.)

Install the flange.

Install the direct clutch hub to the planetary gear assembly.

NOTICE:

Be careful not to damage the bushing inside the overdrive clutch hub during installation.

Coat the thrust bearing with ATF.

Install the bearing race and the thrust bearing to the direct clutch hub.

NOTICE:

When installing the bearing, hold the side of the overdrive clutch hub.

Coat a new O-ring with ATF, and install it to the direct clutch drum.

NOTICE:

Ensure that the O-ring is not twisted or pinched.

Coat the direct clutch drum with ATF, and install it to the intermediate shaft.

NOTICE:

1. Be careful not to damage the O-ring.
   
2. Be careful not to damage the lip seal of the direct clutch drum.
   

Coat the overdrive direct clutch piston with ATF, and install it to the overdrive direct clutch drum sub-assembly.

NOTICE:

Be careful not to damage the lip seal of the direct clutch piston.

Install the overdrive clutch return spring sub-assembly to the overdrive direct clutch drum sub-assembly.

NOTICE:

When installing the spring sub-assembly, ensure that all springs are fitted in the piston correctly.

Coat the clutch balancer with ATF.

Install the clutch balancer to the overdrive direct clutch drum sub-assembly.

NOTICE:

1. Be careful not to damage the lip seal of the direct clutch balancer.
   
2. Ensure that the clutch balancer is not pinched and there are no other defects at the sealing lip.
   
3. Apply enough ATF to the sealing lip prior to installation.
   

Place SST on the clutch balancer and compress the piston return spring with a press.

SST

09387-00020

Using a snap ring expander, install the snap ring to the direct clutch drum.

NOTICE:

1. Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Position the end gap of the snap ring in the piston as shown in the illustration.

NOTICE:

Ensure that the end gap of the snap ring is not aligned with any of the stoppers.

Coat the 3 discs with ATF.

Install the 3 plates, 3 discs and flange to the intermediate shaft.

NOTICE:

Be sure to install the plates, disks and flange in the correct order.

Using a screwdriver, install the snap ring.

NOTICE:

The snap ring should be securely engaged in the groove of the drum.

Coat the 3 discs with ATF.

Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft.

NOTICE:

1. Install the cushion plate with the mark on the white surface facing the plate.
   
2. Be sure to install the cushion plate, plates, disks and flange in the correct order.
   

Using a screwdriver, install the snap ring.

NOTICE:

The snap ring should be securely engaged in the groove of the drum.

Install the intermediate shaft on the transaxle rear cover.

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

Pack clearance:

1.05 to 1.47 mm (0.04134 to 0.05787 in.)

HINT:

There are 8 different thicknesses of flanges available.

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

Pack clearance:

0.61 to 0.83 mm (0.02402 to 0.03268 in.)

HINT:

There are 7 different thicknesses of flanges available.

Check that the disc rotates after inserting the rear planetary sun gear.

NOTICE:

Do not place the rear planetary sun gear in a vise.

Coat the thrust bearing with ATF.

Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.

NOTICE:

The disc in the direct clutch should be completely matched with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

Clean the contact surfaces of the transaxle case and the rear cover.

As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension C).

Using a vernier caliper and a simple straightedge, measure the dimension shown in the illustration.

Calculate the end play value using the following formula. Select a thrust bearing which satisfies the specified end play value and install it.

End play:

0.199 to 0.970 mm (0.00783 to 0.0382 in.)

NOTICE:

Make sure that the uncolored race side is facing the direct clutch assembly.

HINT:

End play = Dimension D - Dimension C

Install 3 new No. 1 governor apply gaskets to the transaxle case.

Install the clamp to the brake apply tube.

NOTICE:

Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

Install the clutch apply tube.

Install the brake apply tube to the transaxle case with the bolt.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

NOTICE:

Each pipe should be securely inserted until it reaches the stopper.

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

SST

09950-60010(09951-00230,09952-06010,09951-00360)

Press fit depth:

20.55 to 21.25 mm (0.8091 to 0.8366 in.)

NOTICE:

1. Face the inscribed side of the bearing race up.
   
2. Keep pressing until the specified value is obtained.
   

Coat the needle roller bearing with ATF.

Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.

NOTICE:

The rear clutch oil seal rings should be securely engaged in the grooves of the drum.

Install a new O-ring to each No. 1 transaxle case plug.

Install the 4 No. 1 transaxle case plugs to the transaxle rear cover.

Torque:

7.4 N*m{75 kgf*cm, 65 in.*lbf}

Remove any packing material and keep the contact surfaces of the transaxle rear cover and the transaxle case away from oil.

Apply FIPG to the cover.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

NOTICE:

Apply FIPG in a continuous bead (width 1.2 mm (0.0472 in.)) along the sealing surface.

Apply adhesive to the threads of bolt A.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Install the 11 bolts.

Torque:

Bolt A:

19 N*m{190 kgf*cm, 14 ft.*lbf}

Other bolts:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Coat the 3 discs with ATF.

Install the 3 discs, 3 plates and flange to the transaxle case.

NOTICE:

Be sure to install the disks, plates and flange in the correct order.

Using a screwdriver, install the snap ring.

NOTICE:

The snap ring should be securely engaged in the groove of the drum.

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

Pack clearance:

1.81 to 2.20 mm (0.0713 to 0.0866 in.)

Select an appropriate flange from the table below so that the pack clearance will be within the specified range.

Temporarily remove the snap ring and attach the flange to the transaxle case.

Reinstall the snap ring to the transaxle case.

Install the underdrive clutch assembly to the one-way clutch.

Make sure that the underdrive one-way clutch turns freely counterclockwise and locks when turned clockwise.

Remove the underdrive clutch assembly from the one-way clutch.

Install the outer race retainer to the one-way clutch.

NOTICE:

Securely install the outer race retainer onto the tooth of the one-way clutch.

Install the one-way clutch to the transaxle case.

NOTICE:

Ensure that the outer race retainer and the mark on the transaxle case are aligned.

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

NOTICE:

The snap ring should be securely engaged in the groove of the transaxle case.

Coat a new O-ring with ATF, and install it to the underdrive clutch drum.

NOTICE:

Install the O-ring carefully so that it is not twisted or pinched.

Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.

NOTICE:

1. Be careful not to damage the O-ring.
   
2. Be careful not to damage the lip seal of the piston.
   

Install the return spring to the underdrive clutch drum.

NOTICE:

After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.

Coat the clutch balancer with ATF.

Install the clutch balancer to the underdrive clutch drum.

NOTICE:

Be careful not to damage the lip seal of the clutch balancer.

Place SST on the clutch balancer and compress the piston return spring with a press.

SST

09350-32014(09351-32070)

Using a snap ring expander, install the snap ring to the underdrive clutch drum.

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Position the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.

NOTICE:

The end gap of the snap ring should not be aligned with any of the stoppers.

Coat the 3 discs with ATF.

Install the 3 plates, 3 discs, and flange to the underdrive clutch drum.

NOTICE:

Be careful about the order of discs, plates, and flange.

Using a screwdriver, install the No. 2 underdrive clutch flange hole snap ring.

Check that the end gap of the snap ring is not aligned with one of the cutouts.

NOTICE:

The snap ring should be securely engaged in the groove of the drum.

Coat the bearing and bearing race with ATF, and install them onto the underdrive clutch.

Install the underdrive clutch assembly to the transaxle case.

NOTICE:

When installing the underdrive clutch drum sub-assembly, do not damage the oil seal ring.

Install the pawl pin and spring to the parking lock pawl.

Temporarily install the parking lock pawl, pin and spring to the transaxle case as shown in the illustration.

Install a new snap ring to the outer race of the tapered roller bearing.

HINT:

If replacing the bearing, also replace the counter driven gear with a new one.

Using a piston ring compressor, squeeze the snap ring.

Using SST and a press, press in the outer race of the angular ball bearing.

SST

09950-60020(09951-00890)
09950-70010(09951-07100)

NOTICE:

Do not damage the snap ring during installation of the outer race.

Install the underdrive planetary ring gear to the counter driven gear.

Using snap ring pliers, install the snap ring.

Using a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear.

SST

09726-40010
09950-60010(09951-00260)
09950-70010(09951-07100)

Install the counter driven gear with planetary ring gear to the underdrive planetary gear.

Using SST and a press, press in the angular ball bearing inner race (front side).

SST

09726-40010
09950-60010(09951-00260)
09950-70010(09951-07100)

NOTICE:

Press the counter driven gear while rotating it.

Using a press, press in the parking lock gear.

SST

09316-20011
09950-60010(09951-00260)
09950-70010(09951-07100)

NOTICE:

Press the counter driven gear while rotating it.

Using a press, press in the differential drive pinion.

SST

09726-40010
09950-60010(09951-00260)
09950-70010(09951-07100)

NOTICE:

Press the counter driven gear while rotating it.

Using a press, press in the cylindrical roller bearing race inner.

SST

09515-21010
09950-60010(09951-00260)
09950-70010(09951-07100)

NOTICE:

Press the counter driven gear while rotating it.

Clamp the underdrive planetary gear in a soft jaw vise.

NOTICE:

Be careful not to damage the differential drive pinion.

Using a socket wrench, install a new gear nut.

Torque:

280 N*m{2855 kgf*cm, 207 ft.*lbf}

HINT:

Use a torque wrench with a fulcrum length of 750 mm (29.53 in.).

Using a chisel and hammer, stake the gear nut.

CAUTION:

Be sure that there are no cracks on the nut.

Install the underdrive planetary gear assembly to the transaxle case.

NOTICE:

Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly and securely assemble them.

Install the parking lock pawl shaft.

Install the pawl shaft clamp with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Using a straightedge and a vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle case and housing (Dimension E).

NOTICE:

Take a note of dimension E because it is necessary for the following process.

As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the following formula.

NOTICE:

Take a note of dimension F because it is necessary for the following process.

HINT:

Dimension F = Dimension (1) - Dimension (2)

Install the No. 1 thrust bearing race to the transaxle case while checking its direction.

Coat the thrust needle roller bearing and race with ATF, and install them onto the multiple disc clutch hub.

Coat the needle roller bearing with ATF.

Install the needle roller bearing to the multiple disc clutch hub.

Install the multiple disc clutch hub to the transaxle case.

Compress a new input shaft oil seal ring from both sides to adjust dimension A.

Dimension A:

5 mm (0.197 in.)

Coat the oil seal ring with ATF and install it to the input shaft.

NOTICE:

Do not expand the gap of the oil seal ring too much. Securely engage the hooks.

Coat the forward clutch piston with ATF, and install it to the input shaft.

NOTICE:

Be careful not to damage the lip seal of the forward clutch piston.

Install the return spring to the input shaft.

NOTICE:

After installing the spring sub-assembly, check that all of the springs are fitted to piston correctly.

Coat the clutch balancer with ATF.

Install the clutch balancer to the input shaft.

NOTICE:

1. Be careful not to damage the lip seal of the forward clutch balancer.
   
2. Install the clutch balancer carefully not to pinch or damage at the sealing lip.
   
3. Apply sufficient ATF to the sealing lip prior to installation.
   

Place SST on the clutch balancer, and compress the clutch balancer with a press.

SST

09387-00020

Install the snap ring with a snap ring expander.

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Position the end gap of the snap ring in the piston as shown in the illustration.

NOTICE:

The end gap of the snap ring should not be aligned with any of the stoppers.

Coat the 5 discs with ATF.

Install the 5 plates, 5 discs, and flange to the input shaft.

NOTICE:

Be careful about the order of discs, plates, and flange.

Using a screwdriver, install the snap ring.

Check that the end gap of the snap ring is not aligned with one of the cutouts.

NOTICE:

The snap ring should be securely engaged in the groove of the drum.

Install the forward clutch on the oil pump.

NOTICE:

Be careful not to damage the oil seal ring of the oil pump.

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

Pack clearance:

1.00 to 1.25 mm (0.0394 to 0.0492 in.)

HINT:

1. As the opening is large, cover it with a piece of cloth or shop rag to prevent the compressed air from being released.
   
2. There are 7 different thicknesses of flanges available.
   

Flange Thickness:

No.	Thickness (mm (in.))	No.	Thickness (mm (in.))
0	2.85 (0.1122)	4	3.45 (0.1358)
1	3.00 (0.1181)	5	3.60 (0.1417)
2	3.15 (0.1240)	6	3.75 (0.1476)
3	3.30 (0.1299)	-	-

Check if the sliding surfaces of the discs, plates, and flange are worn or burnt.
If necessary, replace them.

HINT:

1. If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
   
2. Before assembling new discs, soak them in ATF for at least 15 minutes.
   

Coat the thrust needle roller bearing with ATF.

Install the thrust needle roller bearing to the forward clutch.

NOTICE:

Install the thrust bearing properly so that the tempered side of the race will be visible.

Install the forward clutch to the forward clutch assembly.

NOTICE:

1. Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely.
   
2. Be careful not to damage the bush inside the forward clutch hub during installation.
   

Install 2 new overdrive brake gaskets.

Install the differential gear assembly to the transaxle case.

Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly.

Coat the thrust needle roller bearing with ATF.

Calculate the end play value using the following formula and values of Dimensions E and F that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate No. 2 underdrive planetary gear thrust bearing race which satisfies the specified end play value, and install it.

End play:

0.198 to 0.693 mm (0.00779 to 0.02728 in.)

HINT:

End play = Dimension F - Dimension E - Thrust bearing thickness 2.5 mm (0.0984 in.) - No. 2 underdrive thrust bearing race thickness.

Install the oil pump to the transaxle case with the 7 bolts.

Torque:

22 N*m{225 kgf*cm, 16 ft.*lbf}

Coat the O-ring of the oil pump with ATF.

NOTICE:

Confirm that the input shaft rotates smoothly by hand after installing the oil pump.

Remove any FIPG material and keep the contact surfaces of the transaxle case and transaxle housing away from oil.

Apply FIPG to the transaxle case.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Install the transaxle housing to the transaxle case with the 18 bolts.

Torque:

Bolt A:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Bolt B:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Bolt C:

22 N*m{225 kgf*cm, 16 ft.*lbf}

Bolt D:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Bolt E:

33 N*m{336 kgf*cm, 24 ft.*lbf}

Bolt F:

25 N*m{255 kgf*cm, 18 ft.*lbf}

HINT:

Apply seal packing or equivalent to bolts C and F.

Seal packing:

Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent

Bolt length:

Bolt B, C, D, F:

50 mm (1.969 in.)

Bolt A, E:

42 mm (1.654 in.)

NOTICE:

Apply seal packing to new bolts and tighten them within 10 minutes of application.

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

End play:

0.262 to 1.249 mm (0.0103 to 0.0492 in.)

Secure the transaxle assembly onto wooden blocks.

Coat a new oil seal with MP grease.

Using SST and hammer, install the oil seal to the transaxle case.

SST

09950-60010(09951-00230)
09950-70010(09951-07100)

Oil seal drive in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in. )

Install the parking lock rod to the manual valve lever.

HINT:

Align the dial with the notches on the manual valve lever and turn the dial 90° to install the parking lock rod.

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

NOTICE:

Do not damage the oil seal while installing the shaft to the transaxle case.

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

Turn the spacer and the lever shaft to align the smaller hole of the spacer with 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.

Using needle-nose pliers, install the retainer spring.

NOTICE:

Securely attach the spring onto the shaft.

Install the parking lock pawl bracket with the 2 bolts.

Torque:

20 N*m{205 kgf*cm, 15 ft.*lbf}

Bolt length:

25 mm (0.984 in.)

NOTICE:

Be sure the parking rod is placed between the parking pawl and the guide of the parking bracket after the parking bracket is installed.

Install the manual detent spring sub-assembly with the 2 bolts.

NOTICE:

Make sure to install the manual detent spring and cover in this order.

HINT:

Tighten bolt A first, then B.

Torque:

Bolt A:

20 N*m{205 kgf*cm, 15 ft.*lbf}

Bolt B:

12 N*m{120 kgf*cm, 9 ft.*lbf}

Bolt length:

Bolt A:

27 mm (1.06 in.)

Bolt B:

16 mm (0.630 in.)

Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.

NOTICE:

Install the O-ring to the accumulator piston, being careful not to twist or pinch it. Apply enough ATF to the O-ring prior to installation. Be sure to confirm the installation position.

Coat the piston and springs with ATF, and install them to the transaxle case.

NOTICE:

Install the correct springs to the B-3 accumulator piston after confirming the color and dimension of the springs.

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

NOTICE:

Install the O-rings to the accumulator piston, being careful not to twist or pinch it. Apply enough ATF to the O-rings prior to installation. Be sure to confirm the installation positions.

Coat the piston and spring with ATF, and install them to the transaxle case.

NOTICE:

Install the correct spring to the reverse clutch accumulator piston after confirming the color or dimension of the spring.

Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.

NOTICE:

Install the O-ring to the accumulator piston, being careful not to twist or pinch it. Apply enough ATF to the O-ring prior to installation. Be sure to confirm the installation position.

Coat the piston with ATF, and install it to the transaxle case.

Install the spring to the C-3 accumulator piston.

NOTICE:

Install the correct spring to the C-3 accumulator piston after confirming the color and dimension of the spring.

Coat the check ball body with ATF.

Install the check ball body and spring.

NOTICE:

Regarding the installation of the spring and the check ball body, be sure to place the spring into ball body. Be sure to install the parts in the correct direction.

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

NOTICE:

Do not damage the lip portion of the brake drum gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket prior to installation. Be sure to install the parts in the correct direction.

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

NOTICE:

Do not damage the lip portion of the transaxle case 2nd brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket prior to installation. Be sure to install the parts in the correct direction.

Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case.

NOTICE:

Do not damage the lip portion of the No. 1 governor apply gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket prior to installation. Be sure to install the parts in the correct direction.

Check the manual valve lever position. Install the valve body to the transaxle case with the 17 bolts.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Bolt length:

Bolt A:

25 mm (0.984 in.)

Bolt B:

57 mm (2.244 in.)

Bolt C:

41 mm (1.614 in.)

NOTICE:

1. Push the valve body against the accumulator piston spring and the check ball body to install it.
   
2. When installing the valve body to the transaxle case, do not hold the solenoids.
   
3. Temporarily tighten the bolts marked by (1) in the illustration first because they are positioning bolts.
   

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

NOTICE:

Install the O-ring carefully to avoid twists or pinches. Apply sufficient ATF to the O-ring prior to installation.

Install the oil strainer to the valve body with the 3 bolts.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

NOTICE:

Apply ATF to the bolts prior to installation.

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

NOTICE:

Install the O-ring carefully to avoid twists or pinches. Apply enough ATF to the O-ring prior to installation.

Install the transmission wire retaining bolt.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Coat the ATF temperature sensor O-ring with ATF.

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

Torque:

6.6 N*m{67 kgf*cm, 58 in.*lbf}

Connect the 7 solenoid connectors.

NOTICE:

1. Connect the connectors to A, B, C, D, E, F and G, starting with shorter connectors first.
   
2. Apply ATF to the bolt prior to installation.
   

Install the 2 magnets to the oil pan.

Apply seal packing or equivalent to the 18 bolts.

Seal packing:

Toyota Genuine Seal Packing 1344, Three Bond 1344 or Equivalent

NOTICE:

1. Apply seal packing to new bolts and tighten them within 10 minutes of application.
   
2. Completely remove any oil or grease from the gasket contact surface of the transaxle case and the oil pan before installing the oil pan to the case.
   

Install a new oil pan gasket and the oil pan to the transaxle case with the 18 bolts.

Torque:

7.8 N*m{80 kgf*cm, 69 in.*lbf}

NOTICE:

1. Apply seal packing to new bolts and tighten them within 10 minutes of application.
   
2. Completely remove any oil or grease from the gasket contact surface of the transaxle case and the oil pan before installing the oil pan to the case.
   

Install a new gasket to the drain plug.

Install the drain plug.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Coat 4 new O-rings with ATF, and install them to the 4 No. 1 transaxle case plugs.

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

Torque:

7.4 N*m{75 kgf*cm, 65 in.*lbf}

Coat 2 new O-rings with ATF, and install them to the 2 speed sensors.

Apply adhesive to the bolts threads.

Sealant:

Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

Install the 2 speed sensors to the transaxle case with the 2 bolts.

Torque:

Bolt A:

8.8 N*m{90 kgf*cm, 78 in.*lbf}

Bolt B:

11 N*m{112 kgf*cm, 8 ft.*lbf}

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

Install the union to the transaxle case.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

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

Install the elbow to the transaxle case.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

Coat a new O-ring with ATF.

Install the hose and the O-ring to the breather plug.

Install the No. 2 breather plug hose to the transaxle case.

Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.

Install a new nut stopper and nut.

Torque:

6.9 N*m{70 kgf*cm, 61 in.*lbf}

Temporarily install the control shaft lever.

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

Remove the control shaft lever.

Align the groove with the neutral basic line.

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

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Using a screwdriver, stake the nut with the nut stopper.

Install the control shaft lever, washer and nut.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}